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Club Car Carryall XRT 1550 Manuals
Manuals and User Guides for Club Car Carryall XRT 1550. We have
3
Club Car Carryall XRT 1550 manuals available for free PDF download: Maintenance And Service Manual
Club Car Carryall XRT 1550 Maintenance And Service Manual (456 pages)
Brand:
Club Car
| Category:
Golf Cars
| Size: 40.53 MB
Table of Contents
Table of Contents
5
Section 1 - Safety
15
Safety Details
15
Personal Safety
15
Machine Safety
15
Information
16
General Warnings
16
Disabling the Vehicle
17
Disconnecting the Battery - Gasoline/Diesel Vehicles
17
Connecting the Battery - Gasoline/Diesel Vehicles
18
Recycling Lead-Acid Batteries
18
International Safety Symbols on Batteries
19
Section 2 - Vehicle Specifications
21
295/295 SE and 1550/1550 SE Specifications
21
295 Homologated Specifications
24
Intellitach Specifications
26
Section 3 - General Information
29
Model Identification - Domestic
30
Identification Numbers
31
Model Identification - Homologated
33
Identification Numbers
33
Storage
35
Preparing the Vehicle for Extended Storage
36
Returning the Stored Vehicle to Service
36
Lifting the Vehicle
37
Lifting Only the Front
37
Lifting Only the Rear
37
Lifting the Entire Vehicle
38
Using a Booster Battery (Jump Starting)
39
Section 4 - Body and Trim
41
Cleaning the Vehicle
41
Seat Cleaning
41
Front Body Repair
42
Light Scratches
42
Abrasions and Haze
42
Large Scratches and Abrasions
42
Front Body Components
43
Instrument Panel Removal
43
Instrument Panel Installation
43
Front Fascia Removal
44
Front Fascia Installation
44
Hood Removal
44
Hood Installation
44
Center Cowl Panel Removal
44
Center Cowl Panel Installation
45
Side Cowl Panel (Fender) Removal
45
Side Cowl Panel (Fender) Installation
45
Front Fender Flare Removal
46
Front Fender Flare Installation
46
Roll-Over Protective Structure (ROPS)
46
ROPS Removal
46
ROPS Installation
48
Seat
49
Seat Removal
49
Seat Adjustment
49
Seat Installation
49
Seat Support Removal
49
Seat Support Installation
50
Seat Belts
50
Bench Seat Belt Removal - 2008 Models
50
Bench Seat Belt Installation - 2008 Models
51
Bench Seat Belt Removal - 2009 and Newer Models
51
Bench Seat Belt Installation - 2009 and Newer Models
52
Seat Belt Removal - Homologated Models
52
Seat Belt Installation - Homologated Models
53
Cargo Bed - Electric Lift
53
Testing the Bed Lift Motor
53
Bed Lift Motor Removal
53
Bed Lift Motor Installation
54
Cargo Bed Removal
54
Cargo Bed Installation
54
Cargo Bed - Manual Lift
55
Cargo Bed Removal
55
Cargo Bed Installation
55
Rear Fender
57
Rear Fender Removal
57
Rear Fender Installation
57
Section 5 - Accelerator and Brake Pedal Assemblies
59
Accelerator Pedal - through Early 2010 Model Year
59
Accelerator Pedal Removal - through Early 2010 Model Year
59
Accelerator Pedal Installation - through Early 2010 Model Year
60
Accelerator Pedal and RPM Adjustment - through Early 2010 Model Year
60
Accelerator Pedal - from Late 2010 Model Year
61
Accelerator Pedal Removal - from Late 2010 Model Year
61
Accelerator Pedal Installation - from Late 2010 Model Year
61
Brake Pedal
63
Brake Pedal Removal
63
Brake Pedal Installation
63
Brake Pedal Adjustment
63
Park Brake Pedal
64
Park Brake Pedal Assembly Removal - Bell Crank System
64
Park Brake Pedal Assembly Installation - Bell Crank System
64
Park Brake Pedal Assembly Removal - Cable Only System
64
Park Brake Pedal Assembly Installation - Cable Only System
65
Section 6 - Hydraulic and Park Brake Systems
67
Brake System Inspection
67
Brake Pedal Inspection
67
Master Cylinder Inspection
