Preliminary TRACKER OFF ROAD LX6 Repair And Service Manual
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Preliminary TRACKER OFF ROAD LX6 Repair And Service Manual

Electric powered utility vehicle
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REPAIR AND SERVICE MANUAL
699327-A
Issued August 2019
PRELIMINARY

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  • Page 1 REPAIR AND SERVICE MANUAL 699327-A Issued August 2019 PRELIMINARY...
  • Page 2 A WARNING indicates a dangerous condition that can cause death or serious injury. A DANGER indicates a dangerous condition that will cause death or serious injury. The battery posts, terminals and all related accessories contain lead and lead compounds. Wash your hands after contacting any of these components. PRELIMINARY...
  • Page 3 THE MANUFACTURER DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDEN- TAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this manual. These are the original instructions as defined by 2006/42/EC. Dealer: 800-296-4804 Consumer: 877-394-6727 www.trackeroffroad.com 699327 Repair and Service Manual PRELIMINARY...
  • Page 4 For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dis- pose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information. Repair and Service Manual 699327 PRELIMINARY...

  • Page 5: Table Of Contents

    GENERAL MAINTENANCE....................7 BEFORE SERVICING THE VEHICLE ................7 ADDITIONAL WARNINGS....................8 BATTERY REMOVAL & INSTALLATION ................. 8 LIFTING THE VEHICLE....................9 Entire Vehicle ....................... 9 Front of Vehicle ....................10 Rear of Vehicle ....................10 699327 Repair and Service Manual PRELIMINARY...
  • Page 6 Wheel Bearing and King Pin Bushing inspection ..........35 Wheel Bearing Packing ..................35 Wheel Bearing Adjustment .................36 Wheel Alignment ....................36 FRONT SUSPENSION ....................37 Front Shock Absorber Replacement ..............37 Front Spring Replacement ..................38 Hub Replacement ....................40 Wheel Bearing and Race Replacement ..............40 Repair and Service Manual 699327 PRELIMINARY...
  • Page 7 Prolonged Storage ..................... 58 Battery Charging ....................58 AC Voltage ......................59 FAULT TESTING ......................59 Hydrometer ......................59 Using Hydrometer ....................60 BATTERY CHARGER..................... 61 Charger Description ................... 61 Portable Charger Installation ................61 699327 Repair and Service Manual PRELIMINARY...
  • Page 8 Accessory Wiring ....................78 Faulty Wire Replacement ..................78 Tail Light and Bulb ....................78 Halogen Headlight Bulb ..................79 LED Bulb ......................79 Headlight Assembly ....................79 Controller Replacement ..................80 Solenoid Replacement ..................81 DC to DC Converter ....................82 Reverse Buzzer ....................82 Repair and Service Manual 699327 PRELIMINARY...
  • Page 9 MAINTENANCE AND REPAIRS................... 101 Parts Replacement vs. Repair ................. 101 Adjusting Brake Pedal Free Travel ..............101 Parking Brake Latching Force ................102 Brake Drum Removal and Installation .............. 102 Wheel Brake Service ..................103 699327 Repair and Service Manual PRELIMINARY...
  • Page 10 Installation ......................115 REAR LEAF SPRINGS....................116 Removal ......................116 Installation ......................116 REAR AXLE........................117 Removal ......................117 Installation ......................118 WEATHER PROTECTION GENERAL........................121 Trailering ......................121 SUN TOP ........................121 SPILT WINDSHIELD ..................... 123 FULL WINDSHIELD....................... 124 viii Repair and Service Manual 699327 PRELIMINARY...
  • Page 11 Electronic Speed Controller Solenoid - Testing ..........149 Temperature Sensor - Testing ................. 150 Electronic Speed Sensor - Testing ..............151 AC Motor Bench Test ..................151 GENERAL SPECIFICATIONS VEHICLE SPECIFICATIONS..................155 APPENDIX A BATTERY CHARGER USER’S GUIDE ................ 157 699327 Repair and Service Manual PRELIMINARY...
  • Page 12 TABLE OF CONTENTS Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 13: Safety Information

    • Be careful when you make sharp turns, or turns you are not familiar with. • Be careful when you drive on loose terrain. • Be careful when you operate the vehicle in a populated area. 699327 Repair and Service Manual PRELIMINARY...

  • Page 14: Maintenance

    • Use a dedicated circuit for the battery charger. Do not plug other appliances into the receptacle when the charger is in operation. • Operate the charger according to the charger manufacturers recommendations or applicable electrical code. Repair and Service Manual 699327 PRELIMINARY...

  • Page 15: General Information And Routine Maintenance

    Design changes take place on an ongoing basis. In order Label No. to obtain correct components for the vehicle, the manu- facture date code, serial number and vehicle model must be provided when ordering service parts. Fig. 2 Serial Number Labels 699327 Repair and Service Manual PRELIMINARY...

  • Page 16: Transporting Vehicle

    To prevent the possibility of motor ting could damage grease seals and cause premature disintegration, never operate vehicle at full throttle for more than 4 - 5 seconds while bearing failure. vehicle is in a “no load” condition. Repair and Service Manual 699327 PRELIMINARY...

  • Page 17: Rear Axle

    The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water is the best method of pre- serving the painted surfaces. 699327 Repair and Service Manual PRELIMINARY...

  • Page 18: Service Schedule

    Rack End Ball Joint - Check for noise and loose or missing hardware. NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions. Fig. 5 Periodic Service Schedule Repair and Service Manual 699327 PRELIMINARY...

