Section 6 Maintenance
4200ATR Light Utility Vehicle 710-040M
7/14/08
20
Table of Contents
Jacking the Vehicle
!
DANGER
For your safety and safety of others, a jacked vehicle must be
supported properly with jack stands before working under and
around it. Also the wheels on the ground must be chocked on
both sides to prevent the vehicle from rolling forward or
backward.
1.
Park vehicle on a level surface, set park brake, turn
ignition switch off and remove switch key.
2.
Chock front and back side of the wheels not being
jacked off the ground.
3.
Loosen the lug nuts on any wheel being removed
approximately 1/2 turn counterclockwise while it is still
on the ground.
4.
See important note above. Place proper jack under
vehicle as follows:
a.
Front tires: Center jack under the body frame
between the two A-Frame struts.
b.
Rear tires: Center jack under the receiver hitch.
5.
Jack vehicle only high enough to do the work
intended.
6.
Support the vehicle securely with jack stands before
working under or around the vehicle.
7.
Work may now be performed on the vehicle. Be sure
to properly torque all bolts that were loosened. Wheel
bolts should be torqued after the vehicle is lowered to
the ground.
8.
Lower the vehicle by first jacking the vehicle up high
enough to remove the jack stands. Then carefully
lower the jack until the vehicle is on the ground.
9.
Remove wheel chocks.
Shock Absorber Adjustment
Traveling fast and carrying heavy loads can cause the
shock absorbers to bottom-out making the ride rough and
hard on the vehicle. This can be compensated for by
adjusting the front and rear shock springs. Typically, the
shock absorber springs are set soft for slow speeds and
light loads. Fast speeds and heavy loads require a firmer
setting.
Adjust front and rear shock absorber springs as follows:
1.
The shocks may be adjusted without jacking the
vehicle; however, it is easier if the tire near the shock
being adjusted is removed and the vehicle weight is
lifted off the shock.
2.
Locate the step collar below the shock absorber
spring. Notice the stepped notches in the collar and
that one of the notches rest on a pin.
3.
Use a pipe wrench to rotate the step collar only when
a special step collar wrench is not available.
4.
Rotation direction is defined by looking down on the
shocks from the top side of the vehicle.
a.
Rotate the step collar counterclockwise to
increases spring pressure and ride firmness.
b.
Rotate the step collar clockwise to decrease
spring pressure and to soften the ride.
5.
Return any removed tires and lower the vehicle to the
ground.
Electrical System
The electrical system is 12 volt, 10 amp with negative
ground. The electrical system is protected by a fuse
located at the battery positive post and a liquid tight self-
resetting circuit breaker in the wiring harness at the
starter’s positive connection. The amp ratings are as
follows:
•
Battery post fuse: - 175 Amps
•
Self-resetting circuit breaker- 30 Amps
Common circuit failures are “shorts”, corroded or dirty
terminals, loose connections, defective wire insulation or
broken wires. Switches, solenoids and ignition
components can also not function, causing a short or open
circuit.
Before attempting any fault diagnosis of the electrical
system, use a test light or voltmeter to check the battery
voltage. If the battery voltage is satisfactory, check the
cleanliness and tightness of the terminals and ground
connections. A general understanding of electrical
servicing and use of basic test equipment is necessary for
troubleshooting and repair.
Major overhaul or repair of the starting motor or alternator
should be performed by trained technicians only.
Battery
Refer to Figure 6-1
The battery is located behind the removable front grill.
Remove grill by pressing down on the grill in the location of
the two tabs shown. Pull back at the top and lift up.
IMPORTANT: Use a hydraulic jack, floor jack, or
scissor type jack to lift the vehicle. Do not use a
handyman jack or bumper jack and don’t jack against
the bumper, body, front 4-wheel drive transfer case,
rear transmission, or axles.