68
Brake Line Inspection
69
Park Brake Inspection
69
Brake Disc and Pad Inspection
69
Brake System Troubleshooting
70
Brake Pads and Caliper - 2008-2011 Models
72
Front Brake Pad and Caliper Removal
72
Front Brake Pad and Caliper Installation
73
Rear Brake Pad and Caliper Removal
74
Rear Brake Pad and Caliper Installation
75
Brake Disc and Hub - 2008-2011 Models
76
Front Wheel Disc and Hub Removal
76
Front Wheel Disc and Hub Installation
80
Rear Wheel Disc Removal
81
Rear Wheel Disc Installation
82
Brake Pads and Caliper - Starting 2012 Model Year
83
Brake Pad and Caliper Removal
83
Brake Pad and Caliper Installation
84
Brake Discs - Starting 2012 Model Year
85
Disc Removal
85
Disc Installation
86
Hydraulic Line Replacement
86
Front Brake Line Removal
86
Front Brake Line Installation
87
Rear Brake Line Removal
88
Rear Brake Line Installation
88
Master Cylinder and Reservoir
89
Filling the Hydraulic System
89
Master Cylinder Removal
89
Master Cylinder Installation
90
Bleeding the Hydraulic Brake System
90
Bleeding Brakes on a DOT 5 Fluid Filled System
91
Purging the Hydraulic System
92
Park Brake System
93
Park Brake Adjustment - at Rear Calipers
93
Front Park Brake Cable Adjustment - Bell Crank System
93
Front Park Brake Cable Adjustment - Cable Only System
94
Park Brake Wheel Cables
94
Front Park Brake Cable Removal - Bell Crank System
96
Front Park Brake Cable Installation - Bell Crank System
97
Front Park Brake Cable Removal - Cable Only System
97
Front Park Brake Cable Installation - Cable Only System
98
Park Brake Equalizer Removal - Bell Crank System
98
Park Brake Equalizer Installation - Bell Crank System
98
Park Brake Equalizer Removal - Cable Only System
99
Park Brake Equalizer Installation - Cable Only System
99
Section 7 - Steering and Front Suspension
101
Steering Wheel
101
Steering Wheel Removal
101
Steering Wheel Installation
102
Steering Column
102
Steering Column Removal
102
Steering Column Installation
103
Rack and Pinion
103
Rack and Pinion Inspection
104
Rack and Pinion Removal
104
Rack and Pinion Installation
104
Rack and Pinion Disassembly
105
Rack and Pinion Assembly
109
Front Suspension
110
Wheel Alignment
110
Front Suspension Components
112
Steering Upright Removal
112
Upper A-Arm Removal
114
Upper A-Arm Installation
115
Lower A-Arm Removal
115
Lower A-Arm Installation
116
Front Coil-Over Shock Absorber Removal
117
Front Coil-Over Shock Absorber Installation
118
Steering Upright Installation
118
Section 8 - Wheels and Tires
119
General Information
119
Wheels
120
Wheel Removal
120
Wheel Installation
120
Tires
120
Tire Removal
120
Tire Installation
121
Section 9 - Rear Suspension
123
Rear Coil-Over Shock Absorber - 2008-2011 Models
123
Rear Shock Absorber Removal
123
Rear Shock Absorber Installation
124
Swing Arms - 2008-2011 Models
125
Swing Arm Removal
125
Swing Arm Installation
125
Rear Coil-Over Shock Absorber - Starting 2012 Model Year
126
Rear Shock Absorber Removal
126
Rear Shock Installation
127
Trailing Arms and Lateral Links - Starting 2012 Model Year
128
Lateral Link Removal
128
Lateral Link Installation
128
Trailing Arm Removal
130
Trailing Arm Installation
130
Section 10 - Periodic Maintenance
131
Periodic Service Schedule
131
Periodic Lubrication Schedule
134
Periodic Lubrication Schedule - Intellitach
136
Lubricating the Attachment Arm and Interface
137
Brake Fluid Reservoir
138
Brake Fluid
138
Engine Oil
138
Oil Pressure - Gasoline Engine
139
Engine Oil Level Check
139
Engine Oil and Filter Change
139
Oil Viscosity
142
Spark Plugs
143
Spark Plug Cleaning and Inspection
143
