Preliminary TRACKER OFF ROAD LX6 Repair And Service Manual Download Page 43

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BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Repair and Service Manual

699327

Fig. 13 Truck Bed

Front of Vehicle

PRELIMINARY

Summary of Contents for TRACKER OFF ROAD LX6

Page 1: ...REPAIR AND SERVICE MANUAL 699327 A Issued August 2019 PRELIMINARY...

Page 2: ...hicle from one location to another location If the vehicle is used in a commercial environment signs must be in position to inform of possible conditions that can be dangerous Examples shown below NOT...

Page 3: ...is manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by the manufacturer and therefore is subject to chan...

Page 4: ...n certification applicable at the time of manu facture BATTERY PROLONGED STORAGE Batteries self discharge over time The rate of self discharge varies depending on the ambient temperature the age and c...

Page 5: ...LE 2 ROUTINE MAINTENANCE 2 REAR AXLE 3 BRAKES 3 TIRES 3 LIGHT BULB REPLACEMENT 3 VEHICLE CLEANING AND CARE 3 VEHICLE CARE PRODUCTS 3 SUN TOP AND WINDSHIELD 3 SERVICE SCHEDULE 4 HARDWARE 5 SAFETY NOTIC...

Page 6: ...eat Frame 24 Flip Seat Seat Back Support and Footrest 26 Truck Bed and Bed Support 28 Rear Body 30 PAINTING 32 Minor Scratches 32 Larger Scratches 32 Complete Panel Repair 32 FRONT SUSPENSION STEERING...

Page 7: ...on to Rack and Pinion Unit Clearance 48 Steering Wheel Replacement 49 Steering Shaft and Column Replacement 50 BATTERIES AND BATTERY CHARGER SAFETY 53 BATTERY 53 Batteries Removal 54 Battery Installat...

Page 8: ...65 Controller 65 GENERAL FAULT TESTING 65 Testing 65 INDUCTIVE THROTTLE SENSOR ITS TESTING AND REPLACEMENT 66 MOTOR GENERAL 69 Motor Removal 69 Motor Installation 70 MOTOR TESTS 70 ELECTRICAL SYSTEM...

Page 9: ...qualizer Link 90 Automatic Adjuster Mechanism 90 How the Parking Brake Works 91 Compensator Assembly 91 Kick Off Actuating Linkage 91 FAULT TESTING TABLE 92 FAULT TESTING AND INSPECTION 94 New Vehicle...

Page 10: ...08 Parking Brake Pedal Removal and Installation 108 Pedal Bumper Adjustment 108 Parking Brake Release Linkage and Kick Off Cam Removal and Replacement 109 REAR AXLE REAR AXLE MAINTENANCE 111 Replacing...

Page 11: ...de Chart 133 Curtis Handheld Diagnostic Tool Function 142 COMPONENT TESTING 148 Voltmeter 148 Fuses Testing 148 Key Switch Testing 149 State of Charge SOC Hour Meter Testing 149 Electronic Speed Contr...

Page 12: ...x Repair and Service Manual TABLE OF CONTENTS Notes 699327 PRELIMINARY...

Page 13: ...the federal Motor Vehicle Safety Standards of the United States of America USA and are not for operation on the public streets Refer to the General Specifications section for capacity of the vehicle...

Page 14: ...jack alone Lift the vehicle according to the manufacturers instructions Make sure you service the vehicle in an area away from open flame or sparks Know that a vehicle in need of repair does not opera...

Page 15: ...rear wheels Part C is located under the charger receptacle Part D is located on the frame rail below the driver s seat floorboard The PIN plates are located on the inside of the frame rail at the driv...

Page 16: ...care when working around batteries or using solvents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads f...

Page 17: ...l require the use of a commercially available vinyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water...

Page 18: ...st if required C A C A C A C A Wiring Inspect for loose connections broken or missing insulation C C C C Direction Selector Inspect attachment and mechanism C A C A C A C A Steering Assembly Check for...

Page 19: ...s Grade 2 Fig 6 Torque Specifications ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten all hardware in accordance w...

Page 20: ...rvice Manual GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699...

