Club Car Carryall 1500 Manual

2015
Carryall 1500/1700 and XRT 1550
Maintenance and Service
Manual
Carryall 1500/1700, XRT 1550/1550 SE Gasoline, Diesel and
IntelliT ach V ehicles
ManualNumber105157210
EditionCode0814A00000

FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance ef ciency; however , proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation.
Thismanualprovidesdetailedinformationforthemaintenanceandrepairof2015Carryall1500,Carryall1700,XRT
1550, XR T 1550 SE and IntelliT ach vehicles, and should be thoroughly reviewed prior to servicing the vehicles. The
procedures provided must be properly implemented, and the DANGER, W ARNING, and CAUTION statements
must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical and
mechanical repair . If the technician does not have such knowledge and skills, attempted service or repairs to the
vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed
by an authorized Club Car distributor/dealer representative or by a Club Car factory trained technician.
It is the policy of Club Car , LLC to assist its distributors and dealers in continually updating their service knowledge
and facilities so they can provide prompt and ef cient service for vehicle owners. Regional technical representatives,
periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car ’ s
continuing commitment to customer support.
Club Car of fers a full line of training and continuing education classes for technicians who want to learn more about
our products. For more information, contact your local dealer or Club Car ’ s T echnical Services department for a
list of upcoming classes.
This manual covers all aspects of typical vehicle service; however , unique situations sometimes occur when servicing a
vehicle. If it appears that a service question is not answered in this manual, please contact your nearest authorized
Club Car dealer or distributor for assistance. Y ou may also write to us at: Club Car , LLC; P .O. Box 204658; Augusta,
GA 30917 - 4658 USA, Attention: T echnical Services.
Copyright ©2014 Club Car , LLC
Club Car , Carryall, and ArmorFlex
are registered trademarks of Club Car , LLC
ThismanualeffectiveSeptember1,2014
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page i

FOREWORD
WARNING
•ReadSafetyonpage1-1beforeattemptinganyserviceonthisvehicle.
•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe
relevanttotheserviceorrepairtobeperformed.
NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.Themanufactureriscontinually
workingtofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicing
procedures.Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoall
dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.
Damagetoavehicleorcomponentthereofnotresultingfromadefectorthatoccursduetounreasonable
orunintendeduse,overloading,abuse,orneglect(includingfailuretoprovidereasonableornecessary
maintenanceasinstructedinthevehicleowner’smanual),accidentoralteration,includingincreasingvehicle
speedbeyondfactoryspecicationsormodicationsthataffectthestabilityofthevehicleortheoperation
thereof,willvoidthewarranty.
Themanufacturerreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeand
withoutincurringanyobligationorliabilitywhatsoever.
Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle
owner’smanualorwritetoClubCar,LLC,P .O.Box204658,Augusta,GA30917-4658USA,Attention:
WarrantyDepartment.

CONTENTS
SECTION 1 – SAFETY ...................................................................................................................................... 1 -1
Safety Details ................................................................................................................................................ 1 -1
Personal Safety ......................................................................................................................................... 1 -1
Machine Safety .......................................................................................................................................... 1 -1
Information ................................................................................................................................................ 1 -2
General W arnings .......................................................................................................................................... 1 -2
Disabling the V ehicle .................................................................................................................................. 1 -3
Disconnecting the Battery – Gasoline/Diesel V ehicles .................................................................................. 1 -3
Connecting the Battery – Gasoline/Diesel V ehicles ...................................................................................... 1 -4
Recycling Lead -Acid Batteries .................................................................................................................... 1 -4
International safety symbols on batteries ..................................................................................................... 1 -5
SECTION 2 – VEHICLE SPECIFICA TIONS ........................................................................................................ 2 -1
1500/1700 and 1550/1550 SE Specications ............................................................................................... 2 -1
Intellitach Specications ............................................................................................................................. 2 -4
SECTION 3 – GENERAL INFORMA TION ........................................................................................................... 3 -1
Model Identication ........................................................................................................................................ 3 -3
Identication Numbers ............................................................................................................................... 3 -3
Storage ......................................................................................................................................................... 3 -5
Preparing the V ehicle for Extended Storage ................................................................................................ 3 -6
Returning the Stored V ehicle to Service ...................................................................................................... 3 -6
Lifting The V ehicle ......................................................................................................................................... 3 -7
Lifting Only The Front ................................................................................................................................ 3 -7
Lifting Only The Rear ................................................................................................................................. 3 -7
Lifting The Entire V ehicle ............................................................................................................................ 3 -8
Using A Booster Battery (Jump Starting) ......................................................................................................... 3 -9
SECTION 4 – BODY AND TRIM ......................................................................................................................... 4 -1
General Information ....................................................................................................................................... 4 -1
Cleaning the V ehicle ...................................................................................................................................... 4 -1
Seat Cleaning ............................................................................................................................................ 4 -1
Front Body Repair ......................................................................................................................................... 4 -2
Light Scratches .......................................................................................................................................... 4 -2
Abrasions and Haze .................................................................................................................................. 4 -2
Large Scratches and Abrasions .................................................................................................................. 4 -3
Front Body Components ................................................................................................................................ 4 -3
Instrument Panel Removal ......................................................................................................................... 4 -3
Instrument Panel Installation ...................................................................................................................... 4 -3
Front Fascia Removal ................................................................................................................................ 4 -4
Front Fascia Installation ............................................................................................................................. 4 -4
Hood Removal .......................................................................................................................................... 4 -4
Hood Installation ........................................................................................................................................ 4 -4
