Tracker LX4 2020, Repair And Service Manual

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

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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...

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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 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...

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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...

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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...

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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...

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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...

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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...

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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 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...

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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 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...

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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...

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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...

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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 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 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...