  • Page 19: Hardware

    (922) BOLT SIZE Class 5.8 (14) (27) (47) (76.4) (Grade 2) Class 8.8 (10) (24) (47) (83) (131) (Grade 5) Class 10.9 (14) (34) (66) (117) (184) (Grade 8) 10.9 Fig. 6 Torque Specifications 699327 Repair and Service Manual PRELIMINARY...
  • Page 20 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: Repair and Service Manual 699327 PRELIMINARY...

  • Page 21: Safety

    If repairs are to be made that will require Do not modify the vehicle in any manner that will change welding or cutting, the batteries must be the weight distribution of the vehicle. removed. 699327 Repair and Service Manual PRELIMINARY...

  • Page 22: Additional Warnings

    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. Repair and Service Manual 699327 PRELIMINARY...

  • Page 23: Lifting The Vehicle

    Lower the jack and test the stability of the vehicle on the two jack stands. Center of Front Axle Controller B- Flat Portion Disconnect BL- cable of Frame Fig. 1 Battery Connections Outside End of Rear Axle Fig. 2 Lifting the Vehicle 699327 Repair and Service Manual PRELIMINARY...

  • Page 24: Front Of Vehicle

    Raise the vehicle and locate a jack stand under the outer ends of the rear axle. Lower the jack and test the stability of the vehicle on the jack stands. Lower the vehicle by reversing the lifting sequence. Repair and Service Manual 699327 PRELIMINARY...
  • Page 25 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699327 Repair and Service Manual PRELIMINARY...
  • Page 26 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 27: Wheels And Tires

    All four tires should have the same pressure for optimum han- 699327 Repair and Service Manual PRELIMINARY...
  • Page 28 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Valve Stem Cap Tire style may vary 'Cross Sequence' Fig. 1 Wheel and Tire Installation Repair and Service Manual 699327 PRELIMINARY...
  • Page 29 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 Repair and Service Manual PRELIMINARY...
  • Page 30 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 31: Body

    Body components can be replaced by removing securing hardware, replacing the component and securing with Fig. 3 Remove Ratchet Fastener hardware in same orientation. Drill out rivet Pop Rivet head only Fig. 1 Drill Out Metal Rivet 699327 Repair and Service Manual PRELIMINARY...

  • Page 32: Rocker Panel

    Rivet Gun..............1 Item Torque Specification Torque Wrench, in. lbs..........1 45 - 55 in. lbs. (5 - 6.2 Nm) 18 - 20 in. lbs. (2 - 2.2 Nm) Front of Vehicle Fig. 4 Rocker Panel Repair and Service Manual 699327 PRELIMINARY...

  • Page 33: Fender Flare

    Drill out the rivets (9) securing the fender flare (10) to the cowl (Ref Fig. 5). Assemble in the reverse order of removal using new riv- ets and lock nuts. Front of Vehicle Fig. 5 Fender Flare 699327 Repair and Service Manual PRELIMINARY...

  • Page 34: Cowl

    Pry Bar................. 1 Assemble in the reverse order of removal using new riv- Disconnect the headlights from the main harness ets. (See Headlight Assembly on page 79). Front of Vehicle Fig. 6 Cowl Repair and Service Manual 699327 PRELIMINARY...

  • Page 35: Control Panel

    Pull the top of the control panel out and up. A small pry bar may be necessary. Disconnect the electrical accessories from the main harness. Assemble in the reverse order of removal. Fig. 7 Control Panel 699327 Repair and Service Manual PRELIMINARY...

  • Page 36: Instrument Panel

    Disconnect the battery cable at the negative (-) bat- to the new instrument panel. tery terminal. Front of Vehicle Fig. 8 Instrument Panel Repair and Service Manual 699327 PRELIMINARY...

  • Page 37: Front Fascia And Mounting Bracket

    Tighten the bolts (17, 21) to the torque val- ues below. Front of Vehicle Item Torque Specification 17, 21 6 - 8 ft. lbs. (8 - 11 Nm) Front of Vehicle Fig. 10 Seat Back Fig. 9 Fascia 699327 Repair and Service Manual PRELIMINARY...

  • Page 38: Front Seat And Seat Frame

    Assemble in the reverse order of removal using new lock nuts (29, 36), rivets (39), and washers (37, 38). Tighten the lock nuts to the torque values below. Item Torque Specification 29, 36 14 - 18 ft. lbs. (19 - 24 Nm) Repair and Service Manual 699327 PRELIMINARY...
  • Page 39 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 11 Front Seat Pod and Frame 699327 Repair and Service Manual PRELIMINARY...

  • Page 40: Flip Seat, Seat Back Support, And Footrest

    (59) securing the seat frame support to the vehicle frame. Remove the bolts (64) securing the seat back sup- port to the vehicle frame. 10. Remove the lock nuts (68), washers (67), and bolts (66) securing the footrest to the vehicle frame. Repair and Service Manual 699327 PRELIMINARY...
  • Page 41 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Front of Vehicle Fig. 12 Flip Seat 699327 Repair and Service Manual PRELIMINARY...

  • Page 42: Truck Bed And Bed Support

    (73) securing the seat support to the support brack- ets (70). 11. Remove the bolts (77) securing the seat support to the frame. 12. Remove the lock nuts (89), washers (87), and bolts (88) securing the support brackets to the frame. Repair and Service Manual 699327 PRELIMINARY...
  • Page 43 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 13 Truck Bed 699327 Repair and Service Manual PRELIMINARY...