Center Cowl Panel Removal ....................................................................................................................... 4 -4
Center Cowl Panel Installation .................................................................................................................... 4 -5
Side Cowl Panel (Fender) Removal ............................................................................................................ 4 -5
Side Cowl Panel (Fender) Installation ......................................................................................................... 4 -5
Front Fender Flare Removal ....................................................................................................................... 4 -6
Front Fender Flare Installation .................................................................................................................... 4 -6
Roll -Over Protective Structure (ROPS) ............................................................................................................ 4 -6
ROPS Removal ......................................................................................................................................... 4 -7
ROPS Installation ...................................................................................................................................... 4 -8
Seat .............................................................................................................................................................. 4 -9
Seat Removal ............................................................................................................................................ 4 -9
Seat Adjustment ........................................................................................................................................ 4 -9
Seat Installation ....................................................................................................................................... 4 -10
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Seat Support Removal ............................................................................................................................. 4 -10
Seat Support Installation .......................................................................................................................... 4 -10
Seat Belts ................................................................................................................................................... 4 -10
Bench Seat Belt Removal ......................................................................................................................... 4 -10
Bench Seat Belt Installation .......................................................................................................................4 -1 1
Cargo Bed – Electric Lift ................................................................................................................................4 -1 1
T esting the Bed Lift Motor ..........................................................................................................................4 -1 1
Bed Lift Motor Removal .............................................................................................................................4 -1 1
Bed Lift Motor Installation ......................................................................................................................... 4 -12
Cargo Bed Removal ................................................................................................................................ 4 -12
Cargo Bed Installation .............................................................................................................................. 4 -12
Cargo Bed – Manual Lift ............................................................................................................................... 4 -13
Cargo Bed Removal ................................................................................................................................ 4 -13
Cargo Bed Installation .............................................................................................................................. 4 -13
Rear Fender ................................................................................................................................................ 4 -14
Rear Fender Removal .............................................................................................................................. 4 -14
Rear Fender Installation ........................................................................................................................... 4 -14
SECTION 5 – ACCELERA T OR AND BRAKE PEDAL ASSEMBLIES ................................................................... 5 -1
Accelerator Pedal .......................................................................................................................................... 5 -1
Accelerator Pedal Removal ........................................................................................................................ 5 -1
Accelerator Pedal Installation ..................................................................................................................... 5 -2
Brake Pedal .................................................................................................................................................. 5 -3
Brake Pedal Removal ................................................................................................................................ 5 -3
Brake Pedal Installation ............................................................................................................................. 5 -3
Brake Pedal Adjustment ............................................................................................................................. 5 -3
Park Brake Pedal ........................................................................................................................................... 5 -4
Park Brake Pedal Assembly Removal ......................................................................................................... 5 -4
Park Brake Pedal Assembly Installation ...................................................................................................... 5 -4
SECTION 6 – HYDRAULIC AND P ARK BRAKE SYSTEMS ................................................................................ 6 -1
Brake System Inspection ................................................................................................................................ 6 -1
Brake Pedal Inspection .............................................................................................................................. 6 -1
Master Cylinder Inspection ......................................................................................................................... 6 -2
Brake Line Inspection ................................................................................................................................ 6 -3
Park Brake Inspection ................................................................................................................................ 6 -3
Brake Disc and Pad Inspection ................................................................................................................... 6 -3
Brake System T roubleshooting ....................................................................................................................... 6 -4
Brake Pads and Caliper ................................................................................................................................. 6 -6
Brake Pad and Caliper Removal ................................................................................................................. 6 -6
Brake Pad and Caliper Installation .............................................................................................................. 6 -7
Brake Discs ................................................................................................................................................. 6 -10
Disc Removal .......................................................................................................................................... 6 -10
Disc Installation ....................................................................................................................................... 6 -10
Hydraulic Line Replacement ..........................................................................................................................6 -1 1
Front Brake Line Removal .........................................................................................................................6 -1 1
Front Brake Line Installation ......................................................................................................................6 -1 1
Rear Brake Line Removal ........................................................................................................................ 6 -12
Rear Brake Line Installation ...................................................................................................................... 6 -13
Master Cylinder and Reservoir ..................................................................................................................... 6 -14
Filling the Hydraulic System ..................................................................................................................... 6 -14
Master Cylinder Removal ......................................................................................................................... 6 -14
