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Tracker Off-Road EViS 2020, Руководство по ремонту и обслуживанию

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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.

1

Repair and Service Manual

10002660

GENERAL INFORMATION AND ROUTINE MAINTENANCE

SERIAL NUMBER AND PIN PLATE 

LOCATION

The PIN plate is attached to the frame below the seat 

wrap panel (Ref. Fig. 3).
Two serial number labels, PART A and PART B, and a 

PIN label are attached to the frame below the flip seat 

(Ref. Fig. 2).
Design changes occur continuously. When you order ser-

vice parts, the PIN number, manufacture date code, or 

serial number must be available.

Fig. 1  SN Label

Fig. 2  Serial Number and PIN Labels

Fig. 3  PIN Plate 

SERVICING THE VEHICLE

To prevent severe injury or death, 

resulting from improper servicing 

techniques, observe the following 

warnings:

Do not attempt any type of servicing operations 

before reading and understanding all notes, cau-

tions, and warnings in this manual.
Any service that requires adjustments to be made to 

the powertrain while the motor is in operation must 

be made with all four wheels raised.
Wear eye protection when working on the vehicle. In 

particular, use care when working around batteries 

or using solvents or compressed air.
To reduce the possibility of causing an electrical 

arc, which could cause a battery explosion, disable 

all electrical loads from the batteries before remov-

ing any heavy gauge battery wires.
To prevent the possibility of motor disintegration in 

the electric powertrain, never operate vehicle at full 

throttle for more than 4 - 5 seconds while vehicle is 

in a “no load” condition (all 4 wheels off of the 

ground).

It is in the best interest of both vehicle owner and servic-

ing dealer to carefully follow the procedures recom-

mended in this manual. Adequate preventative 

maintenance, applied at regular intervals, is the best 

guarantee for keeping the vehicle both dependable and 

economical.
In any product, components will eventually fail to perform 

properly as the result of normal use, age, wear, or abuse.
It is impossible to anticipate all possible component fail-

ures or the manner in which each component can fail.
A vehicle requiring repair indicates that the vehicle is no 

longer functioning as designed and should be considered 

potentially hazardous. Use caution when working on a 

vehicle. When diagnosing, removing or replacing any 

components that are not operating properly, consider the 

safety of yourself and those around you should the com-

ponent move unexpectedly.
Some components are heavy, spring loaded, highly corro-

sive, explosive, or can produce amperage or reach high 

temperatures. Carbon monoxide, battery acid and hydro-

gen gas could cause serious bodily injury to the techni-

cian/mechanic and bystanders if not treated with the 

utmost caution. Be careful not to place hands, face, feet, 

or body in a location that could expose them to injury 

should an unforeseen dangerous situation occur.
Always use the appropriate tools listed in the tool list and 

wear approved safety equipment.
Before a new vehicle is put into operation, the items 

shown in the INITIAL SERVICE CHART should be per-

formed (Ref. Fig. 4). 

PART C

PART B

PART A

PIN Label

Serial Number
Part A

Serial Number
Part B

PIN Plate

Front of Vehicle

Содержание EViS 2020

Страница 1: ...REPAIR AND SERVICE MANUAL TRACKER EViS 10002660 C Revised Dec 2019 Issued Aug 2019...

Страница 2: ...ove the vehicle 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...

Страница 3: ...ts in this 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...

Страница 4: ...ower from the battery pack and eventually drain the batteries if power is not restored in a timely manner As with all electric vehicles the batteries must be checked and recharged as required or at a...

Страница 5: ...vehicle is designed and manufactured for off road use It does not conform to Federal Motor Vehicle Safety Stan dards and is not equipped for operation on public streets Some communities may permit th...

Страница 6: ...sing wheel chocks and safety stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Never attempt to maintain a vehicle in an...

Страница 7: ...ICLE CLEANING AND CARE 2 VEHICLE CARE PRODUCTS 3 OPS CANOPY TOP AND WINDSHIELD 3 TRANSPORTING VEHICLE 3 EMERGENCY ELECTRIC PARK BRAKE RELEASE 3 TOWING A TRAILER 4 PROLONGED STORAGE 4 HARDWARE 4 TORQUE...

Страница 8: ...yte Level and Water 16 Cleaning Batteries 17 Prolonged Storage 17 Battery Charging 18 AC Voltage 18 FAULT TESTING 18 Hydrometer 19 Using Hydrometer 19 BATTERY CHARGER 20 Charger Description 20 Portabl...