Spark Plug Gap Inspection
143
Gearcase Lubrication
143
Lubrication Level Check for Front Differential, Transmission, and Rear Differential
143
Lubrication Change for Front Differential, Transmission, and Rear Differential
144
Hydraulic System - Intellitach Vehicle
145
Engine Coolant - Diesel Vehicles
146
Engine Coolant Level Check
146
Fueling Instructions
146
Biodiesel Fuel (Diesel Vehicles Only)
147
Draining Water from Fuel Filter
148
Battery
149
Section 11 - Troubleshooting and Electrical System: Gasoline Vehicles
151
Troubleshooting Guide
151
Wiring Diagram
158
Test Procedures
160
Section 12 - Troubleshooting and Electrical System: Diesel Vehicles
191
Troubleshooting Guide
191
Wiring Diagram
198
Test Procedures
202
Section 13 - Electrical Components: Gasoline Vehicles
237
Starter and Starter Solenoid
237
Relays
237
Testing the Relay
237
Relay Removal
238
Relay Installation
238
Neutral Switch
238
Testing the Neutral Switch
238
Neutral Switch Removal
238
Neutral Switch Installation
238
Carburetor Solenoid
239
Testing the Carburetor Solenoid
239
Carburetor Solenoid Removal
239
Carburetor Solenoid Installation
239
Carburetor Heater
240
Carburetor Heater Removal
240
Carburetor Heater Installation
240
Voltage Regulator
241
Testing the Voltage Regulator
241
Voltage Regulator Removal
241
Voltage Regulator Installation
241
Warning Lights
242
Testing the Warning Lights
242
Warning Light Removal
242
Warning Light Installation
242
Fuel Gauge/Hour Meter
243
Testing the Fuel Gauge/Hour Meter
243
Fuel Gauge/Hour Meter Removal
243
Fuel Gauge/Hour Meter Installation
244
Key Switch
244
Testing the Key Switch
244
Key Switch Removal
244
Key Switch Installation
244
12-Volt Accessory Receptacle
245
Testing the 12-Volt Accessory Receptacle
245
12-Volt Accessory Receptacle Removal
245
12-Volt Accessory Receptacle Installation
245
Bed Lift Switch
246
Testing the Bed Lift Switch
246
Bed Lift Switch Removal
246
Bed Lift Switch Installation
246
Bed Lift Circuit Breaker
246
Testing the Bed Lift Circuit Breaker
246
Bed Lift Circuit Breaker Removal
246
Bed Lift Circuit Breaker Installation
247
Light Switch
247
Testing the Light Switch
247
Light Switch Removal
247
Light Switch Installation
247
Fuse
247
Testing the Fuse
247
Fuse Removal
248
Fuse Installation
248
Reverse Warning Buzzer (if Equipped)
248
Testing the Reverse Warning Buzzer
248
Reverse Warning Buzzer Removal
248
Reverse Warning Buzzer Installation
249
Reverse Warning Buzzer Limit Switch (if Equipped)
249
Testing the Reverse Warning Buzzer Limit Switch
249
Reverse Warning Buzzer Limit Switch Removal
249
Reverse Warning Buzzer Limit Switch Installation
250
Front Differential Limit Switch
250
Testing the Front Differential Limit Switch
251
Front Differential Limit Switch Removal
251
Front Differential Limit Switch Installation
251
Fuel Level Sending Unit
252
Testing the Fuel Level Sending Unit
252
Fuel Level Sending Unit Removal
252
Fuel Level Sending Unit Installation
252
Ignition Coil and Charge Coil
252
Testing the Ignition Coil
252
Ignition Coil And/Or Charge Coil Removal
252
Oil Pressure Sensor
253
Headlights
253
Testing the Headlight Bulb and Socket
253
Headlight Bulb Removal
253
Headlight Bulb Installation
253
Wire Harness Diodes
254
Testing the Wire Harness Diodes
254
Wire Harness Diode Removal
254
Wire Harness Diode Installation
254
Battery
255
General Information
255
Testing the Battery
255
Preventive Maintenance
255
Self-Discharge
256
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Club Car Carryall XRT 1550 Maintenance And Service Manual (432 pages)
Brand:
Club Car
| Category:
