Tracker LX4 2020 Repair And Service Manual Download

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Repair and Service Manual

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

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Steering Wheel Replace-

ment

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Install with arch
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Steering

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Summary of Contents for LX4 2020

Page 1: ...REPAIR AND SERVICE MANUAL 699326 A Issued August 2019...

Page 2: ...PHQW RI WKH FDSDELOLWLHV DQG UHOLDELOLW RI WKLV YHKLFOH 0 18 785 5 6 17 1 86 7KLV YHKLFOH LV GHVLJQHG DQG PDQXIDFWXUHG LQ WKH 8QLWHG 6WDWHV RI PHULFD 86 7KH VWDQGDUGV DQG VSHFLILFDWLRQV OLVWHG LQ WKH...

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Page 13: ...7 2 217 176 L Repair and Service Manual 6 8 0 17 1 1 6 8 0 17 1 1 57 5 200 1 8 5 176 1 8 6 5 3 0 17 2 0 17 1 1 7 06 33 1 7 4 86 5 6 8...

Page 14: ...LL Repair and Service Manual Notes 7 2 217 176...

Page 15: ...LLL Repair and Service Manual 7 2 217 176 Notes...

Page 16: ...LY Repair and Service Manual 7 2 217 176...

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Page 18: ...djustments to be made to the powertrain while the motor is running must be made with both wheels raised Wear eye protection when working on vehicle In particular use care when working around batteries...

Page 19: ...protection from tree limbs or flying objects 7KH FDQRS DQG ZLQGVKLHOG VXSSO VRPH SURWHFWLRQ IURP WKH HOHPHQWV EXW GR QRW NHHS WKH RSHUDWRU DQG SDVVHQ JHU GU LQ KHDY UDLQ OHDQ WKH ZLQGVKLHOG ZLWK ORWV...

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Page 21: ...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 1 5 1 2 699326...

Page 22: ...Repair and Service Manual 1 5 1 2 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

Page 23: ...OO FKDQJH WKH ZHLJKW GLVWULEXWLRQ RI WKH YHKLFOH Changes to the weight distribution or the center of gravity decreases the stability of the vehicle and can cause it to easily turn over 1 5 0 17 1 1 Al...

Page 24: ...contacting battery termi nals which could result in an explosion Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle Expelled electrolyte may cause...

Page 25: ...WKH ZKHHO FKRFNV LQ IURQW DQG EHKLQG HDFK IURQW ZKHHO 3XW WKH MDFN EHORZ WKH FHQWHU RI WKH UHDU IUDPH FURVV PHPEHU LIW WKH YHKLFOH HQRXJK WR SXW MDFN VWDQGV EHORZ WKH RXWHU HQGV RI WKH UHDU D OH DV V...

Page 26: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699326 RZHU WKH YHKLFOH LIW WKH YHKLFOH HQRXJK WR UHPRYH WKH MDFN VWDQGV DUHIXOO ORZHU WKH YHKLFOH WR WKH JUR...

Page 27: ...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 6 7 699326...

Page 28: ...Repair and Service Manual 6 7 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

Page 29: ...a drill depth stop will also provide addi tional protection RG FRPSRQHQWV FDQ EH UHSODFHG ZLWK D PLQLPXP RI VSHFLDO WRROV 0RVW ERG FRPSRQHQWV DUH KHOG LQ SRVLWLRQ ZLWK VWDQGDUG UHPRYDEOH KDUGZDUH QXWV...

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Page 35: ...H RI WKH YHKLFOH QVWDOO WKH DUP UHVW LQ UHYHUVH RUGHU RI UHPRYDO 7LJKWHQ WKH QXWV WR WKH WRUTXH YDOXH VSHFLILHG EHORZ LJXUH UP 5HVW 5HSODFHPHQW RRW 5HVW DQG DQGUDLO QVWDOODWLRQ 5HPRYH WKH KDQGUDLO DWW...

Page 36: ...this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699326 LJXUH RRWUHVW HOGPHQW 5HSODFHPHQW 5HDU 6HDW UDPH 5HSODFHPHQW 16 3 19 20 Bottom Re...