Page 21: ...passenger s do not make changes to the weight distribution or the center of gravity which could make the vehicle unstable or prone to roll over Do not modify the vehicle in any manner that will change...

Page 22: ...r death Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which could result in an explosion Ov...

Page 23: ...ks 4 Some servicing operations may require the vehicle to be raised To prevent possible injury or death resulting from a vehicle falling from a jack be sure the vehicle is on a firm and level surface...

Page 24: ...and behind each rear wheel in order to stabilize the vehicle 2 Place the jack at the center of the front axle Ref Fig 2 3 Raise the vehicle and position the jack stands under the inner frame member a...

Page 25: ...11 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SAFETY 699327 PRELIMINARY...

Page 26: ...12 Repair and Service Manual SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMINARY...

Page 27: ...page 155 For outdoor applica tions with major use on grassy areas the following should be considered On hard turf it is desirable to have a slightly higher inflation pressure On very soft turf a lower...

Page 28: ...all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699327 Fig 1 Wheel and Tire Installation 1 2 3 4 Cross Sequence 1 2 5...

Page 29: ...Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers WHEELS AND TIRES 699327 PRELIMINA...

Page 30: ...Repair and Service Manual WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMINA...

Page 31: ...e of a drill depth stop will also provide additional protection In general body component replacement can be accom plished with a minimum of specialized tools Most body components are held in place wi...

Page 32: ...3 securing the rear of the rocker panel 5 to the frame 2 Remove the lock nut 6 washer 7 and screw 1 securing the front of the rocker panel 5 to the fender flare 3 Remove the remaining lock nuts 4 spac...

Page 33: ...e Tool List Screwdriver Phillips 1 Drill Bit 1 Drill 1 Rivet Gun 1 1 Remove the lock nut 6 washer 7 and screw 1 securing the front of the rocker panel 5 to the fender flare Ref Fig 4 2 Drill out the r...

Page 34: ...ghts from the main harness See Headlight Assembly on page 79 2 Drill out the rivets securing the top of the fender flairs to each side of the cowl See Fender Flare on page 19 3 Drill out the rivets 12...

Page 35: ...ol Panel Tool List Qty Screwdriver Phillips 1 Pry Bar 1 1 Remove the screws 11 securing the top of the con trol panel 10 to the instrument panel 15 Ref Fig 7 2 Pull the top of the control panel out an...

Page 36: ...o cost 1 Disconnect the battery cable at the negative bat tery terminal 2 Remove the control panel See Control Panel on page 21 3 Disconnect the push on connectors to the reverse buzzer See Reverse Bu...

Page 37: ...curing the fascia to the frame and set the horn to the side 5 Remove the bolts 21 securing the mounting bracket to the frame Assemble in the reverse order of removal using new ratchet rivets Tighten t...

Page 38: ...4 Remove the on board charger 5 Drill out the rivets 39 securing the seat frame to the front of the seat pod and discard the washers 37 38 Ref Fig 11 6 Remove the lock nuts 29 bolts 27 and washers 28...

Page 39: ...ore attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 25 Repair and Service Manual 699327 Fig 11 Front Seat Pod and Frame 26 40 35 29 28 27 27 28 29 31 32 33 3...

Page 40: ...rails 55 to the foot rest 60 5 Remove the lock nuts 41 washers 42 and bolts 43 securing the hand rails to the seat frame 6 Remove the lock nuts 54 washers 53 and bolts 52 securing the seat frame to th...

Page 41: ...rocedure Pay particular attention to Notices Cautions Warnings and Dangers 27 Repair and Service Manual 699327 Fig 12 Flip Seat 41 45 42 43 44 47 46 48 49 51 55 50 60 50 53 52 54 53 56 57 58 59 61 61...

Page 42: ...81 securing the deck of the bed to the bed frame 5 If the latch 85 is damaged remove the screws 86 securing it to the bed frame 6 Remove the lock nuts 71 washers 72 and bolts 69 securing the bed frame...

Page 43: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 29 Repair and Service Manual 699327 Fig 13 Truck Bed 89 87 88 87 69 71 72 74 73 76 74 77 78 79 81 82 83 84 8...