Страница 9: ...rake Pads Replacement 37 Rotor Replacement 38 BLEEDING AND FLUSHING 38 Bleeding 38 Bleeding Sequence 39 Flushing 39 BRAKE PEDAL REMOVAL AND INSTALLATION 40 ELECTRICAL VOLTAGE TESTING FOR BATTERIES 47...

Страница 10: ...7 Front Strut Assembly Replacement 57 Control Arm Assembly Replacement 58 Lower Ball Joint Replacement 58 Wheel Bearing Replacement 59 Strut Replacement 60 FRONT AXLE 61 CV Shaft Replacement 61 CV Joi...

Страница 11: ...acement 78 Rear Seat Belt Buckle Replacement 78 UPPER OPERATOR PROTECTION SYSTEM 80 Upper OPS Frame Removal and Installation 80 LOWER OPERATOR PROTECTION SYSTEM 81 Brush Guard Removal and Installation...

Страница 12: ...119 Key Switch Testing 119 State of Charge SOC Meter Testing 120 Electronic Speed Controller Solenoid Testing 120 Temperature Sensor Testing 121 Electronic Speed Sensor Testing 121 AC Motor Bench Tes...

Страница 13: ...xi Repair and Service Manual Notes 10002660...

Страница 14: ...xii Repair and Service Manual Notes 10002660...

Страница 15: ...vehicle at full throttle for more than 4 5 seconds while vehicle is in a no load condition all 4 wheels off of the ground It is in the best interest of both vehicle owner and servic ing dealer to care...

Страница 16: ...h caused from driving a vehicle with an improperly operating brake sys tem the braking system must be properly main tained All driving brake tests must be done in a safe location with regard for the s...

Страница 17: ...ect against large falling objects such as trees or heavy limbs The optional windshield deflects oncoming wind from occupants but will not protect against flying objects and tree limbs The optional can...

Страница 18: ...ring periods of storage the batteries must be main tained to prevent discharge During cold conditions the batteries must be fully charged to prevent the possibility of freezing A fully charged battery...

Страница 19: ...12G02 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 with this chart This chart specif...

Страница 20: ...nd Service 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 Note...

Страница 21: ...e vehicle Changes to the weight distribution or the center of gravity decreases the stability of the vehicle and can cause it to easily roll over GENERAL MAINTENANCE Always use correct service proce d...

Страница 22: ...ls which could result in an explosion Make sure to fill the batteries to a level of 1 2 inch 13 mm above the plates Electrolyte more than 1 2 inch 13 mm above the plates can cause a spill from the bat...

Страница 23: ...the jack and test the stability of the vehicle on jack stands by gently rocking the vehicle 5 The jack can be left under the center front of the frame while the front end of the vehicle is on the jack...

Страница 24: ...10 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 10002660...

Страница 25: ...ocket 7 16 1 Socket 13 mm Wrench 7 16 1 Wrench 13 mm Ratchet 1 Torque Wrench ft lbs 1 1 To access the accelerator pedal 1 remove two bolts 3 washers 4 and nuts 7 that secure the cover 5 to the mountin...

Страница 26: ...12 Repair and Service Manual ACCELERATOR Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 10002660...

Страница 27: ...es when add ing 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 water an...

Страница 28: ...nch 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...

Страница 29: ...ion from the battery terminals or the wire terminals with a solution of sodium bicarbonate baking soda and brush 6 Connect the battery wires as shown Ref Fig 2 Be sure that all battery terminals are i...

Страница 30: ...e that results from the charging cycle Fig 4 Correct Electrolyte Level Do not overfill batteries The charging cycle will increase electro lyte volume and force it out of the battery and damage surroun...

Страница 31: ...n batteries for minimum of three minutes Use a soft bristle brush or cloth to clean the tops of the batteries to remove any residue that could cause the self discharge of the battery Rinse the entire...

Страница 32: ...cts NOTICE In some portable chargers an audible rat tle is present in the body of the charger DC plug This rattle is caused by an internal magnet within the charger plug The magnet is part of the inte...

Страница 33: ...yes with extended flushing with clear water Contact a physician immediately Always wear a safety shield or approved safety goggles when using a hydrometer to test the elec trolyte solution Any electro...