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Page 38: ...tration of the body panel Place a piece of sheet metal between the battery case and the rivets to be removed as a secondary precaution W WKH IURQW RI WKH UHDU ERG UHPRYH WKH ULYHWV VHFXU LQJ WKH UHDU...

Page 39: ...WKH VXUIDFH WR EH UHSDLUHG ZLWK DOFRKRO DQG GU 0DVN WKH DUHD WR EH SDLQWHG FRPPRQ PDVNLQJ WDSH LV DGHTXDWH SULRU WR UHSDLU DQG XVH DHURVRO W SH WRXFK XS SDLQW SSO VSUD WRXFK XS SDLQW LQ OLJKW HYHQ RY...

Page 40: ...Repair and Service Manual 2 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

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Page 42: ...e lug nuts to make sure the wheel is evenly seated against the hub LWK WKH YDOYH VWHP WR WKH RXWVLGH RI ZKHHO LQVWDOO WKH ZKHHO RQWR WKH KXE ZLWK OXJ QXWV LQJHU WLJKWHQ OXJ QXWV LQ WKH FURVV VHTXHQFH...

Page 43: ...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 6 1 7 5 6 699326...

Page 44: ...Repair and Service Manual 6 1 7 5 6 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

Page 45: ...air and Service Manual 699326 5217 6863 16 21 1 67 5 1 LJXUH OH 0RXQWHG 6WHHULQJ DQG URQW 6XVSHQVLRQ Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate Shaft...

Page 46: ...ting from a vehicle falling from a jack follow the lifting procedure in SAFETY section of this man ual Be sure vehicle is on a firm and level surface Never get under a vehicle while it is supported by...

Page 47: ...RI DQRWKHU SURFHGXUH PDNH VXUH ZKHHO LV PRXQWHG WR WKH KXE KDQG WLJKW ZLWK OXJ QXWV DQG KXE LV ORRVHO UHWDLQHG RQ VSLQGOH ZLWK WKH FDVWHOODWHG QXW LJXUH 6HDW WKH EHDULQJV E URWDWLQJ ZKHHO ZKLOH WLJKWH...

Page 48: ...g the jam nut NOTICE The tie rod has different threads on each end The end with the flat area has left hand threads clockwise to loosen while the end without the flat has conventional right hand threa...

Page 49: ...ticular attention to Notices Cautions Warnings and Dangers Repair and Service Manual 699326 5217 6863 16 21 LJXUH URQW 6XVSHQVLRQ RPSRQHQWV NOTE Tie Rod Not Shown for Clarity Part of Frame Part of Fra...

Page 50: ...ase the intermediate shaft connecting the rack and pinion unit to the steering column from pulling apart due to the weight of the steering system NOTICE The intermediate shaft is assembled with the un...

Page 51: ...VHFXULQJ UHDU RI WKH VSULQJ WR WKH YHKLFOH IUDPH LVFDUG WKH ORFN QXWV To decrease the risk of stress and possible damage to the rack and pinion unit the driver side spring must be mounted to the axle...

Page 52: ...H WKH QHZ KXE RQWR WKH VSLQGOH DQG ILOO WKH DUHD EHWZHHQ WKH WZR ZKHHO EHDULQJV IXOO ZLWK JUHDVH SSO D OLJKW FRDWLQJ RI JUHDVH WR WKH RXWHU EHDULQJ UDFH QVWDOO WKH RXWHU ZKHHO EHDULQJ DQG VHFXUH WKH K...

Page 53: ...and Dangers Repair and Service Manual 699326 LJXUH KHHO HDULQJ 5HSODFHPHQW QVWDOO WKH LQQHU ZKHHO EHDULQJ DQG WKH QHZ JUHDVH VHDO LQ WKH KXE 0RXQW WKH KXE WR WKH VSLQGOH 7R DGMXVW WKH ZKHHO EHDULQJ 6H...

Page 54: ...QG VXSSRUW WKH IURQW RI WKH YHKLFOH SHU 6 7 VHFWLRQ LJXUH 5HPRYH WKH SDVVHQJHU VLGH IURQW ZKHHO DQG WXUQ VWHHULQJ ZKHHO IXOO WR WKH OHIW 5HPRYH WKH FRWWHU SLQ DQG ORRVHQ WKH FDVWHOODWHG QXW XQWLO WKH...

