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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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Содержание LX4 2020

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

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Страница 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...

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

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

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

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Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 41: ...HFRPPHQGHG RQ WKH WLUH VLGHZDOO OO IRXU WLUHV PXVW KDYH WKH VDPH SUHVVXUH IRU EHVW FRQ WURO TXDOLWLHV OZD V LQVWDOO WKH YDOYH VWHP FDS DIWHU RX FKHFN RU LQIODWH WKH WLUHV 7LUH 5HSDLU 7KH YHKLFOH LV HT...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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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Страница 69: ...XDO OHDQ DOO GLUW DQG GHEULV IURP WKH PRWRU 8QSOXJ WKH VSHHG VHQVRU FRQQHFWRU IURP WKH ZLUH KDUQHVV LJXUH 6SHHG 6HQVRU 5HPRYDO 5HPRYH WKH WRU KHDG VFUHZ WKDW VHFXUHV WKH VSHHG VHQVRU WR WKH PRWRU 3XOO...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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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Страница 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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Страница 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...

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Страница 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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Страница 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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Страница 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...

Страница 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...

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Страница 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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Страница 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...

Страница 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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Страница 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...

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Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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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Страница 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...

Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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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