Page 44: ...additional protection 1 Remove the sun top if equipped See SUN TOP on page 121 2 Remove the truck bed or flip seat See Truck Bed and Bed Support on page 28 See Flip Seat Seat Back Support and Footres...

Page 45: ...TY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 31 Repair and Service Manual 699327 Fig 14 Rear Body 100 95 91 92 93 94 96 Front o...

Page 46: ...ean the surface to be repaired with alcohol and dry 2 Mask the area to be painted common masking tape is adequate prior to repair and use aerosol type touch up paint 3 Apply spray touch up paint in li...

Page 47: ...33 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BODY 699327 PRELIMINARY...

Page 48: ...34 Repair and Service Manual BODY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMINARY...

Page 49: ...before beginning any repair pro cedure Always place chocks in front and behind wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting pro cess Lift the fr...

Page 50: ...felt If the cotter pin hole in the spindle 5 aligns with a slot in the castel lated nut insert a new cotter pin 2 If the hole does not align the castellated nut must be loosened to align with the clo...

Page 51: ...s not centered proceed below 1 Remove the bolt connecting the intermediate shaft to the steering shaft and center the steering wheel Ref Fig 4 2 Reconnect the intermediate shaft and tighten the bolt t...

Page 52: ...lts 29 and spring plate 31 securing the rear of the spring 20 to the vehicle frame To prevent stress and possible dam age to the rack and pinion unit the driver side spring must be mounted to the axle...

Page 53: ...Tighten all hardware to the torque values below 4 Replace the upper portion of the floor mat in the plastic trim retainers 5 Install the front wheels See Wheel Installation on page 13 and lower the ve...

Page 54: ...ub 30 loosely with the castellated nut 37 12 Place the wheel onto the hub and hand tighten the lug nuts Fig 8 Hub Replacement 13 Adjust the bearing See Wheel Bearing Adjustment on page 36 Wheel Bearin...

Page 55: ...n the spindle 35 and pack the new bearings with grease See Wheel Bearing Packing on page 35 Fig 9 Wheel Bearing Replacement 13 Install the inner wheel bearing 33 and new grease seal in the hub 14 Moun...

Page 56: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699327 STEERING Fig 10 Steering Components 48 47 26 13 16 19 23 21 14 15 22 Front of...

Page 57: ...e Bellows Replacement on page 44 11 Using the measurement made earlier thread the jam nut 48 and the new rack ball 50 joint to the previ ous location on the rack extension 55 and set the jam nut 48 ha...

Page 58: ...ach the tie rod to the spindle 12 Tighten the lock nut 46 to the torque values below 13 Tighten the jam nut 44 to the torque values below 14 Install the front wheel s and lower the vehicle See Wheel I...

Page 59: ...from the passenger side spindle arm 6 Remove the lock nut from the ball joint and the ball joint from the spindle arm 7 Remove the lock nuts 16 19 bolts 13 47 wash ers 14 and spacers 49 securing the...

Page 60: ...Loosen the front wheel and lift and support the front of the vehicle See Wheel Installation on page 13 2 Remove the front wheel 3 Loosen the lock nut 46 until the tie rod ball joint 45 threads are pr...

Page 61: ...nion unit back to rest on top of the front springs 11 Secure the rack and pinion unit to the spring with a wire to prevent the intermediate shaft from pulling apart 12 Remove the lock nuts 11 bolts 17...

Page 62: ...seal See Pinion Seal Replacement on page 45 15 Insert the rack gear 75 into the rack and pinion unit Turn the pinion gear 80 clockwise to help pull the rack in if necessary 16 Install the bellows 65 a...

Page 63: ...List Qty Socket 15 16 1 Ratchet 1 Plastic Faced Hammer 1 Ball Peen Hammer 1 Anti seize Compound 1 Torque Wrench ft lbs 1 NOTICE To maintain the correct orientation when replacing the steering wheel f...

Page 64: ...Snap Ring Pliers 1 Bearing Separator 1 Gear Puller 1 Arbor Press 1 Bearing Driver Set 1 Torque Wrench ft lbs 1 Wheel Bearing Grease AR 1 Remove the steering wheel See Steering Wheel Replacement on pag...