Page 55: ...GMXVW LI QHFHVVDU 6HH Wheel Alignment 7LH 5RG QVSHFWLRQ 5HSODFHPHQW 7RRO LVW 4XDQWLW 0HDVXULQJ 7DSH UHQFK UHQFK 1HHGOH 1RVH 3OLHUV UHQFK DOO RLQW 6HSDUDWRU 3ODVWLF DFHG DPPHU 6RFNHW 7RUTXH UHQFK IW OE...

Page 56: ...WHQVLRQ QVWDOO WKH QHZ EHOORZV DOLJQ WKH VPDOO HQG RYHU WKH JURRYH LQ WKH UDFN H WHQVLRQ DQG VHFXUH ZLWK QHZ ZLUH WLH HDYH WKH ODUJH HQG RI WKH EHOORZV ORRVH XQWLO UDFN H WHQVLRQ WR UDFN DQG SLQLRQ X...

Page 57: ...6HSDUDWRU 3ODVWLF DFHG DPPHU UHQFK 6RFNHW 6RFNHW 7RUTXH UHQFK IW OEV The spindle bearings are designed to be used dry Lubrication attracts dirt and will ruin the bear ings Do not apply grease to the s...

Page 58: ...O 6HH Pinion Seal Replace ment 5HPRYH WKH LQWHUQDO UHWDLQLQJ ULQJ IURP WKH UDFN DQG SLQLRQ XQLW SXOO RXW WKH SLQLRQ DQG EDOO EHDULQJ DV DQ DVVHPEO LJXUH 5DFN DQG 3LQLRQ 8QLW LVDVVHPEO OHDQ WKH UDFN SL...

Page 59: ...RYH WKH UDFN DQG SLQLRQ XQLW IURP WKH YHKLFOH 5HWDLQ ZDVKHUV VSDFHUV DQG WKH WZR EROWV IRU DVVHPEO 5HSODFH WKH UDFN DQG SLQLRQ XQLW LQ WKH UHYHUVH RUGHU RI UHPRYDO QVWDOO WKH QHZ ORFN QXWV DQG WLJKWHQ...

Page 60: ...perform the follow ing removal procedure Do not use a screwdriver to push or pry the retaining tabs URP WKH IURQW VLGH RI WKH VWHHULQJ ZKHHO UHPRYH WKH FOLSERDUG E SXOOLQJ VWUDLJKW XS RQ WKH ERWWRP RI...

Page 61: ...WKH 6 7 VHFWLRQ 5HPRYH WKH OXJ QXWV DQG WKH IURQW ZKHHOV 5HPRYH WKH EROW DQG ZDVKHU WKDW VHFXUH WKH LQWHU PHGLDWH VKDIW WR WKH VWHHULQJ VKDIW 5HPRYH WKH IRXU EROWV DQG ZDVKHUV WKDW VHFXUH WKH VWHHULQ...

Page 62: ...9326 VWHHULQJ VKDIW WR WKH WRUTXH YDOXH VSHFLILHG EHORZ QVWDOO WKH IURQW ZKHHO V SHU WKH 6 1 7 5 6 VHFWLRQ RZHU YHKLFOH SHU WKH 6 7 VHFWLRQ QVWDOO WKH VWHHULQJ ZKHHO 6HH Steering Wheel Replace ment LJ...

Page 63: ...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 5217 6863 16 21 1 67 5 1 699326...

Page 64: ...Repair and Service Manual 5217 6863 16 21 1 67 5 1 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

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Page 66: ...rewdriver by the insulated portion NOTICE Note the location of the wiring before dis connecting from the solenoid to ensure correct connections when reassembling 8VH DQ LQVXODWHG ZUHQFK WR UHPRYH WKH...

Page 67: ...QG PRWRU KRXVLQJV WR DVVLVW ZLWK UHDOLJQPHQW GXULQJ UHDVVHPEO RI PRWRU WR UHDU D OH LJ XUH LVFRQQHFW WKH PRWRU ZLUHV IURP WKH FRQWUROOHU WHUPLQDOV 8 9 DQG LJXUH 0DUN OH DQG 0RWRU Be careful not to dam...