Страница 34: ...local codes and ordinances A grounded outlet is required to reduce risk of electric shock do not use ground adapters or modify the plug Do not touch uninsulated por tion of output connector or uninsu...

Страница 35: ...e batteries are fully charged and the DC plug can be removed from the vehicle NOTICE Routing the DC cord through the steering wheel when charging the batteries serves as a good reminder to store the c...

Страница 36: ...epair 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 10002...

Страница 37: ...nts can be replaced with a minimum of special tools Most body components are held in position with standard removable hardware nuts bolts washers and screws Some components are installed with pop riv...

Страница 38: ...The gauge panel can be removed without removing the instrument panel To prevent personal injury discon nect negative battery cables before servicing vehicle Removal 1 Remove two screws 6 that secure t...

Страница 39: ...out the remaining rivets 11 5 Remove cowl assembly 15 from vehicle Ref Fig 6 Assemble in the reverse order of removal using new riv ets Fig 6 Cowl Removal Removal of Headlight Grille Assembly Tool Lis...

Страница 40: ...r Weldment Removal and Installation on page 82 3 Remove the rocker panels See Rocker Panel Replacement on page 24 4 Remove the cowl See Cowl Replacement on page 25 5 Remove the gauge panel See Gauge P...

Страница 41: ...ETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 27 Repair and Service Manual 10002660 Fig 8 Instrument Panel Rear 22 25 23 21 10...

Страница 42: ...To replace either driver or passenger side panel 1 Disconnect the tail light leads from the main wiring harness 2 Drill out the two rivets 36 securing the side panel 35 to the rear fender 30 3 Remove...

Страница 43: ...uring installation 2 Remove the 6 screws 42 connecting the front of the seat wrap 40 to the sides 45 3 Pull the front portion 40 of the seat wrap out of the vehicle 4 Remove the screws 46 connecting t...

Страница 44: ...16 1 Wrench 9 16 1 Torque Wrench ft lbs 1 Socket 7 16 1 Socket 9 16 1 Torque Wench ft lbs 1 1 Remove the bolts 53 lock washers 52 washers 54 and nuts 51 securing rear closeout panel 50 to chassis fram...

Страница 45: ...ssembly Front of Vehicle Yellow wire Cable bundle continues towards vehicle rear Winch Fairlead Plow Assembly Torque to 45 55 Nm 33 2 40 6 ft lbs Insert and bend cotter pin after inserting hook retent...

Страница 46: ...hes the manufacturer of the Durashield body panels recommends the following steps be taken 1 Thoroughly clean the surface to be repaired with alcohol and allow to dry 2 Apply tape to area surrounding...

Страница 47: ...33 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 10002660...

Страница 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 10002660...

Страница 49: ...ome ini tial free play and then become resistant This indicates proper performance If the brake pedal has a soft feel or loses resistance per form a brake system inspection See Brake System Inspection...

Страница 50: ...r deposits formed in the cylinder bore that are due to moisture or dirt in the hydraulic system may cause wear of the cylinder bore or related parts Do not try to remove corrosion or deposits with a c...

Страница 51: ...front and rear brake pads must be replaced as a full set Replace the brake pads as a full set on both wheels To remove the brake pads lift and support the vehicle See LIFTING THE VEHICLE on page 8 1...

Страница 52: ...er of removal Tighten all hardware in a cross pattern to the torque values specified below Fig 4 Rotor BLEEDING AND FLUSHING Tool List Qty Shop Towels A R Hose A R Clean Container Glass 1 Brake Fluid...

Страница 53: ...s air bubbles as they come out of the system and prevents air from being sucked into the system through the bleeder screw 2 Apply moderate 40 50 lbs 18 23 kg steady pressure on the brake pedal and ope...

Страница 54: ...iver Flat Head 1 Allen Socket 1 4 1 Ratchet 1 Wrench 1 2 1 Socket 1 2 1 Torque Wrench ft lbs 1 1 Disconnect the master cylinder shaft from the brake pedal 8 See Master Cylinder Replacement on page 36...

Страница 55: ...41 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 BRAKES 10002660...

Страница 56: ...42 Repair and Service Manual BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 10002660...

Страница 57: ...r attention to Notices Cautions Warnings and Dangers 43 Repair and Service Manual 10002660 ELECTRICAL Fig 1 Main Harness Routing Front of Vehicle Main Harness to Headlight Main Harness to Contactor Ma...