Page 65: ...t 105 to the torque values below Ref Fig 21 17 Install the front wheel s and lower vehicle See Wheel Installation on page 13 18 Install the steering wheel See Steering Wheel Replacement on page 49 Fig...

Page 66: ...and Service Manual FRONT SUSPENSION STEERING AXLE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PR...

Page 67: ...goggles when adding water or charging batteries Any electrolyte spills should be neutralized with a solution of 1 4 cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of wat...

Page 68: ...ench 1 2 1 Insulated Wrench 9 16 1 Insulated Socket 1 2 1 Insulated Socket 9 16 1 Ratchet 1 Battery Carrier 1 Torque Wrench ft lbs 1 Torque Wrench in lbs 1 Putty Knife 1 Wire Brush 1 Terminal Spreader...

Page 69: ...with the hold down bolts 4 3 Tighten the lock nuts 6 to torque values below tight enough to prevent movement of the battery but not tight enough to cause distortion of the battery cases 4 Inspect all...

Page 70: ...e tempera ture The colder the temperature the less energy the bat tery is able to store As the temperature increases so does the storage capacity of the battery Ref Fig 3 The ideal battery temperature...

Page 71: ...aintenance Kit P N 25587G01 can be used with an approved water source Ref Fig 6 These water ing devices are fast and accurate to use and maintain the correct electrolyte level within the battery cells...

Page 72: ...above 75 F 60 C Although the chemical reaction is slowed in cold tem peratures the battery must be stored fully charged and disconnected from any circuit that could discharge the battery Disconnect t...

Page 73: ...ttery in a set with a lower than normal specific gravity Once the problematic cell or cells are identified the suspect battery can be removed and replaced At this point there is nothing that can be do...

Page 74: ...ding to conform with the electrolyte temperature e g if the reading indicates a specific gravity of 1 250 and the electrolyte temperature is 90 F 32 C add four points 004 to the 1 250 which gives a co...

Page 75: ...ng the connections to the battery while charging Do not open or disassemble the charger Do not operate the charger if the AC supply cord is damaged or if the charger has received a sharp blow been dro...

Page 76: ...and Service Manual BATTERIES AND BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRE...

Page 77: ...the motor gen erates power which is returned to the batteries Walk Away Feature Walk Away limits the movement of the vehicle without driver input decreases vehicle speed to 2 mph 3 kph and activates...

Page 78: ...gned speed range the warning beeper will not sound When the electronic braking system is acti vated by this sequence of events the motor generates power which is returned to the batteries 72 volt mode...

Page 79: ...to oper ate at its fullest potential A light on the controller face will blink a code informing the technician to the likely cause of the vehicle malfunction A series of blinks will indicate the fault...

Page 80: ...of specifica tion the ITS sensor must be replaced The ITS attaches to the plastic pedal box using two plastic studs and two speed nuts Use caution not to over tighten the nuts which could strip the p...

Page 81: ...air and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRONIC SPEED CONTROL 699327 PRELI...

Page 82: ...air and Service Manual ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELI...

Page 83: ...n insulated wrench before removing wires from the motor A short circuit of the motor wires can cause an explosion Motor Removal Tool List Qty Wrench 10mm 1 Insulated Wrench 9 16 1 Chalk or Paint Pen 1...

Page 84: ...ig 3 then tighten in 25 in lbs 2 82 Nm increments of torque using the same cross sequence pattern 4 Reconnect the temperature sensor 9 and speed sensor 8 wiring harnesses 5 Reconnect the U V and W ter...

Page 85: ...71 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers MOTOR 699327 PRELIMINARY...

Page 86: ...72 Repair and Service Manual MOTOR Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMINARY...

Page 87: ...ead all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 73 Repair and Service Manual 699327 ELECTRICAL SYSTEM Fig 1 Wiring...

Page 88: ...d Service Manual ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699327 Fig 2 Electrical Schemat...

Page 89: ...Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 75 Repair and Service Manual 699327 Fig 3 Electrical Schematic Co...