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Page 70: ...WHUPLQDO DQG WKH RWKHU SUREH RQ WKH WHUPLQDO XOO FRQWLQXLW VKRXOG EH REVHUYHG LJXUH LJXUH 9 DQG WHUPLQDO 7KHQ SODFH RQH PHWHU SUREH RQ WKH 8 WHUPLQDO DQG WKH RWKHU SUREH RQ WKH 9 WHUPLQDO XOO FRQWLQXL...

Page 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 02725 699326...

Page 72: ...Repair and Service Manual 02725 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

Page 73: ...arger Do not operate the charger if the AC sup ply cord is damaged or if the charger has received a sharp blow been dropped or otherwise damaged in any way Refer to all repair work to qualified person...

Page 74: ...ICE Routing the DC cord through the steering wheel when charging the batteries serves as a good reminder to store the cord out of the way when charging is complete The DC plug can be damaged by drivin...

Page 75: ...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 77 5 5 5 699326...

Page 76: ...Repair and Service Manual 77 5 5 5 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

Page 77: ...ectant must be used with caution Insulate metal container to decrease the risk of can from contacting battery terminals which could result in an explosion Wrap wrenches with vinyl tape to decrease the...

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Page 81: ...rnal magnet con tained within the charger plug The magnet is part of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the vehicle charging receptac...

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Page 83: ...4 110 43 3 012 010 100 37 8 008 006 90 32 2 004 002 80 26 7 0 002 70 21 1 004 006 60 15 6 008 010 50 10 012 014 40 4 4 016 018 30 1 1 020 022 20 6 7 024 026 10 12 12 028 EXAMPLE 1 Electrolyte Temperat...

Page 84: ...Repair and Service Manual 77 5 6 1 5 1 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

Page 85: ...NTERLOC CONN2 SPEED ENCODER CONN4 PROGRAMMING PORT CONN5 ACCEL PEDAL HARN PUSH ON 2 REV BUZZER PUSH ON 8 HORN PUSH ON 9 HORN PUSH ON 22 TAIL LT PS PUSH ON 3 12V ACC PUSH ON 23 TAIL LT GND PS PUSH ON 2...

Page 86: ...0 Front of Vehicle Black from Main Contactor White from Control Harness Yellow from Control Harness Black from Controller 10GA Black from Control Harness 14GA Black from Control Harness 72 0 75 219 56...

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Page 93: ...e travel is correctly adjusted the clevis pins will not be under tension by the brake cables Test Result Fails 2 out of 3 Fails 2 out of 3 Perform the Periodic Brake Performance Test PBPT 3 Times 3 Ag...

Page 94: ...this by first verifying that some braking function exists Then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start driving a...

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Page 98: ...use of worn park brake components do not attempt to renew worn compo nents The park brake latch arm kick off cam and catch bracket are hardened parts Do not grind or file them as doing so will cause t...

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Page 101: ...e purpose of this procedure is to adjust the brakes and seat brake system components The brake system cannot be effective for the first few applications of the brake pedal 3UH DGMXVW VHUYLFH EUDNH SHG...

Page 102: ...when raising the adjuster arm Excessive force will damage the adjuster and necessi tate both wheel brake assem blies be replaced I WKH GUXP GRHV QRW VOLGH IURP WKH EUDNH DVVHPEO WKH EUDNH VKRHV PXVW...

Page 103: ...NH GXVW ZLWK D EUXVK 5HPRYH WKH EUDNH VKRHV 6HH Brake Shoe Removal OHDQ EDFNLQJ SODWH ZLWK D FRPPHUFLDO EUDNH FOHDQHU OORZ WR GU FRPSOHWHO Friction areas between the back ing plate and the brake shoes...

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Page 105: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Repair and Service Manual 699326 97 ADJUSTER ASSEMBLY TOP PULL 9 5 4 4 3 1 2 6 8 10 L...