Golf Cars
| Size: 39.37 MB
Table of Contents
Table of Contents
5
Section 1 - Safety
15
Safety Details
15
Personal Safety
15
Machine Safety
15
Information
16
General Warnings
16
Disabling the Vehicle
17
Disconnecting the Battery - Gasoline/Diesel Vehicles
17
Connecting the Battery - Gasoline/Diesel Vehicles
18
Recycling Lead-Acid Batteries
18
International Safety Symbols on Batteries
20
Section 2 - Vehicle Specifications
21
295/295 SE and 1550/1550 SE Specifications
21
295 Homologated Specifications
24
Intellitach Specifications
26
Section 3 - General Information
29
Model Identification - Domestic
31
Identification Numbers
31
Model Identification - Homologated
33
Identification Numbers
33
Storage
34
Preparing the Vehicle for Extended Storage
35
Returning the Stored Vehicle to Service
35
Lifting the Vehicle
36
Lifting Only the Front
36
Lifting Only the Rear
36
Lifting the Entire Vehicle
37
Using a Booster Battery (Jump Starting)
38
Section 4 - Body and Trim
41
General Information
41
Cleaning the Vehicle
41
Seat Cleaning
41
Front Body Repair
42
Light Scratches
42
Abrasions and Haze
42
Large Scratches and Abrasions
43
Front Body Components
43
Instrument Panel Removal
43
Instrument Panel Installation
43
Front Fascia Removal
44
Front Fascia Installation
44
Hood Removal
44
Hood Installation
44
Center Cowl Panel Removal
44
Center Cowl Panel Installation
45
Side Cowl Panel (Fender) Removal
45
Side Cowl Panel (Fender) Installation
45
Front Fender Flare Removal
46
Front Fender Flare Installation
46
Roll-Over Protective Structure (ROPS)
46
ROPS Removal
47
ROPS Installation
48
Seat
49
Seat Removal
49
Seat Adjustment
49
Seat Installation
50
Seat Support Removal
50
Seat Support Installation
50
Seat Belts
50
Bench Seat Belt Removal
50
Bench Seat Belt Installation
51
Seat Belt Removal - Homologated Models
51
Seat Belt Installation - Homologated Models
52
Cargo Bed - Electric Lift
52
Testing the Bed Lift Motor
52
Bed Lift Motor Removal
52
Bed Lift Motor Installation
53
Cargo Bed Removal
53
Cargo Bed Installation
53
Cargo Bed - Manual Lift
54
Cargo Bed Removal
54
Cargo Bed Installation
54
Rear Fender
54
Rear Fender Removal
54
Rear Fender Installation
55
Section 5 - Accelerator and Brake Pedal Assemblies
57
Accelerator Pedal
57
Accelerator Pedal Removal
57
Accelerator Pedal Installation
58
Brake Pedal
59
Brake Pedal Removal
59
Brake Pedal Installation
59
Brake Pedal Adjustment
59
Park Brake Pedal
60
Park Brake Pedal Assembly Removal - Cable Only System
60
Park Brake Pedal Assembly Installation - Cable Only System
60
Section 6 - Hydraulic and Park Brake Systems
63
Brake System Inspection
63
Brake Pedal Inspection
63
Master Cylinder Inspection
64
Brake Line Inspection
65
Park Brake Inspection
65
Brake Disc and Pad Inspection
65
Brake System Troubleshooting
66
Brake Pads and Caliper
68
Brake Pad and Caliper Removal
68
Brake Pad and Caliper Installation
69
Brake Discs
71
Disc Removal
72
Disc Installation
72
Hydraulic Line Replacement
72
Front Brake Line Removal
73
Front Brake Line Installation
73
Rear Brake Line Removal
74
Rear Brake Line Installation
75
Master Cylinder and Reservoir
76
Filling the Hydraulic System
76
Master Cylinder Removal
76
Master Cylinder Installation
76
Bleeding the Hydraulic Brake System
77
Bleeding Brakes on a DOT 5 Fluid Filled System
77
Purging the Hydraulic System
79
Park Brake System
80
Park Brake Adjustment - at Rear Calipers
80
Front Park Brake Cable Adjustment - Cable Only System
80
Park Brake Wheel Cables
81
Front Park Brake Cable Removal - Cable Only System
82
Front Park Brake Cable Installation - Cable Only System