  • Page 44: Rear Body

    Pry out the ratchet rivets (94) securing the top of the rear body to the frame. Remove the drive rivets (96) securing the rear of the rear body to the frame. Repair and Service Manual 699327 PRELIMINARY...
  • Page 45 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 14 Rear Body 699327 Repair and Service Manual PRELIMINARY...

  • Page 46: Painting

    Multiple coats may be applied to provide adequate coverage and finish. Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match. Repair and Service Manual 699327 PRELIMINARY...
  • Page 47 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699327 Repair and Service Manual PRELIMINARY...
  • Page 48 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 49: Front Suspension, Steering & Axle

    Force the grease up through and around all of the rollers until the entire bearing is saturated in grease. 699327 Repair and Service Manual PRELIMINARY...

  • Page 50: Wheel Bearing Adjustment

    (Ref Fig. 3). The measurement taken at the front of the tires should be 0" - 1/8” (0 - 3 mm) less than the rear. Repair and Service Manual 699327 PRELIMINARY...

  • Page 51: Front Suspension

    (5). Item Torque Specification Jam Nut 36 - 40 ft. lbs. (49 - 54 Nm) 13 - 18 ft. lbs (18-24 Nm) 699327 Repair and Service Manual PRELIMINARY...

  • Page 52: Front Spring Replacement

    (15) until only one rear of the right spring to the center bolt (47) at the thread is engaged (Ref Fig. 6). front of the left spring. The two measurements must be equal. Repair and Service Manual 699327 PRELIMINARY...
  • Page 53 11, 12, 16, 19, 27 35 - 50 ft. lbs. (47 - 67 Nm) Install the front wheels (See Wheel Installation on page 13) and lower the vehicle. Front of Vehicle Low Suspension Shown Fig. 6 Leaf Springs 699327 Repair and Service Manual PRELIMINARY...

  • Page 54: Hub Replacement

    Press the new race into the hub using an arbor press and a bearing driver. 10. If an arbor press is not available, evenly tap with a hammer and a bearing driver to drive race fully into the bore. Repair and Service Manual 699327 PRELIMINARY...
  • Page 55 14. Mount the hub to the spindle (See Hub Replacement on page 40). 15. Adjust the bearing (See Wheel Bearing Adjustment on page 36). 16. Lower the vehicle and tighten the front wheel(s) (See Wheel Installation on page 13). 699327 Repair and Service Manual PRELIMINARY...

  • Page 56: Steering

    FRONT SUSPENSION, STEERING & AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STEERING Front of Vehicle Low Suspension Shown Fig. 10 Steering Components Repair and Service Manual 699327 PRELIMINARY...

  • Page 57: Rack Ball Joint Replacement

    (Ref Fig. ball joint at same location 10). Fig. 11 Rack Ball Joint Installation Lift and support the front of the vehicle and remove the front wheel(s) (See LIFTING THE VEHICLE on page 9). 699327 Repair and Service Manual PRELIMINARY...

  • Page 58: Bellows Replacement

    15. A worn tie rod is likely to have caused incorrect Install the jam nut (48) and rack ball joint (50) on the wheel alignment. Check the front wheel alignment rack extension (55) and reattach it to the spindle arm. Repair and Service Manual 699327 PRELIMINARY...

  • Page 59: Rack And Pinion Unit Replacement

    Slide a small straight blade screwdriver between the side spindle arm. lip of the seal and the pinion and pry the top portion of the seal up to remove (Ref Fig. 14). 699327 Repair and Service Manual PRELIMINARY...

  • Page 60: Spindle Replacement

    Loosen the lock nut (46) until the tie rod ball joint (45) threads are protected (Ref Fig. 15). Using a ball joint separator as a lever, apply pressure to the ball joint and tap the nut with a plastic faced Repair and Service Manual 699327 PRELIMINARY...

  • Page 61: Front Axle Replacement

    11. Secure the rack and pinion unit to the spring with a vice by the mounting ears only. The wire to prevent the intermediate shaft from pulling rack and pinion unit is made of alu- apart. minum and can be damaged if held otherwise. 699327 Repair and Service Manual PRELIMINARY...

  • Page 62: Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance

    (50) assembly in the reverse order of removal, making (Ref Fig. 16). sure to lubricate the pinion seal lip prior to installing seal (See Pinion Seal Replacement on page 45). Repair and Service Manual 699327 PRELIMINARY...

  • Page 63: Steering Wheel Replacement

    1/8” gap. nut and strike a plastic faced hammer sharply with a Tighten the jam nut (48) to the torque values below. ball peen hammer. 699327 Repair and Service Manual PRELIMINARY...

  • Page 64: Steering Shaft And Column Replacement

    14. Secure with the large retaining ring (87), making sure it is fully seated in the groove of the column. 15. Place the steering column on the vehicle and tighten the four column bolts (82) to the torque values below. Repair and Service Manual 699327 PRELIMINARY...
  • Page 65 45 - 55 in. lbs. (5 - 6 Nm) 155 -215 in. lbs (18-24 Nm) Fig. 21 Steering Shaft and Column Install with arch Small up as shown Retaining Ring Steering Shaft Bearing Groove Fig. 22 Small Retaining Ring Orientation 699327 Repair and Service Manual PRELIMINARY...
  • Page 66 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: Repair and Service Manual 699327 PRELIMINARY...