Master Cylinder Installation ...................................................................................................................... 6 -14
Bleeding the Hydraulic Brake System ........................................................................................................... 6 -15
Bleeding Brakes on a DOT 5 Fluid Filled System ....................................................................................... 6 -15
Purging the Hydraulic System ................................................................................................................... 6 -17
Park Brake System ...................................................................................................................................... 6 -18
Park Brake Adjustment – At Rear Calipers ................................................................................................ 6 -18
Front Park Brake Cable Adjustment – Cable Only System .......................................................................... 6 -18
Park Brake Wheel Cables ........................................................................................................................ 6 -19
Front Park Brake Cable Removal – Cable Only System ............................................................................. 6 -20
Front Park Brake Cable Installation – Cable Only System ........................................................................... 6 -21
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Park Brake Equalizer Removal – Cable Only System ................................................................................. 6 -21
Park Brake Equalizer Installation – Cable Only System .............................................................................. 6 -22
SECTION 7 – STEERING AND FRONT SUSPENSION ....................................................................................... 7 -1
Steering Wheel .............................................................................................................................................. 7 -1
Steering Wheel Removal ............................................................................................................................ 7 -1
Steering Wheel Installation ......................................................................................................................... 7 -2
Steering Column ............................................................................................................................................ 7 -2
Steering Column Removal .......................................................................................................................... 7 -2
Steering Column Installation ....................................................................................................................... 7 -3
Rack and Pinion ............................................................................................................................................ 7 -3
Rack and Pinion Inspection ........................................................................................................................ 7 -4
Rack and Pinion Removal .......................................................................................................................... 7 -4
Rack and Pinion Installation ....................................................................................................................... 7 -4
Rack and Pinion Disassembly .................................................................................................................... 7 -5
Rack and Pinion Assembly ......................................................................................................................... 7 -9
Front Suspension ........................................................................................................................................ 7 -10
Wheel Alignment ..................................................................................................................................... 7 -10
Front Suspension Components ..................................................................................................................... 7 -14
Steering Upright Removal ........................................................................................................................ 7 -14
Steering Upright Installation ...................................................................................................................... 7 -16
Upper A -Arm Removal ............................................................................................................................. 7 -16
Upper A -Arm Installation .......................................................................................................................... 7 -18
Lower A -Arm Removal ............................................................................................................................. 7 -18
Lower A -Arm Installation .......................................................................................................................... 7 -19
Front Coil -Over Shock Absorber Removal ................................................................................................. 7 -20
Front Coil -Over Shock Absorber Installation .............................................................................................. 7 -21
SECTION 8 – WHEELS, TIRES AND HUBS ....................................................................................................... 8 -1
General Information ....................................................................................................................................... 8 -1
Wheels ......................................................................................................................................................... 8 -2
Wheel Removal ......................................................................................................................................... 8 -2
Wheel Installation ...................................................................................................................................... 8 -2
T ires ............................................................................................................................................................. 8 -2
T ire Removal ............................................................................................................................................. 8 -2
T ire Installation .......................................................................................................................................... 8 -3
Front Hubs .................................................................................................................................................... 8 -3
Front Hub Removal .................................................................................................................................... 8 -3
Front Hub Installation ................................................................................................................................. 8 -5
Rear Hubs ..................................................................................................................................................... 8 -6
Rear Hub Removal .................................................................................................................................... 8 -6
Rear Hub Installation ................................................................................................................................. 8 -7
SECTION 9 – REAR SUSPENSION ................................................................................................................... 9 -1
Rear Coil -Over Shock Absorber ...................................................................................................................... 9 -1
Rear Shock Absorber Removal ................................................................................................................... 9 -1
Rear Shock Installation .............................................................................................................................. 9 -2
T railing Arms and Lateral Links ....................................................................................................................... 9 -3
Lateral Link Removal ................................................................................................................................. 9 -3
Lateral Link Installation .............................................................................................................................. 9 -3
T railing Arm Removal ................................................................................................................................. 9 -3
T railing Arm Installation .............................................................................................................................. 9 -3
SECTION 10 – PERIODIC MAINTENANCE ...................................................................................................... 10 -1
Periodic Service Schedule ............................................................................................................................ 10 -1
Periodic Service Schedule – IntelliT ach ......................................................................................................... 10 -4