83
Park Brake Equalizer Removal - Cable Only System
83
Park Brake Equalizer Installation - Cable Only System
84
Section 7 - Steering and Front Suspension
85
Steering Wheel
85
Steering Wheel Removal
85
Steering Wheel Installation
86
Steering Column
86
Steering Column Removal
86
Steering Column Installation
87
Rack and Pinion
87
Rack and Pinion Inspection
88
Rack and Pinion Removal
88
Rack and Pinion Installation
88
Rack and Pinion Disassembly
89
Rack and Pinion Assembly
93
Front Suspension
94
Wheel Alignment
94
Front Suspension Components
98
Steering Upright Removal
98
Steering Upright Installation
100
Upper A-Arm Removal
100
Upper A-Arm Installation
102
Lower A-Arm Removal
102
Lower A-Arm Installation
103
Front Coil-Over Shock Absorber Removal
104
Front Coil-Over Shock Absorber Installation
105
Section 8 - Wheels, Tires and Hubs
107
General Information
107
Wheels
108
Wheel Removal
108
Wheel Installation
108
Tires
108
Tire Removal
108
Tire Installation
109
Front Hubs
109
Front Hub Removal
109
Front Hub Installation
111
Rear Hubs
112
Rear Hub Removal
112
Rear Hub Installation
113
Section 9 - Rear Suspension
115
Rear Coil-Over Shock Absorber
115
Rear Shock Absorber Removal
115
Rear Shock Installation
116
Trailing Arms and Lateral Links
117
Lateral Link Removal
117
Lateral Link Installation
117
Trailing Arm Removal
119
Trailing Arm Installation
119
Section 10 - Periodic Maintenance
121
Periodic Service Schedule
121
Periodic Service Schedule - Intellitach
124
Periodic Lubrication Schedule
126
Periodic Lubrication Schedule - Intellitach
128
Lubricating the Attachment Arm and Interface - Intellitach
129
Brake Fluid Reservoir
130
Brake Fluid
130
Engine Oil
130
Oil Pressure - Gasoline Engine
131
Engine Oil Level Check
131
Engine Oil and Filter Change
131
Oil Viscosity
134
Spark Plugs
135
Spark Plug Cleaning and Inspection
135
Spark Plug Gap Inspection
135
Gearcase Lubrication
135
Lubrication Level Check for Front Differential, Transmission and Rear Differential
135
Lubrication Change for Front Differential, Transmission and Rear Differential
136
Hydraulic System - Intellitach Vehicle
138
Engine Coolant - Diesel Vehicles
138
Engine Coolant Level Check
139
Fueling Instructions
139
Biodiesel Fuel (Diesel Vehicles Only)
140
Draining Water from Fuel Filter
141
Battery
142
Section 11 - Troubleshooting and Electrical System: Gasoline Vehicles
143
Troubleshooting Guide
143
Wiring Diagram
148
Test Procedures
150
Section 12 - Troubleshooting and Electrical System: Diesel Vehicles
181
Troubleshooting Guide
181
Wiring Diagram
186
Test Procedures
190
Section 13 - Electrical Components: Gasoline Vehicles
225
Starter and Starter Solenoid
225
Relays
225
Testing the Relay
225
Relay Removal
226
Relay Installation
226
Neutral Switch
226
Testing the Neutral Switch
226
Neutral Switch Removal
226
Neutral Switch Installation
226
Carburetor Solenoid
227
Testing the Carburetor Solenoid
227
Carburetor Solenoid Removal
227
Carburetor Solenoid Installation
227
Carburetor Heater
228
Carburetor Heater Removal
228
Carburetor Heater Installation
228
Voltage Regulator
229
Testing the Voltage Regulator
229
Voltage Regulator Removal
229
Voltage Regulator Installation
229
Warning Lights
230
Testing the Warning Lights
230
Warning Light Removal
230
Warning Light Installation
230
Fuel Gauge/Hour Meter
231
Testing the Fuel Gauge/Hour Meter
231
Fuel Gauge/Hour Meter Removal
231
Fuel Gauge/Hour Meter Installation
232
Key Switch
232
Testing the Key Switch
232
Key Switch Removal
232
Key Switch Installation
232
12-Volt Accessory Receptacle
233
Testing the 12-Volt Accessory Receptacle