  • Page 67: Batteries And Battery Charger

    Use insulated wrenches to prevent the possibility of a dropped wrench from ‘shorting out’ a battery, which could result in an explosion and severe per- sonal injury or death. 699327 Repair and Service Manual PRELIMINARY...

  • Page 68: Batteries Removal

    Ratchet ................ 1 specified. If torque values are not specified, refer to the Torque Specifications table (See TORQUE SPEC- Battery Carrier ............. 1 IFICATIONS on page 5). Repair and Service Manual 699327 PRELIMINARY...

  • Page 69: Battery Installation

    This will cause a “mushroom” effect on the battery post, preventing the terminal nut from being proper- ly tightened. Protect the battery terminals and bat- tery wire terminals with a commercially available protective coating. 699327 Repair and Service Manual PRELIMINARY...

  • Page 70: Battery Maintenance

    1/2” (13 mm) (6 mm to 10 mm) Plates Electrolyte level should be at least 1/2” (13mm) above the plates and 1/4” to 3/8” (6 to 10 mm) below vent. Fig. 4 Correct Electrolyte Level Repair and Service Manual 699327 PRELIMINARY...

  • Page 71: Cleaning Batteries

    (baking soda) solution. 1/4 cup (60 ml) Plastic Sodium 1-1/2 gallons Spray Bicarbonate (6 liter) Bottle (Baking Soda) Clear Water Fig. 7 Preparing Acid Neutralizing Solution 699327 Repair and Service Manual PRELIMINARY...

  • Page 72: Prolonged Storage

    • The charger connector and cord set must be pro- tected from damage and located in an area to prevent injury resulting from personnel running over or tripping over the cord set. Repair and Service Manual 699327 PRELIMINARY...

  • Page 73: Ac Voltage

    The greater the concentration of sulfuric acid, the more dense the electrolyte becomes. The higher the den- sity, the higher the state of charge. 699327 Repair and Service Manual PRELIMINARY...

  • Page 74: Using Hydrometer

    If the results indicate a weak cell, the battery or batteries should be removed and replaced with a good battery of the same brand, type and approximate age. Repair and Service Manual 699327 PRELIMINARY...

  • Page 75: Battery Charger

    The charger should also be installed in an area that will be rel- atively free of dirt, mud, or dust. Accumulations within the charger vents will reduce their heat dissipating qualities. 699327 Repair and Service Manual PRELIMINARY...
  • Page 76 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: Repair and Service Manual 699327 PRELIMINARY...

  • Page 77: Electronic Speed Control

    2 mph (3 kph), storage facility for problem diagnosis. and activates an alarm. The technician can put the controller in diagnostic mode and the controller will report the likely failure. 699327 Repair and Service Manual PRELIMINARY...

  • Page 78: Operation

    As a vehicle begins to accelerate while descending a hill, the speed sensor will cause the motor Fig. 1 Access to Pedal Box to electrically reduce the speed of the vehicle through regenerative braking. Repair and Service Manual 699327 PRELIMINARY...

  • Page 79: Speed Sensor

    Once the functionality of the wiring has been confirmed, the remaining tests are used to identify which of the compo- nents (controller or ITS) must be replaced. 699327 Repair and Service Manual PRELIMINARY...

  • Page 80: Inductive Throttle Sensor (Its) Testing And Replacement

    Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the plastic pedal box studs. Install a new ITS being careful to align the ITS and not to overtighten the retaining nuts. Repair and Service Manual 699327 PRELIMINARY...
  • Page 81 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 Repair and Service Manual PRELIMINARY...
  • Page 82 ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 83: Motor

    Fig. 2 Mark Axle and Motor Do not damage the splines when removing and installing the motor to the rear axle housing. Disconnect the speed sensor (8) and temperature sensor (9). (Ref Fig. 3). 699327 Repair and Service Manual PRELIMINARY...

  • Page 84: Motor Installation

    Item Torque Specification and should be replaced. 72 - 78 in. lbs. (8 - 9 Nm) Repair and Service Manual 699327 PRELIMINARY...
  • Page 85 MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699327 Repair and Service Manual PRELIMINARY...
  • Page 86 MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 87: Electrical System

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM Fig. 1 Wiring Diagram 699327 Repair and Service Manual PRELIMINARY...
  • Page 88 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 2 Electrical Schematic Repair and Service Manual 699327 PRELIMINARY...
  • Page 89 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Electrical Schematic (Continued) 699327 Repair and Service Manual PRELIMINARY...
  • Page 90 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 4 Harness Overview Repair and Service Manual 699327 PRELIMINARY...

  • Page 91: Voltage Testing For Batteries

    Place the black probe (-) on the battery post with the black wire attached. NOTICE: The power wire supplies power to the entire fuse block. c. A reading of 11 VDC or greater indicates ade- quate battery condition. 699327 Repair and Service Manual PRELIMINARY...

  • Page 92: Accessory Wiring

    Assemble in the reverse order of removal. Tighten the screws to the torque listings below. RELAY Item Torque Specification RESISTOR 5 - 10 in. lbs. (.6 - 1.1 Nm) Fig. 6 Fuse Block Repair and Service Manual 699327 PRELIMINARY...

  • Page 93: Halogen Headlight Bulb

    (15) to the cowl (Ref Fig. 9). Reconnect the harness. Assemble in the reverse order of removal. Tighten the self threading nuts to the torque values below, Item Torque Specification 18 - 30 in. lbs. (2 - 3.4 Nm) 699327 Repair and Service Manual PRELIMINARY...