Страница 58: ...ir and Service Manual ELECTRICAL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 10002660 Fig 2 Main Harness Wirin...

Страница 59: ...TRICAL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 45 Repair and Service Manual 10002660 Fig 3 Electrical Sche...

Страница 60: ...and Service Manual ELECTRICAL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 10002660 Fig 4 Electrical Schematic...

Страница 61: ...unction A faulty wire must be replaced See Faulty Wire Replacement on page 48 3 Check the condition of the 72V batteries set a Check for adequate battery volts nominal 12 VDC by setting the DVOM to 30...

Страница 62: ...circuit to the ground connection Correct any interruption of electricity flow by repairing or replacing the wire or the switch or accessory Faulty Wire Replacement Replace a faulty wire with one of th...

Страница 63: ...troller is a solid state unit that activates a sole noid and controls the function of the vehicle by respond ing to inputs from the rotary position sensor motor speed sensor and many other units The c...

Страница 64: ...st on page 122 1 Use an insulated wrench to remove the negative B wire from the battery 2 Remove the bolts 21 and flat washers 22 Ref Fig 10 3 Remove the connectors from the controller 24 Ref Fig 10 4...

Страница 65: ...olenoid 20 2 Remove the two screws 16 washers 18 and nuts 17 to remove the solenoid 20 from the rear fender Ref Fig 11 3 Mount new solenoid 20 and connect the wiring 4 Tighten the nut 17 to torque val...

Страница 66: ...device is indicated Testing Battery Voltage Determine the condition of the battery set before proceed ing with any electrical testing An open voltage test is not helpful since a battery that has deter...

Страница 67: ...ition and remove the key 2 Disconnect the negative battery cable using an insulated wrench 3 Remove the gauge panel See Gauge Panel Replacement on page 24 4 Disconnect the main wiring harness from the...

Страница 68: ...switch 43 and push it through the front of the gauge panel 40 Ref Fig 17 Assemble in the reverse order of removal Confirm proper orientation of the switch prior to seating it completely in the gauge p...

Страница 69: ...ing in elec tape And securing with cable tie Removing prior to taping also acceptable Connect red and black contactor cables to and driver side battery using nuts Red cable Yellow wire Connect red wir...

Страница 70: ...56 Repair and Service Manual ELECTRICAL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 10002660...

Страница 71: ...rol arms contain lube free bushings The tie rod ends are sealed and do not require lubrica tion The steering unit is sealed and does not require lubrica tion Front Strut Assembly Replacement Tool List...

Страница 72: ...ssembly 1 5 Remove the bolt 22 flanged bushings 19 and lock nuts 23 6 To remove the control arm 21 from the vehicle Ref Fig 2 Assemble in the reverse order of removal Tighten hardware to torque values...

Страница 73: ...Ring Pliers 1 Arbor Press 1 Hammer Ball Peen 1 Brass Punch 1 1 Lift and support the front of the vehicle See Lift Front of Vehicle on page 9 2 Remove the front wheel See WHEEL AND TIRE SERVICE on pag...

Страница 74: ...CE on page 128 3 Remove the strut assembly See Front Strut Assem bly Replacement on page 57 4 Compress the coil spring 115 just enough to relieve the tension between the coil spring cap 112 and the co...

Страница 75: ...ef Fig 1 4 Remove the cotter pin 24 castle nut 25 and flat washer 26 from the end of the front axle 27 Ref Fig 1 5 Remove the cotter pin 10 and nut 9 from the lower ball joint Ref Fig 1 6 Tap downward...

Страница 76: ...1 Socket 9 16 1 Wrench 9 16 1 Torque Wrench ft lbs 1 To prevent injury caused by acci dental movement of the differential you must have a second person to help support and remove the differ ential 1 L...

Страница 77: ...at this time 3 From below the steering wheel put a plastic faced hammer against the lock nut as shown Ref Fig 10 4 Pull upward on the plastic faced hammer and strike hammer sharply with a ball peen h...

Страница 78: ...he steering wheel See Steering Wheel Replacement on page 63 2 Remove the four bolts 41 and lock nuts 42 that secure the steering column 40 to the frame 3 Remove the yoke bolts 44 lock washers and nuts...