Page 90: ...and Service Manual ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699327 Fig 4 Harness Overview...

Page 91: ...c tion and for worn insulation or bare wires touch ing the frame Bare wires can cause a short cir cuit NOTICE If any DVOM readings indicate a faulty wire check the condition of the terminals and wire...

Page 92: ...nuity at the ground connection then the circuit is complete Electricity must flow from the fuse panel through the full length of the circuit to the ground connection Correct any interruption of electr...

Page 93: ...it into place 4 Reconnect the harness Fig 8 Halogen Bulb LED Bulb If the vehicle is equipped with LED headlights The head light contains an LED light board rather than a light bulb If the LEDs burn ou...

Page 94: ...roller An electrical motor short may be the cause of the controller fail ure and will damage the new controller See AC Motor Bench Test on page 151 1 Use an insulated wrench to disconnect the negative...

Page 95: ...er Be sure to hold the screwdriver by the insulated handle NOTICE Record the location of the wiring on the controller before disconnecting the wiring from the solenoid Use an insulated wrench to remov...

Page 96: ...rque values below Fig 13 DC to DC Converter Reverse Buzzer Tool List Qty Screwdriver Phillips 1 Drill Bit 1 Drill 1 Rivet Gun 1 1 Disconnect the negative battery cable using an insulated wrench 2 Remo...

Page 97: ...he fault is a burned out bulb or a poor con tact between the connectors and the headlight If power is not present but the other headlight functions a wiring problem is indicated between the two headli...

Page 98: ...setting set it to K the meter will indicate 0 when it detects continuity Testing A Switch for Continuity Put one probe on one contact of the switch Put the sec ond probe on the second terminal of the...

Page 99: ...ose 1 1 Set the keyswitch to the OFF position and remove the key 2 Disconnect the negative battery cable using an insulated wrench 3 Remove the control panel See Control Panel on page 21 4 Disconnect...

Page 100: ...ative battery cable using an insu lated wrench 2 Remove the control panel See Control Panel on page 21 3 Disconnect the main wiring harness from the rocker switch 4 Squeeze the tabs on the top and bot...

Page 101: ...Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRICAL SYSTEM 699327 PRELIMINA...

Page 102: ...Repair and Service Manual ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMINA...

Page 103: ...n Clevis Pin Brake Lever Self Adjusting Wheel Brake Spherical Nut Jam Nut Brake Pedal Pivot Bolt Compensator Assembly Pedal Latch Arm Kick Off Cam Torsion Springs Identification Hole Washers Bushing C...

Page 104: ...al pedal and cable travel causes the actuator bracket moving anchor to move and applies force to the front shoe pushing it against the brake drum The force applied to the front and rear shoes is appro...

Page 105: ...rake pedal to return to its original position disengaging the latch arm from the catch bracket This method is preferred as it minimizes wear on components 2 Pressing the accelerator pedal rotates the...

Page 106: ...material System not adjusted properly Check and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace In excess of 1 1 8 2 9 cm free pedal travel...

Page 107: ...omplete adjustment Adjust entire system Brake pedal not returning Check for binding of brake pedal Check brake pedal free travel Grabbing brakes oversensitive Moisture has caused surface rust on drums...

Page 108: ...erformance See Periodic Brake Performance Test PBPT on page 97 Based on the results of the inspection and tests refer to the fault testing table Ref Fig 5 to evaluate symptoms and repairs 3 If require...

Page 109: ...brake pedals See Parking Brake Latching Force on page 102 Adjust the brake pedal free travel if required See Adjusting Brake Pedal Free Travel on page 101 4 Inspect the brake cables Inspect for damag...

Page 110: ...m Replace if showing signs of wear or damage Ref Fig 11 11 Inspect the parking brake kick off cam Look for wear and for correct adjustment With the parking brake engaged and fully latched there must b...

Page 111: ...le weight accessories installed and vehicle speed No specific braking distance can be reliably specified The test is conducted by latching the parking brake to elimi nate different pedal pressures and...