  • Page 94: Controller Replacement

    Harness Be sure to label the wires so they can be installed in the origin al location (Ref Fig. 11). Fig. 11 Controller Wiring Repair and Service Manual 699327 PRELIMINARY...

  • Page 95: Solenoid Replacement

    Assemble in the reverse order of removal using new lock nuts. Tighten the nuts to the torque values below. Item Torque Specification 11, 13 50 - 55 ft. lbs. (5.6 - 6.2 Nm) 699327 Repair and Service Manual PRELIMINARY...

  • Page 96: Dc To Dc Converter

    (-) terminal of the buzzer and the gray wire 50 - 55 in. lbs. (5 - 6 Nm) connects to the positive (+) terminal. Front of Vehicle Fig. 14 Reverse Buzzer Fig. 13 DC to DC Converter Repair and Service Manual 699327 PRELIMINARY...

  • Page 97: Horn

    With the adequacy of the batteries confirmed, use a DVOM connected directly to the battery terminal posts to determine the open voltage of the set. In the following tests, this voltage level will be used as a reference. 699327 Repair and Service Manual PRELIMINARY...

  • Page 98: Continuity Check

    “0” when the switch is activated. The change in display or audible indicator shows that the switch is functioning. Press to Activate Switch Fig. 16 Continuity Check of Switch Repair and Service Manual 699327 PRELIMINARY...

  • Page 99: Accesories

    Assemble in the reverse order of removal. Confirm proper orientation using the alignment pegs. the key. Disconnect the negative (-) battery cable using an insulated wrench. Remove the control panel (See Control Panel on page 21). 699327 Repair and Service Manual PRELIMINARY...

  • Page 100: Hour Meter

    (65) and push it through the front of the gauge panel (50) (Ref Fig. 18). Assemble in the reverse order of removal. Confirm proper orientation of the switch prior to seating it completely in the gauge panel. Repair and Service Manual 699327 PRELIMINARY...
  • Page 101 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699327 Repair and Service Manual PRELIMINARY...
  • Page 102 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 103: Mechanical Brakes

    Nylock Nut Bushing Torsion Equalizer Spring Brake Cables Link Parking Brake Retaining Release Linkage Bushing Ring Washers Cotter Pin Part of Accelerator Pedal Self Adjusting Wheel Brake Brake Lever Fig. 1 Mechanical Brake System 699327 Repair and Service Manual PRELIMINARY...

  • Page 104: Brake System Overview

    This misalignment is normal. Automatic Adjuster Mechanism Never manually adjust the brakes at the star wheel. Doing so will cause permanent damage to the adjuster mechanism and result in a gradual loss of brakes. Repair and Service Manual 699327 PRELIMINARY...

  • Page 105: How The Parking Brake Works

    Pressing the service brake, which permits the spring loaded parking brake 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. 699327 Repair and Service Manual PRELIMINARY...

  • Page 106: Fault Testing Table

    Incorrect compensator spring adjust- Return to factory specification. ment. is latched. (Note: At full speed the wheels may not lock, but should brake Excessive brake pedal free travel. Adjust per manual. aggressively). Fig. 5 Fault Testing Table Repair and Service Manual 699327 PRELIMINARY...
  • Page 107 Check that brake levers return at equal rate - (Indication of dragging cable). Dragging shoes. Check wheel brakes. Parking brake will not stay latched Excessive wear. Check for worn latch mechanism. Fig. 5 Fault Testing Table 699327 Repair and Service Manual PRELIMINARY...

  • Page 108: Fault Testing And Inspection

    Pedal Bushing Torsion Spring Fig. 7 Brake Pedal Inspection Check the brake pedal return. • Apply the brake pedal and release. • Check that the brake pedal arm rests against the pedal bumper when released. Repair and Service Manual 699327 PRELIMINARY...
  • Page 109 Brake Pedal Free Travel on page 101). Inspect the brake cables. • Inspect for damage to the outer cable, fraying of the inner cable, or lack of free motion when the pedal is applied and released. 699327 Repair and Service Manual PRELIMINARY...
  • Page 110 Cam Must Be Against Hinge Torsion Latch Arm At This Point Springs 0.0" Gap (0.0 mm) Catch Bracket Screw Push Fig. 11 Kick-off Cam Inspection Fig. 10 Parking Brake Pedal Hinge Inspection Repair and Service Manual 699327 PRELIMINARY...

  • Page 111: Periodic Brake Performance Test (Pbpt)

    Quickly press the brake pedal to latch the parking brake at the line or marker in the test area and remove your foot from the pedal. The vehicle should stop aggressively. The wheel brakes may or may not lock. 699327 Repair and Service Manual PRELIMINARY...

  • Page 112: Aggressive Stop Test

    If oil is present, a stops acceptably. repair to the rear axle is necessary (See Axle Shaft, The adjuster functions most consistently with aggressive Bearing and Seal Removal on page 112). braking. Repair and Service Manual 699327 PRELIMINARY...
  • Page 113 • Note the location of the two Teflon coated wash- ers (Ref Fig. 21). Check the condition and operation of the moving anchor assembly. • Operate the brake lever to check for free motion. 699327 Repair and Service Manual PRELIMINARY...
  • Page 114 (See Adjusting Brake Pedal Free Travel on page 101). • This includes all linkage and wheel brake com- ponents. Fig. 15 Brake Shoe Wear Repair and Service Manual 699327 PRELIMINARY...