Страница 79: ...1 Floor Jack 1 Wheel Chocks 2 Jack Stands 2 1 Raise the front of the vehicle See Lift Front of Vehi cle on page 9 2 Remove the front wheels See WHEEL AND TIRE SERVICE on page 128 3 Remove the steerin...

Страница 80: ...allation MAINTENANCE All steering and suspension components are lube free Routine examination of the tires provide indications that an alignment is required NOTICE Some maintenance items must be servi...

Страница 81: ...ice Manual 10002660 Counting threads or measuring thread distance are two methods to equalize tie rod length Drive the vehicle to confirm that the steering wheel is cor rectly centered If not remove t...

Страница 82: ...r and Service Manual FRONT CV SHAFT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Страница 83: ...1 Insulated Socket 9 16 1 Ratchet 1 1 Use an insulated wrench to disconnect the negative battery cable from the battery Ref Fig 2 2 Disconnect the harness from the motor brake con nector 7 3 Remove th...

Страница 84: ...otor housings to help with realignment during assembly of the motor to rear axle Ref Fig 3 Fig 2 Disconnect Battery Cable Fig 3 Mark Axle and Motor Do not damage the splines when removing and installi...

Страница 85: ...ferential 10 Finger tighten the bolts 11 in a cross sequence Ref Fig 4 then tighten to 25 in lbs 2 82 Nm increments of torque using the same cross sequence pattern 4 Reconnect the temperature sensor 9...

Страница 86: ...rom terminals U V and W 12 Ref Fig 8 Ref Fig 9 Fig 6 Disconnect Battery Cable Fig 7 Mark Axle and Motor Do not damage the splines when removing and installing the motor to the rear axle housing 4 Disc...

Страница 87: ...cross sequence pattern 4 Reconnect the temperature sensor 9 and speed sensor 8 wiring harnesses 5 Reconnect the U V and W terminals 12 Ref Fig 8 Ref Fig 9 Tighten the hardware to the torque values sp...

Страница 88: ...74 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 10002660...

Страница 89: ...Wrench 9 16 1 1 To remove front seat back 9 remove four screws 11 and lock washers 12 securing the seat back to the lower OPS Ref Fig 1 2 Remove the four lock nuts 8 washers 7 and bolts 6 from the sea...

Страница 90: ...Buckle Removal on page 79 8 Remove the four lock nuts 35 flat washers 20 and bolts 19 to remove the seat bottom 18 Ref Fig 4 Fig 4 Seat Bottom Removal 9 Remove the bolts 42 flat washers 43 and lock nu...

Страница 91: ...the rear closeout panel 4 See Rear Closeout Panel Replacement on page 30 2 Remove the bolts 36 and lock nuts that secure the footrest 24 to the armrest Ref Fig 7 3 Remove the center lock nuts 28 and b...

Страница 92: ...he torque values specified below Fig 9 Front Seat Belt Buckle Removal Rear Seat Belt Buckle Replacement Tool List Qty Socket 5 8 1 Ratchet 1 Wrench 5 8 1 Torque Wrench ft lbs 1 1 Remove bolts 74 and l...

Страница 93: ...FETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 79 Repair and Service Manual 10002660 Fig 10 Rear Seat Belt Buckle Removal 74 73...

Страница 94: ...commended Use a personal back support brace and proper lift ing technique to prevent personal injury 2 Loosen but do not remove the four bolts 84 fas tening the forward 85 and the rear 86 sections of...

Страница 95: ...Socket 1 2 1 Socket 15mm 1 Ratchet 1 Wrench 1 2 1 Wrench 15mm 1 Torque Wrench ft lbs 1 1 Remove the bolts 101 and lock nuts 103 from the brush guard 100 Ref Fig 12 2 Remove the bolts 104 and lock nuts...

Страница 96: ...Installation on page 81 4 Remove the seat belts See Seat Belt Removal and Installation on page 77 5 Remove the front seat belt buckle See Front Seat Belt Buckle Replacement on page 78 6 Loosen but do...

Страница 97: ...83 Repair and Service Manual 10002660 Fig 14 Lower OPS Weldment Assemble in the reverse order of removal Tighten hardware to torques values specified below 110 121 122 123 124 126 125 128 129 127 128...

Страница 98: ...84 Repair and Service Manual SEATING AND OPS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 10002660...

Страница 99: ...cant SAE 80W 90 gear oil Add slowly until lubricant reaches capacity If the lubricant needs to be replaced a drain plug 12 for removing the lubricant is located at the bottom of the dif ferential hous...