Page 112: ...le Ref Fig 13 and apply maximum force and travel to the service brake pedal while moving 2 Do not latch the parking brake 3 Do this a total of 10 times with the first few at slow speed 4 If brake func...

Page 113: ...the back ing plate If the moving anchor assembly is damaged or binds against the backing plate replace both of the wheel brake assemblies A backing plate assembly that shows any indication of galling...

Page 114: ...he opposite wheel brake 14 Check adjust the brake pedal free travel Whenever the brake system is serviced or requires a parts replacement the brake pedal free travel must be checked and adjusted See A...

Page 115: ...mit braking capability Too little pedal free travel may cause the brakes to drag not fully released Either con dition can prevent the brakes from adjusting properly This procedure is intended to adjus...

Page 116: ...1 Anti Seize Compound A N 1 Raise and support the rear of the vehicle See LIFT ING THE VEHICLE on page 9 2 Remove the cotter pin 2 3 Remove the castellated nut 3 and washer 4 NOTICE Do not apply the...

Page 117: ...brication and re assembly of the wheel brake Worn or damaged components must be replaced Wheel brake service is required periodically as a pre ventive maintenance measure See SERVICE SCHED ULE on page...

Page 118: ...e 102 3 Remove the clevis pin securing the brake cable to the brake lever 4 Remove the bolts 7 and lock nuts 8 securing the wheel brake backing plate to the flange 10 on the axle tube Ref Fig 22 Fig 2...

Page 119: ...e adjuster spring is hooked to the adjuster with the hook end facing out 13 The brake shoe springs must be installed with the light spring closest to the adjuster mechanism with the hook installed dow...

Page 120: ...kets 19 9 Install new retaining rings 18 Ref Fig 25 10 Connect the cables 20 to the brake levers using new clevis pins 22 and new cotter pins 21 Ref Fig 27 11 Adjust the brake pedal free travel SeeAdj...

Page 121: ...l 5 Inspect the bolt 37 for corrosion that could cause binding The bolt and both bushings 33 must be replaced if corrosion or wear is found Ref Fig 28 6 Assemble in the reverse order of removal using...

Page 122: ...e two torsion springs 36 2 Remove the push nuts 29 and pin 32 and remove the parking brake pedal Ref Fig 28 To prevent serious injury or death do not attempt to re new worn components The parking brak...

Page 123: ...50 Remove the linkage rod Ref Fig 31 2 Inspect the bushings 48 and replace them if they are worn 3 Loosen the two setscrews 41 securing the cam 42 to the cam pivot 50 4 Remove the cam 42 bushings 44...

Page 124: ...Repair and Service Manual MECHANICAL BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMIN...

Page 125: ...ours of operation is the periodic inspection of the lubricant level Unless leakage is evident the lubricant only needs to be replaced every five years Replacing the Lubricant Tool List Qty Wrench 1 2...

Page 126: ...p 4 Fill with 24 26 fl oz of MOBILFLUID 424 5 Install the fill plug REAR AXLE REMOVAL Please refer to the following section for axle removal See REAR AXLE on page 117 REAR AXLE DISASSEMBLY Axle Shaft...

Page 127: ...e to the inner surface of the axle tube at the seal area 5 Remove the oil seal using a seal puller Ref Fig 7 Fig 7 Oil Seal Removal 6 Install the new oil seal using the seal installer P N 18739G1 to d...

Page 128: ...114 Repair and Service Manual REAR AXLE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMINARY...

Page 129: ...e rear wheels See LIFTING THE VEHICLE on page 9 See WHEEL AND TIRE SERVICE on page 13 2 Remove the vinyl cap 4 hex nut 3 washer 1 and rubber bushing 2 from the lower end of the shock absorber 5 Ref Fi...

Page 130: ...t 15 on the frame 9 The leaf spring 20 can now be removed from the vehicle 10 Remove the lock nut 12 bolt 8 shackles 18 bushings 14 and spacer 17 from the rear mount ing bracket on the frame Installat...

Page 131: ...ocks 4 To reduce the possibility of personal injury follow the lifting procedure of this manual See LIFTING THE VEHICLE on page 9 Place wheel chocks in front and behind the front wheels and check the...