  • Page 115: Maintenance And Repairs

    10. Check to see that the clevis pins attaching the brake cables to the brake levers are loose. If they are not Tighten the jam nut to the torque values below loose, inspect the system again and correct as required (Ref Fig. 18). 699327 Repair and Service Manual PRELIMINARY...

  • Page 116: Parking Brake Latching Force

    (27 - 32 kg). six o’clock position which is directly over the brake mechanism. Fig. 19 Checking Parking Brake Latching Pressure Use a small straight blade screwdriver to raise the adjuster arm just above the star wheel. Repair and Service Manual 699327 PRELIMINARY...

  • Page 117: Wheel Brake Service

    LUBRICATE rain, and other conditions. It is recommended that wheel brake service be performed periodically on a sample of Fig. 21 Wheel Brake Lubrication Points 699327 Repair and Service Manual PRELIMINARY...

  • Page 118: Backing Plate/Entire Wheel Brake Assembly Removal And Installation

    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). Front of Vehicle Fig. 22 Backing Plate Removal and Installation Repair and Service Manual 699327 PRELIMINARY...

  • Page 119: Brake Cable And Equalizer Assembly Removal And Installation

    Screw Adjusting Screw In Until 1 - 2 Threads Are Exposed Existing Brake Shoes Adjust 'in' 10 - 15 'clicks' (Minimum of 1 - 2 Threads Must Be Exposed) Fig. 24 Setting Adjuster Screw 699327 Repair and Service Manual PRELIMINARY...

  • Page 120: Compensator Assembly, Removal And Installation

    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 (See Adjusting Brake Pedal Free Travel on page 101). Repair and Service Manual 699327 PRELIMINARY...

  • Page 121: Brake Pedal Removal And Installation

    Rotate the cam (42) until it is flush with (no gap) the latch arm. Tighten the setscrews to the torque value below. Item Torque Specification 70 - 84 in. lbs. (8 - 9.5 Nm) Pedal Latch Fig. 28 Brake Pedal Removal and Installation. 699327 Repair and Service Manual PRELIMINARY...

  • Page 122: Parking Brake Catch Bracket Removal And Installation

    1/4" (6 mm) Max Gap At This Point Fig. 29 Catch Bracket and Latch Arm 1/4" - 3/8" (6 - 9.5 mm) Diameter Drill or Bolt Must Pass Pedal Bumper Through Gap Fig. 30 Pedal Bumper Adjustment Repair and Service Manual 699327 PRELIMINARY...

  • Page 123: Parking Brake Release Linkage And Kick-Off Cam Removal And Replacement

    Adjust the kickoff cam (42) (See Kick Off Cam Adjustment on page 107). Tighten the setscrews (41) to the torque values than below. Item Torque Specification 70 - 84 in. lbs. (8 - 9.5 Nm) 699327 Repair and Service Manual PRELIMINARY...
  • Page 124 MECHANICAL BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 125: Rear Axle

    Never work on any vehicle that is supported by a jack alone (See LIFTING THE VEHICLE on page 9). 699327 Repair and Service Manual PRELIMINARY...

  • Page 126: Fill Procedure

    (3) from the axle tube as a complete assembly Remove the outer snap ring (3) from the axle tube (Ref Fig. 3) (Ref Fig. 4). (Ref Fig. 2). Fig. 4 Remove Axle Shaft Repair and Service Manual 699327 PRELIMINARY...
  • Page 127 Fig. 6 Inner Snap Ring Install the outer snap ring. 10. Install the rear hub. Use caution to prevent damage to the inner surface of the axle tube at the seal area. 699327 Repair and Service Manual PRELIMINARY...
  • Page 128 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 129: Rear Suspension

    (10). Installation Install a washer (1) with the cupped surface facing upward and the rubber bushing (2) on the top stud Fig. 1 Shock Absorber of the shock absorber (5) (Ref Fig. 1). 699273 Repair and Service Manual PRELIMINARY...

  • Page 130: Rear Leaf Springs

    Inspect all of the bushings and the hardware and replace any worn or damaged parts with new hard- ware. Make sure that the lift bracket (19) is correctly posi- tioned on top of the axle (Ref Fig. 2). Repair and Service Manual 699273 PRELIMINARY...

  • Page 131: Rear Axle

    Ratchet ................ 1 Remove the wheels (See WHEEL AND TIRE SER- VICE on page 13). Torque Wrench, ft. lbs..........1 Floor Jack..............1 Remove the motor (See Motor Removal on page 69). Jack Stands..............4 699273 Repair and Service Manual PRELIMINARY...

  • Page 132: Installation

    Assemble in the reverse order of removal. Tighten all hardware to the torque values listed in the proper section (See SHOCK ABSORBER on page 115)(See REAR LEAF SPRINGS on page 116)(See Motor Installation on page 70). Repair and Service Manual 699273 PRELIMINARY...
  • Page 133 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699273 Repair and Service Manual PRELIMINARY...
  • Page 134 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699273 PRELIMINARY...

  • Page 135: Weather Protection

    Tool List Qty. Remove the sun top from the vehicle. Plastic faced mallet............1 Wrench, 1/2" ..............1 Wrench, 9/16" ..............1 Socket, 1/2” ..............1 Socket, 9/16” ...............1 Ratchet ................1 Screwdriver, Straight Blade .........1 Torque Wrench, ft. lbs..........1 699273 Repair and Service Manual PRELIMINARY...
  • Page 136 Assemble in the reverse order or removal. Tighten all hardware to the torque values below using new lock nuts. Item Torque Specification 4, 7, 13, 19 13 - 15 ft. lbs. (17.6 - 20.3 Nm) Repair and Service Manual 699273 PRELIMINARY...