Periodic Lubrication Schedule ...................................................................................................................... 10 -6
Periodic Lubrication Schedule – IntelliT ach .................................................................................................... 10 -8
Lubricating the Attachment Arm and Interface – IntelliT ach ............................................................................. 10 -9
Brake Fluid Reservoir .................................................................................................................................10 -10
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page v

Brake Fluid .............................................................................................................................................10 -10
Engine Oil ..................................................................................................................................................10 -10
Oil Pressure – Gasoline Engine ............................................................................................................... 10 -1 1
Engine Oil Level Check ...........................................................................................................................10 -1 1
Engine Oil and Filter Change ...................................................................................................................10 -1 1
Oil V iscosity ...........................................................................................................................................10 -14
Spark Plugs ................................................................................................................................................10 -15
Spark Plug Cleaning And Inspection ........................................................................................................10 -15
Spark Plug Gap Inspection ......................................................................................................................10 -15
Gearcase Lubrication ..................................................................................................................................10 -15
Lubrication Level Check for Front Dif ferential, T ransmission and Rear Dif ferential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15
Lubrication Change for Front Dif ferential, T ransmission and Rear Dif ferential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 16
Hydraulic System – IntelliT ach V ehicle .........................................................................................................10 -18
Engine Coolant – Diesel V ehicles ................................................................................................................10 -19
Engine Coolant Level Check ...................................................................................................................10 -19
Fueling Instructions .....................................................................................................................................10 -19
Biodiesel Fuel (Diesel V ehicles Only) .......................................................................................................10 -20
Draining W ater from Fuel Filter ................................................................................................................10 -21
Battery .......................................................................................................................................................10 -22
SECTION 1 1 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES .............................1 1 -1
T roubleshooting Guide ..................................................................................................................................1 1 -1
Wiring Diagram .............................................................................................................................................1 1 -6
T est Procedures ...........................................................................................................................................1 1 -9
SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES ................................. 12 -1
T roubleshooting Guide ................................................................................................................................. 12 -1
Wiring Diagram ............................................................................................................................................ 12 -6
T est Procedures .......................................................................................................................................... 12 -9
SECTION 13 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES ............................................................. 13 -1
Starter and Starter Solenoid ......................................................................................................................... 13 -1
Relays ........................................................................................................................................................ 13 -1
T esting the Relay ..................................................................................................................................... 13 -1
Relay Removal ........................................................................................................................................ 13 -2
Relay Installation ..................................................................................................................................... 13 -2
Neutral Switch ............................................................................................................................................. 13 -2
T esting the Neutral Switch ........................................................................................................................ 13 -2
Neutral Switch Removal ........................................................................................................................... 13 -2
Neutral Switch Installation ........................................................................................................................ 13 -2
Carburetor Solenoid ..................................................................................................................................... 13 -3
T esting the Carburetor Solenoid ................................................................................................................ 13 -3
Carburetor Solenoid Removal ................................................................................................................... 13 -3
Carburetor Solenoid Installation ................................................................................................................ 13 -3
Carburetor Heater ........................................................................................................................................ 13 -4
Carburetor Heater Removal ...................................................................................................................... 13 -4
Carburetor Heater Installation ................................................................................................................... 13 -4
V oltage Regulator ........................................................................................................................................ 13 -5
T esting the V oltage Regulator ................................................................................................................... 13 -5
V oltage Regulator Removal ...................................................................................................................... 13 -5
V oltage Regulator Installation ................................................................................................................... 13 -5
W arning Lights ............................................................................................................................................ 13 -6
T esting the W arning Lights ....................................................................................................................... 13 -6
W arning Light Removal ............................................................................................................................ 13 -6
W arning Light Installation ......................................................................................................................... 13 -6
Fuel Gauge/Hour Meter ............................................................................................................................... 13 -7
T esting the Fuel Gauge/Hour Meter .......................................................................................................... 13 -7
Fuel Gauge/Hour Meter Removal ............................................................................................................. 13 -7
Fuel Gauge/Hour Meter Installation ........................................................................................................... 13 -8
Key Switch .................................................................................................................................................. 13 -8
T esting the Key Switch ............................................................................................................................. 13 -8
Page vi 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual

Key Switch Removal ................................................................................................................................ 13 -8