233
12-Volt Accessory Receptacle Removal
233
12-Volt Accessory Receptacle Installation
233
Bed Lift Switch
233
Testing the Bed Lift Switch
233
Bed Lift Switch Removal
234
Bed Lift Switch Installation
234
Bed Lift Circuit Breaker
234
Testing the Bed Lift Circuit Breaker
234
Bed Lift Circuit Breaker Removal
234
Bed Lift Circuit Breaker Installation
234
Light Switch
234
Testing the Light Switch
235
Light Switch Removal
235
Light Switch Installation
235
Fuse
235
Testing the Fuse
235
Fuse Removal
235
Fuse Installation
235
Reverse Warning Buzzer (if Equipped)
236
Testing the Reverse Warning Buzzer
236
Reverse Warning Buzzer Removal
236
Reverse Warning Buzzer Installation
236
Reverse Warning Buzzer Limit Switch (if Equipped)
237
Testing the Reverse Warning Buzzer Limit Switch
237
Reverse Warning Buzzer Limit Switch Removal
237
Reverse Warning Buzzer Limit Switch Installation
237
Front Differential Limit Switch
238
Testing the Front Differential Limit Switch
238
Front Differential Limit Switch Removal
238
Front Differential Limit Switch Installation
239
Testing the Fuel Level Sending Unit
239
Fuel Level Sending Unit Removal
240
Fuel Level Sending Unit Installation
240
Ignition Coil and Charge Coil
240
Testing the Ignition Coil
240
Ignition Coil And/Or Charge Coil Removal
240
Oil Pressure Sensor
240
Headlights
240
Testing the Headlight Bulb and Socket
241
Headlight Bulb Removal
241
Headlight Bulb Installation
241
Wire Harness Diodes
241
Testing the Wire Harness Diodes
242
Wire Harness Diode Removal
242
Wire Harness Diode Installation
242
Battery
242
General Information
243
Testing the Battery
243
Preventive Maintenance
243
Self-Discharge
243
Water Level
244
Vibration Damage
244
Mineral Content
244
Battery Removal
244
Charging the Battery
245
Battery Installation
245
Battery Storage
245
Club Car Carryall XRT 1550 Maintenance And Service Manual (424 pages)
Brand:
Club Car
| Category:
Golf Cars
| Size: 37.89 MB
Table of Contents
Table of Contents
5
Section 1 - Safety
15
Safety Details
15
Personal Safety
15
Machine Safety
15
Information
16
General Warnings
16
Disabling the Vehicle
17
Disconnecting the Battery - Gasoline/Diesel Vehicles
17
Connecting the Battery - Gasoline/Diesel Vehicles
18
Recycling Lead-Acid Batteries
18
International Safety Symbols on Batteries
19
Section 2 - Vehicle Specifications
21
1500/1700 and 1550/1550 SE Specifications
21
Intellitach Specifications
24
Section 3 - General Information
27
Model Identification
29
Identification Numbers
29
Storage
31
Preparing the Vehicle for Extended Storage
32
Returning the Stored Vehicle to Service
32
Lifting the Vehicle
33
Lifting Only the Front
33
Lifting Only the Rear
33
Lifting the Entire Vehicle
34
Using a Booster Battery (Jump Starting)
35
Section 4 - Body and Trim
37
General Information
37
Cleaning the Vehicle
37
Seat Cleaning
37
Front Body Repair
38
Light Scratches
38
Abrasions and Haze
38
Large Scratches and Abrasions
39
Front Body Components
39
Instrument Panel Removal
39
Instrument Panel Installation
39
Front Fascia Removal
40
Front Fascia Installation
40
Hood Removal
40
Hood Installation
40
Center Cowl Panel Removal
40
Center Cowl Panel Installation
41
Side Cowl Panel (Fender) Removal
41
Side Cowl Panel (Fender) Installation
41
Front Fender Flare Removal
42
Front Fender Flare Installation
42
Roll-Over Protective Structure (ROPS)
42
ROPS Removal
43
ROPS Installation
44
Seat
45
Seat Removal
45
Seat Adjustment
45
Seat Installation
46
Seat Support Removal
46
Seat Support Installation
46
Seat Belts
46
Bench Seat Belt Removal
46
Bench Seat Belt Installation