Page 132: ...end of the outer brake cable and move cables out of the way of the axle 7 Place a floor jack under the center section of the rear axle and raise just enough to place a second set of jack stands under...

Page 133: ...9 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers REAR SUSPENSION 699273 PRELIMINA...

Page 134: ...0 Repair and Service Manual REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699273 PRELIMINA...

Page 135: ...sported at highway speeds the sun top must be removed and the seat bottom secured When transporting the vehicle below highway speeds check for tightness of hardware and cracks in the sun top at the mo...

Page 136: ...8 securing the front struts 15 to the cowl Fig 3 Front Struts 5 Remove the lock nuts 19 bolts 23 and washers 21 22 securing the rear strut 10 to the seat back support 20 Fig 4 Rear Struts Assemble in...

Page 137: ...n of the windshield 3 Pull the sashes 31 away from the front strut by pull ing towards the front of the vehicle starting from the top and working down It may be necessary to pry the sash away using a...

Page 138: ...e sashes 31 away from the front strut by pull ing towards the front of the vehicle starting from the top and working down It may be necessary to pry the sash away using a small pry bar 3 Inspect the r...

Page 139: ...Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers WEATHER PROTECTION 699273 PRELIMIN...

Page 140: ...Repair and Service Manual WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699273 PRELIMIN...

Page 141: ...has accumulated in the bellows Remove the bellows and remove excess grease Insufficient lubricant in king pins tie rod ends idler bushing rack tensioner or steering box Add one shot of lubricant to ea...

Page 142: ...on Connect the Molex plug to the receptacle on the face of the controller Navigation A blinking square on the left indicates the position of the cursor The blinking square moves vertically when the up...

Page 143: ...ller 0 1 0 Monitor Solenoid Coil On Off On Rear Node Select On Off On Solenoid PWM 0 100 0 Rear Controller Run Tow Switch On Off Key Switch or Charger On Off Off Economy Mode Switch On Off Off Forward...

Page 144: ...Controller Temp Cutback 0 100 100 Under voltage Cutback 0 100 0 Over voltage Cutback 0 100 100 Vehicle Vehicle Speed 3276 8 3276 7 0 Vehicle Odometer 0 0 10000000 0 Varies Braking Distance 0 0 1000000...

Page 145: ...n Display the controller protocol version Parameter Block Version Display controller PB version Display controller PB version Model Number Display the controller model number Display the controller mo...

Page 146: ...EM information Reconfigured Display reconfigure status Model Number Display handheld model number Serial Number Display handheld serial number Manufacturing Date Display handheld manufacture date Soft...

Page 147: ...es once to indicate that the first digit of the code will follow and the yellow LED then flashes the appropriate number of times for the first digit The red LED flashes twice to indicate that the seco...

Page 148: ...on capacitor bank preventing capacitor charge 3 Check wiring 4 Check brake sensor if other faults are found 1 5 Controller Sever Undertemp Heat sink temperature below 40 C Vehicle Disabled Raise cont...

Page 149: ...s 1 Normal operation Fault shows that batteries need recharging 2 Battery parameters are mis adjusted 3 Non controller system drain 4 Battery resistance to high 5 Battery disconnected while driving 6...

Page 150: ...Hot stetting and the requested current is being cut back 2 Motor temperature control menu parametersaremis tuned 3 See Monitor menu Motor temperature and Inputs analog 2 4 Reduce load on motor 2 9 Mot...

Page 151: ...r encoder failure 2 Bad crimp or faulty wiring 3 See Monitor menu Motor motor rpm 3 7 Motor Open Motor Phase U V or W detected open Vehicle Disabled KSI cycled 1 Motor phase is open 2 Bad crimps or fa...

Page 152: ...memory and failed Vehicle Disabled Download correct software OS and matching parameter default settings into the controller and c 1 Failure to write to EEPROM memory This can be caused by EEPROM memor...

Page 153: ...dal disable static return to off Vehicle Disabled Condition cleared Correct start sequence applied 1 Verify correct start sequence Unit must be in neutral prior to key on 5 6 Solenoid Coil Open Short...