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Page 108: ...RULHQWDWLRQ RI WKH WZR WRUVLRQ VSULQJV IRU UHDVVHPEO SXUSRVHV 5HPRYH WKH SXVK QXW DQG SLQ LJXUH DQG UHPRYH WKH SDUN EUDNH SHGDO To prevent serious injury or death resulting from the use of worn park...

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Page 110: ...Repair and Service Manual 5 6 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

Page 111: ...FDQW 5 5 6 66 0 The rear axle is a precision assembly and therefore any repair or replacement of parts must be done with extreme care in a clean environment Before attempting to per form any service o...

Page 112: ...ULQJ IURP OH 6KDIW OH 6KDIW 6HDO 5HPRYDO DQG 5HSODFHPHQW 7RROV LVW 4XDQWLW QWHUQDO 6QDS 5LQJ 3OLHUV 6HDO 3XOOHU 6HDO QVWDOOHU 3 1 DOO 3HHQ DPPHU Use care to decrease the risk of damage to the inner su...

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Page 114: ...Repair and Service Manual 5 5 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

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Page 117: ...ETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Repair and Service Manual 699328 LJ HDI 6SULQJV 6 15 12 14 17 8 9 7 25 18 13 11 2...

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Page 119: ...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 5 5 6863 16 21 699328...

Page 120: ...Repair and Service Manual 5 5 6863 16 21 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699328...

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Page 122: ...tices Cautions Warnings and Dangers 699326 LJXUH DQRS 7RS DETAIL A 5 6 DETAIL C Front 9 Outside Tubing On Sun Top 5 16 17 7 Front of Vehicle Front of Vehicle DETAIL B 11 3 4 14 11 18 20 18 19 2 9 7 7...

Page 123: ...the top section of windshield 7R VHFXUH ZLQGVKLHOG ZKHQ ORZHUHG SUHVV HGJH RI ZLQGVKLHOG ILUPO LQWR ORZHU ODWFKHV 6HH HWDLO QVHUW EROW WKURXJK ZDVKHU UXEEHU JURPPHW DQG H LVWLQJ KROH LQ IURQW VWUXW 6H...

Page 124: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699326 SPLIT WINDSHIELD Lower Latch Strut Front of Vehicle Strut Front of Vehicle Windshield DETAIL A 3 Wind...

Page 125: ...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 7 5 3527 7 21 699326...

Page 126: ...Repair and Service Manual 7 5 3527 7 21 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

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Page 141: ...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 1 1267 6 699326...

Page 142: ...Repair and Service Manual 1 1267 6 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

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Page 145: ...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 8 7 7 67 1 699326...

Page 146: ...Repair and Service Manual 8 7 7 67 1 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699326...

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Page 148: ...on before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699326 5HDU 7LUHV HVHUW DJOH SO UDPH HOGHG VWHHO ZLWK XUD6KLHOG70 SRZGHU FRDW URQW RG DQG LQLVK QMH...

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Page 150: ...DULED MAINTENANCE CHART 5 3 0 17 2 0 17 1 1 7 06 7KHVH LWHPV RU WKHLU HTXLYDOHQWV FDQ EH SXUFKDVHG WKURXJK RXU GHDOHU RU DQ RWKHU TXDOLILHG VRXUFH WHP DSDFLW XEULFDQWV OXLGV 1RWHV 5HDU D OH RLO R 0REL...

Page 151: ...33 1 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Repair and Service Manual 33 1 7 4 86 5 6 8...

Page 152: ...s fumer pr s de la batterie et viter toute tincelle ou flamme nue proximit des batteries Fournissez une ventilation ad quate du chargement Ne jamais charger une batterie gel e Prendre connaissance des...

Page 153: ...0320 C14 plug rated 250V 13A minimum or b for all other countries a safety approved detachable cord 3 conductor 1 5mm minimum rated appropriately for industrial use The cord set must be terminated on...

Page 154: ...Notes 33 1 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Repair and Service Manual...

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Page 156: ...gusta GA USA 30909 3852 Dealer 800 296 4804 Consumer 877 394 6772 www trackeroffroad com Owner s Manuals and Repair Manuals are available from the manufacturer Copyrighted Material This manual may not...

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