Key Switch Installation ............................................................................................................................. 13 -8
12 -V olt Accessory Receptacle ...................................................................................................................... 13 -9
T esting the 12 -V olt Accessory Receptacle ................................................................................................. 13 -9
12 -V olt Accessory Receptacle Removal .................................................................................................... 13 -9
12 -V olt Accessory Receptacle Installation ................................................................................................. 13 -9
Bed Lift Switch ...........................................................................................................................................13 -10
T esting the Bed Lift Switch ......................................................................................................................13 -10
Bed Lift Switch Removal .........................................................................................................................13 -10
Bed Lift Switch Installation .......................................................................................................................13 -10
Bed Lift Circuit Breaker ...............................................................................................................................13 -10
T esting the Bed Lift Circuit Breaker ..........................................................................................................13 -10
Bed Lift Circuit Breaker Removal .............................................................................................................13 -10
Bed Lift Circuit Breaker Installation .......................................................................................................... 13 -1 1
Light Switch ................................................................................................................................................13 -1 1
T esting the Light Switch ..........................................................................................................................13 -1 1
Light Switch Removal ............................................................................................................................. 13 -1 1
Light Switch Installation ........................................................................................................................... 13 -1 1
Fuse .......................................................................................................................................................... 13 -1 1
T esting the Fuse .....................................................................................................................................13 -12
Fuse Removal ........................................................................................................................................13 -12
Fuse Installation .....................................................................................................................................13 -12
Reverse W arning Buzzer (If Equipped) .........................................................................................................13 -12
T esting the Reverse W arning Buzzer ........................................................................................................13 -12
Reverse W arning Buzzer Removal ..........................................................................................................13 -12
Reverse W arning Buzzer Installation ........................................................................................................13 -13
Reverse W arning Buzzer Limit Switch (If Equipped) ......................................................................................13 -13
T esting the Reverse W arning Buzzer Limit Switch .....................................................................................13 -13
Reverse W arning Buzzer Limit Switch Removal ........................................................................................13 -13
Reverse W arning Buzzer Limit Switch Installation .....................................................................................13 -14
Front Dif ferential Limit Switch ......................................................................................................................13 -14
T esting the Front Dif ferential Limit Switch .................................................................................................13 -15
Front Dif ferential Limit Switch Removal ....................................................................................................13 -15
Front Dif ferential Limit Switch Installation .................................................................................................13 -15
Fuel Level Sending Unit ..............................................................................................................................13 -16
T esting the Fuel Level Sending Unit .........................................................................................................13 -16
Fuel Level Sending Unit Removal ............................................................................................................13 -16
Fuel Level Sending Unit Installation .........................................................................................................13 -16
Ignition Coil and Charge Coil .......................................................................................................................13 -16
T esting the Ignition Coil ...........................................................................................................................13 -16
Ignition Coil and/or Charge Coil Removal .................................................................................................13 -16
Oil Pressure Sensor ....................................................................................................................................13 -17
Headlights ..................................................................................................................................................13 -17
T esting the Headlight Bulb and Socket .....................................................................................................13 -17
Headlight Bulb Removal ..........................................................................................................................13 -17
Headlight Bulb Installation .......................................................................................................................13 -17
Wire Harness Diodes ..................................................................................................................................13 -18
T esting the Wire Harness Diodes .............................................................................................................13 -18
Wire Harness Diode Removal ..................................................................................................................13 -18
Wire Harness Diode Installation ...............................................................................................................13 -18
Battery .......................................................................................................................................................13 -19
General Information ................................................................................................................................13 -19
T esting the Battery ..................................................................................................................................13 -19
Preventive Maintenance ..........................................................................................................................13 -19
Self -Discharge ........................................................................................................................................13 -20
W ater Level ............................................................................................................................................13 -20
V ibration Damage ...................................................................................................................................13 -20
Mineral Content ......................................................................................................................................13 -20
Battery Removal .....................................................................................................................................13 -21
Charging the Battery ...............................................................................................................................13 -21
Battery Installation ..................................................................................................................................13 -21
Battery Storage ......................................................................................................................................13 -22
Charging a Dead Battery .........................................................................................................................13 -22
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page vii

SECTION 14 – ELECTRICAL COMPONENTS: DIESEL VEHICLES .................................................................. 14 -1