Page 154: ...ult found on slave controller Vehicle Disabled KSI cycled 1 Check slave controller faults with handheld via direct connection to slave controller 8 7 Motor Characterizati on Fault Motor Characterizati...

Page 155: ...isabled KSI Cycled or Fault cleared 1 Limited Operating Strategy control mode has been activated as a result of either an encoder fault or stall detect fault 2 Motor encoder failure 3 Bad crimps or fa...

Page 156: ...ist The System Info menu indicates detailed viewing of the controller informa tion such as model number serial number hardware version protocol ver sion parameter block version mfg date code OS versio...

Page 157: ...min value 3 0 mph max value 6 0 mph Parameters for acceleration and deceleration rates can be adjusted Settings are the same for both Golf and Freedom models Acceleration HS min value 3 0 seconds max...

Page 158: ...s Cautions Warnings and Dangers 699327 The Battery submenu includes the parameters for Reset Volts per Cell Full Volts per Cell Empty Volts per Cell Discharge Time and BDI Reset Percent The Monitor me...

Page 159: ...ection before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 145 Repair and Service Manual 699327 Outputs Battery Motor Controller Controller Cutbacks Fig 8...

Page 160: ...Cautions Warnings and Dangers 699327 Vehicle CAN Status The Diagnostics menu can be used to diagnose present faults and view the fault history Any currently existing faults will appear under the Pres...

Page 161: ...Programming menu allows the user to both save current cpf files and restore former cpf files The user can bookmark frequently used functions in the Favorites menu The HHP Settings shows the settings f...

Page 162: ...vary depending on the make and model Always follow the meter manufacturer s recommendations and instructions for the use and care of the meter For the purpose of this section the red probe is represen...

Page 163: ...ween pin C and pin B Ref Fig 13 To test the hour function of the meter check for continuity between pin C and pin D If either function fails the meter should be replaced If both functions pass and the...

Page 164: ...perature 2 Unplug the temperature sensor harness at the motor Ref 2 3 Use the DVOM set on OHMS and test the resis tance between the two pins on the motor side Fig 15 Temperature Sensor 4 A reading sho...

Page 165: ...meter probe in the black wire con nection Put the positive meter probe in the green wire connection A 0 5V flash signal should be indi cated when the motor armature is rotated slowly If not check the...

Page 166: ...ld be observed Ref Fig 21 Fig 21 U and V terminal NOTICE If continuity is not observed between ter minals an open motor field condition may exist Disassemble the motor to visually confirm 4 Place one...

Page 167: ...53 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers FAULT TESTING 699327 PRELIMINAR...

Page 168: ...54 Repair and Service Manual FAULT TESTING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699327 PRELIMINAR...

Page 169: ...ingle point park brake release with self compensating system Regenerative pedal down and or pedal up braking Item Specification Seating Capacity 6 4 with stake side option Person Overall Length 144 in...

Page 170: ...hydraulic shock absorbers Service Brake Rear wheel mechanical self adjusting drum regenerative pedal down and or pedal up braking Parking Brake Self compensating single point engagement Front and Rea...

Page 171: ...ll of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 157 Repair and Service Manual 699327 APPENDIX A BATTERY CHARGER USER S G...

Page 172: ...tion Risque de d charge lectrique Ne pas toucher les parties non isol es du connecteur de sortie ou les bornes non isol es de la batterie Toujours connecter le chargeur une prise de courant mise la te...

Page 173: ...nectors from the same manufacturer Failure to do so may void warranty and cause a hazardous condition or equipment damage Maintenance Instructions 1 Do not expose charger to high pressure water spray...

Page 174: ...display its default charge profile Profiles 1 6 will display on the ammeter as well as on the bulk charge indicator 6b Charge profiles 7 and above will display on the bulk charge indicator If the cha...

Page 175: ...s the result of normal use age wear or abuse Normal use age wear or abuse can cause some com ponents on the vehicle to fail The manufacturer can not know all possible component failures or the methods...

Page 176: ...ealer 800 296 4804 Consumer 877 394 6772 www trackeroffroad com Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of the manufacturer PRELIMINAR...

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