Страница 100: ...nt separator Ref Fig 3 13 Remove the axle 10 from the strut assembly 13 by pulling the strut assembly outward Ref Fig 2 14 Remove the CV Axle from the differential using a pry bar Fig 3 Control Arm an...

Страница 101: ...se order of removal using red thread locking compound Tighten the mounting bolts to the torque values specified below REAR SUSPENSION NOTICE Hardware that is removed must always be installed in its or...

Страница 102: ...ble in the reverse order of removal using new lock nuts Tighten the lock nut to the torque values specified below Strut Assembly Maintenance Items The following maintenance procedures are identical to...

Страница 103: ...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 AXLE AND SUSPENSION 1000266...

Страница 104: ...0 Repair and Service Manual REAR AXLE AND SUSPENSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 1000266...

Страница 105: ...grease 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 lubrican...

Страница 106: ...3 Curtis Programmer Port Fig 4 Curtis Programmer Port Installation Connect the Molex plug to the receptacle on the face of the controller Navigation A blinking square on the left indicates the positi...

Страница 107: ...Controller 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 F...

Страница 108: ...00 100 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...

Страница 109: ...version 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 contro...

Страница 110: ...play OEM information Reconfigured Display reconfigure status Model Number Display handheld model number Serial Number Display handheld serial number Manufacturing Date Display handheld manufacture dat...

Страница 111: ...ed LED flashes once to indicate that the first digit of the code will follow the yellow LED then flashes the appropri ate number of times for the first digit The red LED flashes twice to indicate that...

Страница 112: ...al load 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 Rai...

Страница 113: ...ler system drain 4 Battery resistance to high 5 Battery disconnected while driving 6 See Monitor menu Battery capacitor voltage 7 Blown B fuse or main contactor did not close 2 4 Overvoltage Cutback C...

Страница 114: ...2 Check sensor 3 1 Coil 1 Driver Open or Short also can be Main Open or Short Driver 1 pin6 is either open or shorted This fault can only be set when main enable off Shutdown driver 1 Correct conditi...

Страница 115: ...k voltage B connection terminal did not charge to B Vehicle Disabled KSI cycled 1 Main contactor did not close 2 Main contactor tips are oxidized burned or not making a good contact 3 External load on...

Страница 116: ...turned to neutral Shutdown Throttle If EMR_interloc k On clear the interlock throttle and direction inputs If EMR_Interloc k Off clear the throttle and direction inputs 1 Emergency Reverse operation h...

Страница 117: ...rrent 2 Fault checking menu parameters Ext supply max and Ext supply min are mis tuned 3 See Monitor menu Outputs ext supply current 7 1 OS General Internal controller fault detected Vehicle Disabled...

Страница 118: ...meter value is out of range 2 Check controller command on hand held 9 1 VCL OS Mismatch VCL and OS software do not match when Ski is cycled a check is made to verify that they match and a fault is iss...

Страница 119: ...controller 9 9 Dual motor Parameter Mismatch Mismatch of front and rear motors Vehicle Disabled Condition clears 1 Check Wires and connections 2 Check for mechanical bind 3 Check for high mechanical...

Страница 120: ...nu selection does not have a controller program option The default parameter is 0 Reset Controller is the view of the reset controller function Normal values are 0 or 1 The Monitor menu selection show...

Страница 121: ...troller allows access to a sub menu to see rear controller inputs The front controller is a SLAVE controller and is controlled by the rear con troller The rear controller sub menu shows the run tow sw...

Страница 122: ...ular attention to Notices Cautions Warnings and Dangers 10002660 Reverse Switch Throttles is the only sub menu below the Rear Controller sub menu This selection indicates throttle voltage range and of...

Страница 123: ...iew Inputs from the input menu and the sub menus Throttle Command shows the of throttle requested at the accelerator pedal Values should range from 0 100 Mapped Throttle shows the mapped throttle requ...

Страница 124: ...e changes from 0 10V This particular input determines the motor temperature readings The Outputs sub menu shows the controller outputs and their sub menus 5 Volts shows the voltage at 5 volt output pi...

Страница 125: ...value ranges between 0 6 25V The Battery sub menu indicates state of charge BDI capacitor voltage and KSI voltage BDI battery discharge indicator indicates the state of charge percentage Capacitor Vol...