  • Page 137: Spilt Windshield

    70 - 97 in. lbs. (8 - 11 Nm) Fold down the upper portion of the windshield. Strut Front of Strut Vehicle Windshield Front of Vehicle Strut Front of Vehicle Fig. 5 Split Windshield 699273 Repair and Service Manual PRELIMINARY...

  • Page 138: Full Windshield

    Pull the sashes (31) away from the front strut by pull- ing towards the front of the vehicle starting from the Strut Front of Vehicle Windshield Front of Vehicle Strut Fig. 6 Full Windshield Repair and Service Manual 699273 PRELIMINARY...
  • Page 139 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699273 Repair and Service Manual PRELIMINARY...
  • Page 140 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699273 PRELIMINARY...

  • Page 141: Fault Testing

    Inspect and replace if out of round drums Incorrect tire pressure Inflate to recommended pressure Dragging wheel brakes Service brake system STEERING PULLS TO ONE SIDE Suspension component failure Repair Alignment incorrect Align Fig. 1 Suspension and Steering Fault Diagnosis 699327 Repair and Service Manual PRELIMINARY...

  • Page 142: Curtis Controller

    Press the favorites (star) key for four sec- onds (until the favorites set screen is dis- played), to set a position in the menu. Press the appropriate favorites key to move to a selected favorites position. Fig. 3 Curtis Programmer Port Repair and Service Manual 699327 PRELIMINARY...

  • Page 143: Main Menu Definitions

    Motor RPM 0 RPM -12000 - 12000 Temperature -100 - 300 Motor Motor Speed A -12000 - 12000 0 RPM Motor Speed B -12000 - 12000 0 RPM Fig. 5 CURTIS Handheld Controller Main/Sub-menus 699327 Repair and Service Manual PRELIMINARY...
  • Page 144 Display non - active faults Get Settings From OK - Abort Controller Functions Settings Write Settings To OK - Abort Controller Reset All Settings Yes - No Fig. 5 CURTIS Handheld Controller Main/Sub-menus (Continued) Repair and Service Manual 699327 PRELIMINARY...
  • Page 145 OS build number build number Display Display SM Version controller SM controller SM version version Display VCL Display VCL VCL App Version App Version App Version Fig. 5 CURTIS Handheld Controller Main/Sub-menus (Continued) 699327 Repair and Service Manual PRELIMINARY...
  • Page 146 Display handheld hardware Hardware Version version MC-Protocol Version Display MC-Protocol version ES-Protocol Version Display ES-Protocol version S-Protocol Version Display S-Protocol version Device Type Display device type Fig. 5 CURTIS Handheld Controller Main/Sub-menus (Continued) Repair and Service Manual 699327 PRELIMINARY...

  • Page 147: Led Fault Code Chart

    The two LED’s have four different display modes that indi- the fault diagnosis chart, which also lists possible fault cate the type of information they provide. causes and describes the conditions that set and clear each fault. 699327 Repair and Service Manual PRELIMINARY...
  • Page 148 Condition 4.Battery disconnected while driving torque and voltage dropped below limit clears 5.See monitor menu - Battery: capacitor speed voltage 6.Blown B+ fuse or main contactor did not close Fig. 7 Fault Code Chart Repair and Service Manual 699327 PRELIMINARY...
  • Page 149 +5V supply None: Check Condition supply is too low 26) outside the +5V Failure clears 2.See Monitor menu-Outputs: 5 volts and ext + or - 10% range supply current Fig. 7 Fault Code Chart (Continued) 699327 Repair and Service Manual PRELIMINARY...
  • Page 150 This fault Shutdown condition 2.Dirty connector pins Open or can only be set driver 2 and cycle 3.Bad crimps or faulty wiring Short when main enable driver =off Fig. 7 Fault Code Chart (Continued) Repair and Service Manual 699327 PRELIMINARY...
  • Page 151 Throttle pot wiper (pin16) voltage is Shutdown Condition 1.See Monitor menu-Inputs: throttle pot Throttle Wiper High higher than high throttle clears 2.Throttle pot wiper voltage too high fault setting Fig. 7 Fault Code Chart (Continued) 699327 Repair and Service Manual PRELIMINARY...
  • Page 152 Throttle inputs. If various inputs were been returned to neutral EMR_Interloc not returned to k=Off, clear neutral the throttle and direction inputs. Fig. 7 Fault Code Chart (Continued) Repair and Service Manual 699327 PRELIMINARY...
  • Page 153 Range range. tuned within range 3.See Monitor menu-Outputs: ext supply current Internal controller Vehicle 1.Internal controller fault detected OS General KSI Cycled fault detected Disabled 2.Cycle KSI Fig. 7 Fault Code Chart (Continued) 699327 Repair and Service Manual PRELIMINARY...
  • Page 154 1. Motor Type parameter value is out of Motor Type Vehicle parameter value is and or range Fault Disabled out of range correct fault 2. Check controller command on hand held Fig. 7 Fault Code Chart (Continued) Repair and Service Manual 699327 PRELIMINARY...
  • Page 155 Number Disabled 2. Software and hardware do not match model number is downloaded 3. Defective controller found, a fault is issued if not Fig. 7 Fault Code Chart (Continued) 699327 Repair and Service Manual PRELIMINARY...