47
Cargo Bed - Electric Lift
47
Testing the Bed Lift Motor
47
Bed Lift Motor Removal
47
Bed Lift Motor Installation
48
Cargo Bed Removal
48
Cargo Bed Installation
48
Cargo Bed - Manual Lift
49
Cargo Bed Removal
49
Cargo Bed Installation
49
Rear Fender
50
Rear Fender Removal
50
Rear Fender Installation
50
Section 5 - Accelerator and Brake Pedal Assemblies
53
Accelerator Pedal
53
Accelerator Pedal Removal
53
Accelerator Pedal Installation
54
Brake Pedal
55
Brake Pedal Removal
55
Brake Pedal Installation
55
Brake Pedal Adjustment
55
Park Brake Pedal
56
Park Brake Pedal Assembly Removal
56
Park Brake Pedal Assembly Installation
56
Section 6 - Hydraulic and Park Brake Systems
59
Brake System Inspection
59
Brake Pedal Inspection
59
Master Cylinder Inspection
60
Brake Line Inspection
61
Park Brake Inspection
61
Brake Disc and Pad Inspection
61
Brake System Troubleshooting
62
Brake Pads and Caliper
64
Brake Pad and Caliper Removal
64
Brake Pad and Caliper Installation
65
Brake Discs
68
Disc Removal
68
Disc Installation
68
Hydraulic Line Replacement
69
Front Brake Line Removal
69
Front Brake Line Installation
69
Rear Brake Line Removal
70
Rear Brake Line Installation
71
Master Cylinder and Reservoir
72
Filling the Hydraulic System
72
Master Cylinder Removal
72
Master Cylinder Installation
72
Bleeding the Hydraulic Brake System
73
Bleeding Brakes on a DOT 5 Fluid Filled System
73
Purging the Hydraulic System
75
Park Brake System
76
Park Brake Adjustment - at Rear Calipers
76
Front Park Brake Cable Adjustment - Cable Only System
76
Park Brake Wheel Cables
77
Front Park Brake Cable Removal - Cable Only System
78
Front Park Brake Cable Installation - Cable Only System
79
Park Brake Equalizer Removal - Cable Only System
79
Park Brake Equalizer Installation - Cable Only System
80
Section 7 - Steering and Front Suspension
81
Steering Wheel
81
Steering Wheel Removal
81
Steering Wheel Installation
82
Steering Column
82
Steering Column Removal
82
Steering Column Installation
83
Rack and Pinion
83
Rack and Pinion Inspection
84
Rack and Pinion Removal
84
Rack and Pinion Installation
84
Rack and Pinion Disassembly
85
Rack and Pinion Assembly
89
Front Suspension
90
Wheel Alignment
90
Front Suspension Components
94
Steering Upright Removal
94
Steering Upright Installation
96
Upper A-Arm Removal
96
Upper A-Arm Installation
98
Lower A-Arm Removal
98
Lower A-Arm Installation
99
Front Coil-Over Shock Absorber Removal
100
Front Coil-Over Shock Absorber Installation
101
Section 8 - Wheels, Tires and Hubs
103
General Information
103
Wheels
104
Wheel Removal
104
Wheel Installation
104
Tires
104
Tire Removal
104
Tire Installation
105
Front Hubs
105
Front Hub Removal
105
Front Hub Installation
107
Rear Hubs
108
Rear Hub Removal
108
Rear Hub Installation
109
Section 9 - Rear Suspension
111
Rear Coil-Over Shock Absorber
111
Rear Shock Absorber Removal
111
Rear Shock Installation
112
Trailing Arms and Lateral Links
113
Lateral Link Removal
113
Lateral Link Installation
113
Trailing Arm Removal
113
Trailing Arm Installation
113
Section 10 - Periodic Maintenance
115
Periodic Service Schedule
115
Periodic Service Schedule - Intellitach
118
Periodic Lubrication Schedule
120
Periodic Lubrication Schedule - Intellitach
122
Lubricating the Attachment Arm and Interface - Intellitach
123
Brake Fluid Reservoir
124
Brake Fluid
124
Engine Oil
124
Oil Pressure - Gasoline Engine
125
Engine Oil Level Check
125
Engine Oil and Filter Change
125
Oil Viscosity
128
Spark Plugs
129
Spark Plug Cleaning and Inspection
129
Spark Plug Gap Inspection
129
Gearcase Lubrication