Страница 126: ...verify that phase A of the encoder is operating correctly Motor speed A should equal Motor speed B in a properly operating power train MotorSpeed B shows the motor encoder phase B speed in revolutions...

Страница 127: ...equency shows the controller electrical frequency Temperature indicates the internal controller temp Regen shows regenerative braking and activates when the brake pedal is pressed Regen deactivates wh...

Страница 128: ...t Overvoltage Cutback or Undervoltage Cutback indicates the current avail able as a result of the condition A value of 100 indicates no cutback in cur rent The Vehicle sub menu selection shows vehicle...

Страница 129: ...starting from a stop In effect the vehicle is used as a tape measure In other words if you travel 300 feet in forward and then 300 feet in reverse the distance would be 600 feet The distance is contin...

Страница 130: ...e technician to upload settings from one controller Save cpf File and then to download the same settings to another controller Restore cpf File This is referred to as Cloning The cloning function is n...

Страница 131: ...Red Red Green 72V 12V 0 5V 0 5V 0 5V 0 5V GND Analog 5V Pink 1 2 3 4 5 6 7 8 9 10 11 12 13 24 25 26 27 28 29 30 31 32 33 34 35 14 15 16 17 18 19 20 21 22 23 Violet 0V or 72V REAR MASTER Green Black Wh...

Страница 132: ...he Service Parts Department P N 27481G01 The actual model can vary depending on availability The DVOM digital volt ohm meter shown in Figure 10 is rep resentative only Any DVOM can be used however the...

Страница 133: ...oved to access the individual component circuit terminals See Gauge Panel Replacement on page 24 Key Switch Testing Use the handheld diagnostic tool to verify operation of the key switch and the direc...

Страница 134: ...st ing To check the electronic speed controller solenoid for energy follow the steps below 1 Put the positive meter probe on the white wire pri mary circuit terminal Put the negative meter probe on th...

Страница 135: ...male pins on the connector Fig 19 PT1000 Temperature Sensor female pins on the connector Electronic Speed Sensor Testing 1 Use the DVOM probes to check the motor speed sensor while the connector is pl...

Страница 136: ...terminal Full continuity should be observed Ref Fig 21 Fig 21 U and W terminal 2 Now place one meter probe on the V terminal and the other probe on the W terminal Full continuity should be observed R...

Страница 137: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 123 Repair and Service Manual 10002660 NOTICE If continuity is observed between the case and terminals a fiel...

Страница 138: ...124 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 10002660...

Страница 139: ...cu pants of other highway vehicles be sure that the vehicle and contents are secured to trailer Do not ride on a vehicle being transported Remove the windshield before transporting Maximum speed with...

Страница 140: ...126 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 10002660...

Страница 141: ...ticular attention to Notices Cautions Warnings and Dangers 127 Repair and Service Manual 10002660 WHEELS AND TIRES Fig 1 Wheels and Tires Tire Style May Vary 1 2 3 4 CROSS SEQUENCE Valve stem should a...

Страница 142: ...optimum handling characteristics Do not over inflate Due to the low volume of the small tires over inflation can occur in seconds Install the valve dust cap after checking or inflating Tire Repair The...

Страница 143: ...129 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 10002660...

Страница 144: ...130 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 10002660...

Страница 145: ...dened Helical Gears Gear Selection Dash mounted Forward Neutral Reverse Speed Selection Dash Mounted Speed Range Switch Rear Axle Ratio 12 49 1 Front Axle Ratio 12 49 1 Seating Capacity 4 People Curb...

Страница 146: ...32 Repair and Service Manual VEHICLE SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 10002660...

Страница 147: ...duct brake performance test adjust if required C A C A C A C A Wiring Inspect for loose connections broken or missing insulation C C C C Steering Assembly Check for excess play loose or missing hardwa...

Страница 148: ...4 Repair and Service Manual PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 100026...

Страница 149: ...ead all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 135 Repair and Service Manual 10002660 APPENDIX A BATTERY CHARGER U...

Страница 150: ...Attention 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...

Страница 151: ...d to connectors 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 wate...

Страница 152: ...r will 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 t...

Страница 153: ...lowing information and warnings before operating vehicle In any product components will eventually fail to per form properly as the result of normal use age wear or abuse The manufacturer can not know...

Страница 154: ...Dealer 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...

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