  • Page 156: Curtis Handheld Diagnostic Tool Function

    VCL application version. The “Parameters” menu includes the submenus for “Profiles,” “Amp Hours,” and “Battery.” The “Profiles” submenu allows the user to access and adjust the parameters for speed and acceleration. Fig. 8 Handheld Tool Function Repair and Service Manual 699327 PRELIMINARY...
  • Page 157 The “Amp Hours” Submenu includes the parameters for “Amp Hour Reset” (normal values are ON and OFF) and “AHr External Load” (normal values are between 0.0 and 100.0). Fig. 8 Handheld Tool Function (Continued) 699327 Repair and Service Manual PRELIMINARY...
  • Page 158 “Full Volts per Cell,” “Empty Volts per Cell,” “Discharge Time,” and “BDI Reset Percent.” The “Monitor” menu allows the user to monitor numerous current conditions of the vehicle. “Amp Hours Submenu” “Inputs” Fig. 8 Handheld Tool Function (Continued) Repair and Service Manual 699327 PRELIMINARY...
  • Page 159 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. “Outputs” “Battery” “Motor” “Controller” “Controller Cutbacks” Fig. 8 Handheld Tool Function (Continued) 699327 Repair and Service Manual PRELIMINARY...
  • Page 160 The “Diagnostics” menu can be used to diagnose present faults and view the fault history. Any currently existing faults will appear under the “Present Errors” submenu. The “Fault History” submenu will show all past faults that have not been cleared. Fig. 8 Handheld Tool Function (Continued) Repair and Service Manual 699327 PRELIMINARY...
  • Page 161 .The “HHP Settings” shows the settings for the Curtis handheld tool. The “File Management” menu is used to manage file on the internal memory of the tool and the SD card (if installed). Fig. 8 Handheld Tool Function (Continued) 699327 Repair and Service Manual PRELIMINARY...

  • Page 162: Component Testing

    Fig. 9 Digital Voltmeter Fig. 10 Fuse Block NOTICE: To test the components on the control panel, the control panel has to be removed to access the individual component circuit terminals (See Control Panel on page 21). Repair and Service Manual 699327 PRELIMINARY...

  • Page 163: Key Switch - Testing

    Put the negative meter probe on controller B or the Schematic on page 74). negative 72V battery terminal. Put the positive probe on the secondary circuit battery side terminal. 72V should be indicated. If not, check the battery voltage and wiring. 699327 Repair and Service Manual PRELIMINARY...

  • Page 164: Temperature Sensor - Testing

    Unplug the temperature sensor harness at the motor (Ref 2.) Minimum Value (-40° C) Room Temperature (25° C) Beginning of Thermal 1555 (145° C) Cutback Thermal Cutoff 1610 (160° C) Temperature Fig. 17 PT1000 Temperature Sensor (female pins on the connector) Repair and Service Manual 699327 PRELIMINARY...

  • Page 165: Electronic Speed Sensor - Testing

    W-terminal. Full continuity should be observed (Ref Fig. 20). Fig. 20 V and W terminal Fig. 18 Speed Sensor Back probe pins are needed to perform electrical tests via wire harness connectors. 699327 Repair and Service Manual PRELIMINARY...
  • Page 166 No continuity should be observed (Ref Fig. 22). NOTICE: If continuity is observed between the case and terminals; a field to motor case short exists. Fig. 22 Terminal and Motor case Repair and Service Manual 699327 PRELIMINARY...
  • Page 167 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699327 Repair and Service Manual PRELIMINARY...
  • Page 168 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699327 PRELIMINARY...

  • Page 169: General Specifications

    250 lbs. (115 kg) Vehicle Load Capacity 1200 lb. (544 kg) Cargo Box Width (Inside) 42.5 in. (108 cm) Cargo Box Depth (Inside) 11.5 in. (29 cm) Cargo Box Capacity 9 cu. ft. (.25 m3) 699327 Repair and Service Manual PRELIMINARY...
  • Page 170 Vibration, WBV Total value of vibration is 2.12 m/s^2. Uncertainty of measurement K is 0.42. Vibration, HAV Highest RMS value of total value is less than 2.5 m/s^2.* Some listed items may be optional equipment. Repair and Service Manual 699327 PRELIMINARY...

  • Page 171: Battery Charger User's Guide

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. APPENDIX A BATTERY CHARGER USER’S GUIDE 699327 Repair and Service Manual PRELIMINARY...
  • Page 172 If flashing: AC voltage is between 105 volts and 185 volts. seconds if no battery If off: AC voltage is below 105 volts. is connected. Fault Indicator (Red Light) Charger error. Refer to troubleshooting information below. Repair and Service Manual 699327 PRELIMINARY...
  • Page 173 WARNING: Charger connectors must be mated to connectors from the same manufacturer. Failure to do so may void warranty and cause a hazardous condition or equipment damage. www.delta-q.com 699327 Repair and Service Manual PRELIMINARY...
  • Page 174 5. Charger will conduct a self-test of its you reach the desired charge profile. LED indicators. Figure 4: Charger LED indicator self-test. Figure 7: Touch the positive lead to the positive battery terminal for 3 seconds. Visit www.youtube.com/deltaqtechnologies for instructional videos. Repair and Service Manual 699327 PRELIMINARY...
  • Page 175 Do not put hands, face, feet or body in a location that can expose them to injury if an unexpected situation occurs. Always use the correct tools shown in the tool list and wear recommended safety equipment. Repair and Service Manual PRELIMINARY...
  • Page 176 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. PRELIMINARY...

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