129
Lubrication Level Check for Front Differential, Transmission and Rear Differential
129
Lubrication Change for Front Differential, Transmission and Rear Differential
130
Hydraulic System - Intellitach Vehicle
132
Engine Coolant - Diesel Vehicles
133
Engine Coolant Level Check
133
Fueling Instructions
133
Biodiesel Fuel (Diesel Vehicles Only)
134
Draining Water from Fuel Filter
135
Battery
136
Section 11 - Troubleshooting and Electrical System: Gasoline Vehicles
137
Troubleshooting Guide
137
Wiring Diagram
142
Test Procedures
145
Section 12 - Troubleshooting and Electrical System: Diesel Vehicles
177
Troubleshooting Guide
177
Wiring Diagram
182
Test Procedures
185
Section 13 - Electrical Components: Gasoline Vehicles
219
Starter and Starter Solenoid
219
Relays
219
Testing the Relay
219
Relay Removal
220
Relay Installation
220
Neutral Switch
220
Testing the Neutral Switch
220
Neutral Switch Removal
220
Neutral Switch Installation
220
Carburetor Solenoid
221
Testing the Carburetor Solenoid
221
Carburetor Solenoid Removal
221
Carburetor Solenoid Installation
221
Carburetor Heater
222
Carburetor Heater Removal
222
Carburetor Heater Installation
222
Voltage Regulator
223
Testing the Voltage Regulator
223
Voltage Regulator Removal
223
Voltage Regulator Installation
223
Warning Lights
224
Testing the Warning Lights
224
Warning Light Removal
224
Warning Light Installation
224
Fuel Gauge/Hour Meter
225
Testing the Fuel Gauge/Hour Meter
225
Fuel Gauge/Hour Meter Removal
225
Fuel Gauge/Hour Meter Installation
226
Key Switch
226
Testing the Key Switch
226
Key Switch Removal
226
Key Switch Installation
226
12-Volt Accessory Receptacle
227
Testing the 12-Volt Accessory Receptacle
227
12-Volt Accessory Receptacle Removal
227
12-Volt Accessory Receptacle Installation
227
Bed Lift Switch
228
Testing the Bed Lift Switch
228
Bed Lift Switch Removal
228
Bed Lift Switch Installation
228
Bed Lift Circuit Breaker
228
Testing the Bed Lift Circuit Breaker
228
Bed Lift Circuit Breaker Removal
228
Bed Lift Circuit Breaker Installation
229
Light Switch
229
Testing the Light Switch
229
Light Switch Removal
229
Light Switch Installation
229
Fuse
229
Testing the Fuse
230
Fuse Removal
230
Fuse Installation
230
Reverse Warning Buzzer (if Equipped)
230
Testing the Reverse Warning Buzzer
230
Reverse Warning Buzzer Removal
230
Reverse Warning Buzzer Installation
231
Reverse Warning Buzzer Limit Switch (if Equipped)
231
Testing the Reverse Warning Buzzer Limit Switch
231
Reverse Warning Buzzer Limit Switch Removal
231
Reverse Warning Buzzer Limit Switch Installation
232
Front Differential Limit Switch
232
Testing the Front Differential Limit Switch
233
Front Differential Limit Switch Removal
233
Front Differential Limit Switch Installation
233
Fuel Level Sending Unit
234
Testing the Fuel Level Sending Unit
234
Fuel Level Sending Unit Removal
234
Fuel Level Sending Unit Installation
234
Ignition Coil and Charge Coil
234
Testing the Ignition Coil
234
Ignition Coil And/Or Charge Coil Removal
234
Oil Pressure Sensor
235
Headlights
235
Testing the Headlight Bulb and Socket
235
Headlight Bulb Removal
235
Headlight Bulb Installation
235
Wire Harness Diodes
236
Testing the Wire Harness Diodes
236
Wire Harness Diode Removal
236
Wire Harness Diode Installation
236
Battery
237
General Information
237
Testing the Battery
237
Preventive Maintenance
237
Self-Discharge
238
Water Level
238
Vibration Damage
238
Mineral Content
238
Battery Removal
239
Charging the Battery
239
Battery Installation
239
Battery Storage
240
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