Starter and Starter Solenoid ......................................................................................................................... 14 -1
Relays ........................................................................................................................................................ 14 -1
T esting the Relay ..................................................................................................................................... 14 -1
Relay Removal ........................................................................................................................................ 14 -2
Relay Installation ..................................................................................................................................... 14 -2
Neutral Switch ............................................................................................................................................. 14 -2
T esting the Neutral Switch ........................................................................................................................ 14 -2
Neutral Switch Removal ........................................................................................................................... 14 -2
Neutral Switch Installation ........................................................................................................................ 14 -2
Fuel Solenoid .............................................................................................................................................. 14 -3
T esting the Fuel Solenoid ......................................................................................................................... 14 -3
Fuel Solenoid Removal ............................................................................................................................ 14 -3
Fuel Solenoid Installation ......................................................................................................................... 14 -3
60 -Amp Fusible Link .................................................................................................................................... 14 -4
T esting the 60 -Amp Fusible Link ............................................................................................................... 14 -4
60 -Amp Fusible Link Removal .................................................................................................................. 14 -4
60 -Amp Fusible Link Installation ............................................................................................................... 14 -4
W arning Lights ............................................................................................................................................ 14 -5
T esting the W arning Lights ....................................................................................................................... 14 -5
W arning Light Removal ............................................................................................................................ 14 -5
W arning Light Installation ......................................................................................................................... 14 -5
Fuel Gauge/Hour Meter ............................................................................................................................... 14 -6
T esting the Fuel Gauge/Hour Meter .......................................................................................................... 14 -6
Fuel Gauge/Hour Meter Removal ............................................................................................................. 14 -7
Fuel Gauge/Hour Meter Installation ........................................................................................................... 14 -7
Key Switch .................................................................................................................................................. 14 -7
T esting the Key Switch ............................................................................................................................. 14 -7
Key Switch Removal ................................................................................................................................ 14 -7
Key Switch Installation ............................................................................................................................. 14 -7
12 -V olt Accessory Receptacle ...................................................................................................................... 14 -8
T esting the 12 -V olt Accessory Receptacle ................................................................................................. 14 -8
12 -V olt Accessory Receptacle Removal .................................................................................................... 14 -8
12 -V olt Accessory Receptacle Installation ................................................................................................. 14 -8
Bed Lift Switch ............................................................................................................................................ 14 -9
T esting the Bed Lift Switch ....................................................................................................................... 14 -9
Bed Lift Switch Removal .......................................................................................................................... 14 -9
Bed Lift Switch Installation ........................................................................................................................ 14 -9
Bed Lift Circuit Breaker ................................................................................................................................ 14 -9
T esting the Bed Lift Circuit Breaker ........................................................................................................... 14 -9
Bed Lift Circuit Breaker Removal .............................................................................................................. 14 -9
Bed Lift Circuit Breaker Installation ........................................................................................................... 14 -9
Light Switch ................................................................................................................................................14 -10
T esting the Light Switch ..........................................................................................................................14 -10
Light Switch Removal .............................................................................................................................14 -10
Light Switch Installation ...........................................................................................................................14 -10
Fuse ..........................................................................................................................................................14 -10
T esting the Fuse .....................................................................................................................................14 -10
Fuse Removal ........................................................................................................................................14 -10
Fuse Installation ..................................................................................................................................... 14 -1 1
Reverse W arning Buzzer (If Equipped) .........................................................................................................14 -1 1
T esting the Reverse W arning Buzzer ........................................................................................................ 14 -1 1
Reverse W arning Buzzer Removal .......................................................................................................... 14 -1 1
Reverse W arning Buzzer Installation ........................................................................................................14 -12
Reverse W arning Buzzer Limit Switch (If Equipped) ......................................................................................14 -12
T esting the Reverse W arning Buzzer Limit Switch .....................................................................................14 -12
Reverse W arning Buzzer Limit Switch Removal ........................................................................................14 -12
Reverse W arning Buzzer Limit Switch Installation .....................................................................................14 -13
Front Dif ferential Limit Switch ......................................................................................................................14 -13
T esting the Front Dif ferential Limit Switch .................................................................................................14 -14
Front Dif ferential Limit Switch Removal ....................................................................................................14 -14
Front Dif ferential Limit Switch Installation .................................................................................................14 -14
Fuel Level Sending Unit ..............................................................................................................................14 -15
Page viii 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual