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Tempo 2+2 2020
Club Car Tempo 2+2 2020 Manuals
Manuals and User Guides for Club Car Tempo 2+2 2020. We have
2
Club Car Tempo 2+2 2020 manuals available for free PDF download: Maintenance And Service Manual
Club Car Tempo 2+2 2020 Maintenance And Service Manual (684 pages)
Brand:
Club Car
| Category:
Electric Vehicles
| Size: 35.72 MB
Table of Contents
Table of Contents
7
SECTION 1 - Safety
23
Safety Details
23
General Warnings
24
Disabling the Vehicle
25
Disconnect the Battery - Gasoline Vehicles
25
Connect the Battery - Gasoline Vehicles
26
Disconnect the Batteries - Electric Vehicles
26
Connect the Batteries - Electric Vehicles
27
Recycling Lead-Acid Batteries
28
International Safety Symbols on Batteries
28
SECTION 2 - Vehicle Specifications
29
Electric - Vehicle Specifications
29
Dimensions
29
Performance
29
Tires
29
Electric Motor
29
Batteries
29
Noise and Vibration
30
Transaxle
30
Vehicle Weights and Load Capacities
30
Kohler ECH440 - Vehicle Specifications
31
Dimensions
31
Performance
31
Tires
31
Gasoline Engine
32
Battery
32
Noise and Vibration
32
Transaxle
32
Vehicle Weights and Load Capacities
32
Subaru EX-40 - Vehicle Specifications
33
Dimensions
33
Performance
34
Tires
34
Gasoline Engine
34
Battery
34
Noise and Vibration
34
Transaxle
34
Vehicle Weights and Load Capacities
34
SECTION 3 - Extended Storage
37
Electric Vehicle Extended Storage
37
Extended Storage Preparation - Electric
37
Return to Service from Extended Storage - Electric
38
Gasoline Vehicle Extended Storage
40
Extended Storage Preparation - Gasoline
40
Return to Service from Extended Storage - Gasoline
41
SECTION 4 - Body and Trim
43
Cleaning the Windshield
43
Cleaning the Vehicle Exterior
43
Cleaning the Vehicle Interior
44
Body Repair
44
Stress Lines or Streaks
44
Minor Impact Damage/Deformations
44
Minor Scratches and Surface Blemishes
45
Gouges, Punctures, Tears, Large Scratches, and Abrasions
45
Seat Hinge
46
Seat Hinge Removal
46
Seat Hinge Installation
46
Hip Restraint
47
Hip Restraint Removal
47
Hip Restraint Installation
47
Front Body
48
Front Body Removal
49
Front Body Installation
49
Front Bumper
50
Front Bumper Removal
50
Front Bumper Installation
50
Underbody Bracket
51
Underbody Bracket Removal
51
Underbody Bracket Installation
51
Headlights
52
Headlight Removal
52
Headlight Installation
52
Instrument Panel
53
Instrument Panel Removal
53
Instrument Panel Installation
53
Dash Assembly
54
Dash Assembly Removal
54
Dash Assembly Installation
54
Floor Mat and Retainers
55
Floor Mat Removal
55
Floor Mat Installation
55
Floor Mat Retainer Removal
55
Floor Mat Retainer Installation
55
Kick Plate and Charger Receptacle Bezel - Electric Vehicles
56
Kick Plate and Charger Receptacle Bezel Removal
56
Kick Plate and Charger Receptacle Bezel Installation
57
Kick Plate - Gasoline Vehicles
59
Kick Plate Removal
59
Kick Plate Installation
59
Access Panel
60
Access Panel Removal
60
Access Panel Installation
60
Visage Display Unit Overhead Baskets
61
Overhead Basket Removal
61
Overhead Basket Installation
61
Overhead Speaker Basket Removal
62
Overhead Speaker Basket Installation
62
Two-Passenger - Canopy
63
Two-Passenger Canopy Removal
63
Two-Passenger Canopy Installation
64
Two-Passenger Canopy with Visage Display Unit Removal
64
Two-Passenger Canopy with Visage Display Unit Installation
66
Two-Passenger Front Canopy Strut Removal
68
Two-Passenger Front Canopy Strut Installation
69
Two-Passenger Rear Canopy Support Removal
70
Two-Passenger Rear Canopy Support Installation
71
Two-Passenger - Rear Body
71
Universal Accessory Mounting
71
Structural Accessory Module (SAM)
72
Seat Back
73
Bag Rack Assembly
74
Bag Strap
75
Sweater Basket
76
Rear Beauty Panel
77
Rear Underbody
78
Rear Crossmember
79
2+2 - Monsoon Canopy
80
Monsoon Canopy Removal
80
Monsoon Canopy Installation
81
2+2 Front Canopy Strut Removal
82
2+2 Front Canopy Strut Installation
83
2+2 Rear Canopy Support Removal
84
2+2 Rear Canopy Support Installation
85
2+2 - Rear Body
86
Seat Backs
86
Fixed Rear Seat
88
Fold-Down Rear Seat
91
Seat Support
95
Foot Deck - 2+2
96
Rear Beauty Panel (2+2 Vehicles)
100
Rear Underbody
101
SECTION 5 - Accelerator and Brake Pedal Group
103
Pedal Group - Electric Vehicle
103
Pedal Group Removal
103
Pedal Group Installation
105
Pedal Group - Gasoline Vehicle
107
Pedal Group Removal
107
Throttle Position Sensor
108
Pedal Group Installation
109
Debris Shields
111
Debris Shields Removal
111
Debris Shields Installation
111
Accelerator Pedal
112
Accelerator Pedal Removal
112
Accelerator Pedal Installation
112
Brake Pedal
113
Brake Pedal Removal
113
Brake Pedal Installation
113
SECTION 6 - Wheel Brake Assemblies
115
General Information
115
Brake Shoe Removal
116
Brake Assembly Cleaning
118
Brake Shoe Installation
121
Brake Cable Equalizer Adjustment
124
Brake Cluster
126
Brake Cluster Removal
126
Brake Cluster Installation
128
Brake Cable
130
Brake Cable Removal
130
Brake Cable Installation
133
SECTION 7 - Steering and Front Suspension
135
General Information
135
Steering Wheel
135
Steering Wheel Removal
135
Steering Wheel Installation
136
Steering Column
137
Steering Column Removal
137
Steering Column Installation
138
Rack and Pinion
138
Rack and Pinion Inspection
139
Rack and Pinion Removal
139
Rack and Pinion Installation
140
Front Suspension
141
Lubrication
141
Wheel Alignment
141
Front Suspension Components
144
Tie Rod End Removal
144
Tie Rod Installation
146
Leaf Spring Removal
146
Leaf Spring Installation
147
Kingpin and Steering Spindle Removal
148
Kingpin and Steering Spindle Installation
149
Control Arm Removal
151
Control Arm Installation
151
Front Shock Absorber Inspection
152
Front Shock Absorber Removal
153
Front Shock Absorber Installation
154
Front Wheel Hubs
155
Front Wheel Free Play Inspection
155
Front Wheel Hub Removal
155
Front Wheel Hub Installation
156
SECTION 8 - Wheels and Tires
157
General Information
157
Lift the Vehicle
157
Lift the Front of the Vehicle
158
Lower the Front of the Vehicle
158
Lift the Rear of the Vehicle
158
Lower the Rear of the Vehicle
160
Tires
160
Tire Pressure Measurement
160
Tire Removal
160
Tire Repair
161
Tire Installation
162
Wheel Assembly
163
Wheel Assembly Removal
163
Wheel Assembly Installation
163
SECTION 9 - Rear Suspension
165
General Information
165
Shock Absorbers
165
Rear Shock Absorber Inspection
165
Rear Shock Absorber Removal
166
Rear Shock Absorber Installation
167
Panhard and Bracket
168
Panhard and Bracket Removal
168
Panhard and Bracket Installation
168
Leaf Springs (Two-Passenger)
169
Leaf Spring Removal (Two-Passenger)
169
Leaf Spring Installation (Two-Passenger)
171
Leaf Springs (Four-Passenger)
172
Leaf Spring Removal (Four-Passenger)
172
Leaf Spring Installation (Four-Passenger)
174
Leaf Springs (Four-Passenger - Heavy Duty with Panhard)
175
Leaf Spring Removal (Four-Passenger - Heavy Duty with Panhard)
175
Leaf Spring Installation (Four-Passenger - Heavy Duty with Panhard)
177
SECTION 10 - Vehicle Maintenance
179
General Information
179
Pre-Operation and Daily Safety Checklist
179
Performance Inspection
180
Maintenance
181
Periodic Service Schedules
182
Electric Vehicle - Period Service Schedule
182
Gasoline Vehicle - Periodic Service Schedule
184
Periodic Lubrication Schedules
186
Electric Vehicle - Periodic Lubrication Schedule
186
Gasoline Vehicle - Periodic Lubrication Schedule
187
Air Filter
188
Air Filter Removal
188
Air Filter Installation
188
Kohler ECH440 - Engine Oil
188
Kohler ECH440 - Engine Oil Viscosity
188
Kohler ECH440 - Engine Oil Level Inspection
189
Kohler ECH440 - Engine Oil Replacement
190
Kohler ECH440 - Add Engine Oil
192
Refuel
194
SECTION 11 - Controller Diagnostic Tool (CDT)
197
General Information
198
Features
198
Plugging the CDT into the Vehicle
199
Introductory Display
199
Quick Reference Guide - ERIC Charging System
200
System Info
201
Model Number
201
Serial Number
201
Hardware Version
201
Protocol Version
201
Param Block Version
201
MFG Date Code
201
OS Version
201
SM Version
201
VCL App Version
201
Parameters
202
Settings
202
Amp Hours
204
Access Codes
204
Vehicle ID
205
Monitor Menu
205
Batt Voltage
206
Min I
206
Signed Battery Current
206
BDI Percent
206
Speed
206
Throttle
206
Temperature
206
Arm Current
206
Field Current
207
Armature PWM
207
Field PWM
207
Speed Pulses
207
Foot Input
207
Key Input
207
Forward Input
207
Reverse Input
207
Mode Switch Input
207
Charger Inhibit
207
LED Driver
208
Password Tries (OEM Access Level Only)
208
Odometer
208
BDI Info
208
Battery Monitor
208
Charging Totals
208
Amp Hours Display
209
Lin
209
Vehicle Speeds
209
Pedal Counters
209
Fault Counters
209
Fault Count Odometers
210
Diagnostics Menu
211
Present Errors Folder
211
Fault History Folder
211
Causes of Faults
212
Fault Recovery
214
Fault Descriptions
215
Incorrect Password (OEM Access Level Only)
215
Max Password Tries (OEM Access Level Only)
215
Throttle Fault
215
Low Battery Voltage (Undervoltage)
215
Overvoltage
215
Thermal Cutback
216
Anti-Tamper Fault
216
Hpd
216
Main Drvr Overcurrent
216
Lockout Fault
216
Low SOC
216
Main Welded
217
High Speed Walkaway
217
Speed Sensor
217
Main Driver on
217
Main Coil Open
217
Main Dropout (1 or 2)
218
Motor Stall
218
Main Driver off
218
Current Sense Fault
218
M- Shorted
218
FLD (Field) Missing
219
HW Failsafe
219
Fault History
219
Clear Fault History
219
Programming
219
Cloning
220
Favorites
220
HHP Settings
220
Plot & Log
222
Plot
222
Log
222
CDT Troubleshooting
223
Connection Tests
224
SECTION 12 - Electric Vehicle - Troubleshooting and Electrical System
228
Battery Wiring Diagram
229
Sonic Weld, Fuse, and 10K Ohm Locations
230
Troubleshooting
231
Troubleshooting the Vehicle with the CDT
231
Troubleshooting Guide 1
231
Troubleshooting Guide 2
234
Test Procedures
237
Testing Basics
237
SECTION 13 - Electric Vehicle - Electrical Components
259
Key Switch
259
Testing the Key Switch
259
Key Switch Removal
259
Key Switch Installation
259
Charge Indicator Light
260
Testing the Charge Indicator Light
260
Charge Indicator Light Removal
260
Charge Indicator Light Installation
260
USB Port
261
USB Port Removal
261
USB Port Installation
262
Forward/Neutral/Reverse Rocker Switch
262
Testing the Forward/Neutral/Reverse Rocker Switch
262
Forward/Neutral/Reverse Rocker Switch Removal
262
Forward/Neutral/Reverse Rocker Switch Installation
263
Electronics Module Cover
264
Electronics Module Cover Removal
264
Electronics Module Cover Installation
264
Tow/Run Switch
265
Testing the Tow/Run Switch
265
Tow/Run Switch Removal
265
Tow/Run Switch Installation
265
Motor Controller Output Regulator (MCOR)
266
Testing the MCOR
266
MCOR Removal
266
MCOR Installation
266
Reverse Buzzer
267
Testing the Reverse Buzzer
267
Reverse Buzzer Removal
267
Reverse Buzzer Installation
267
Electronics Module
268
Electronics Module Removal
268
Electronics Module Installation
269
Speed Controller
270
Testing the Solid State Speed Controller
270
Speed Controller Removal
270
Speed Controller Installation
270
Solenoid
271
Testing the Solenoid
271
Solenoid Removal
271
Solenoid Installation
272
Charger Receptacle
272
Testing the Charger Receptacle
272
Charger Receptacle Inspection
272
Charger Receptacle Removal
272
Charger Receptacle Installation
273
SECTION 14 - Electric Vehicle - Batteries
275
General Information
275
Battery Testing Basics - 8 Volt
276
Observation
276
Measuring Voltage of Battery Set
276
Battery Cell Numbering
276
Battery Testing - 8 Volt
277
Battery Regrouping
277
Battery Replacement
279
Battery Care
280
Water Quality
280
Deionizer
281
Battery Care - Vehicles Equipped with the Single-Point Watering System
282
Battery Care - Vehicles Without the Single-Point Watering System
283
Self-Discharge
283
Electrolyte Level
284
Vibration Damage
284
Single Point Watering System (SPWS)
285
Initial Maintenance of the SPWS
285
Watering Batteries with the SPWS
285
Battery Storage
287
Fleet Rotation
287
Deep-Discharge
287
Early Excessive Discharging
287
SECTION 15 - Electric Vehicle - Battery Charger
289
General Information
290
IC 650 Battery Charger Specifications
291
Governmental and Industry Certifications
291
European Conformity
291
Federal Communications Commission
292
International Protection Marking
292
Underwriters Laboratories and Canadian Standards Association
292
Features
293
AC Electrical Cord and Plug
293
Onboard Battery Charger Interface
293
Status Indicator Lights
294
Battery Charging Interlock
295
External Battery Charger Mounting
295
How to Make a Strain Relief and Drip Loop
296
The Charge Circuit
297
External Charge Circuit
297
Onboard Charge Circuit
298
Battery Charger Operation
299
Charging with External Charger
299
Charging with Onboard Charger
300
Algorithm
301
How to View Algorithm on External Charger
301
How to Install Trojan Algorithm - External Charger
303
How to Change Onboard Charger Algorithm
306
Update Battery Charger with USB
307
Inspection and Maintenance
308
Electrical Cords
308
Electrical Plugs and Receptacles
309
Clean the Electrical Plugs and Receptacles
309
Battery Charger USB Receptacle
309
Clean the USB Receptacle
309
Battery Charger Troubleshooting
310
Numbering Vehicles and Chargers
310
AC Power Source
310
Terminal Block Cover
310
Reset Power - External Charger
311
Reset Power - Onboard Charger
311
External Charger Troubleshooting Indicators
312
Onboard Battery Charger Error Codes
314
Onboard Battery Charger Fault Codes
315
Test Procedures
316
External Charger Repairs
319
Terminal Block Cover Removal
319
Terminal Block Cover Installation
319
DC Cord Removal
320
DC Cord Installation
321
Handle Removal
322
Handle Installation
322
Foot Removal
323
Foot Installation
323
Onboard Charger Repairs
324
Two-Passenger Onboard Charger
324
Fixed Rear Seat Onboard Charger
329
Fold-Down Rear Seat Onboard Charger
335
Terminal Block Cover Removal
339
Terminal Block Cover Installation
339
DC Cord Removal
340
DC Cord Installation
340
SECTION 16 - Electric Vehicle - Motor
341
General Information
341
External Motor Testing
341
Motor
344
Motor Removal
344
Motor Disassembly
345
Motor Component Testing and Inspection
348
Armature Inspection and Testing
348
Motor Frame and Field Windings Inspection
350
Motor Brush, Spring, and Terminal Insulator Inspection
350
Reconditioning the Motor
353
Motor Specifications
353
Motor Assembly
353
Motor Installation
355
SECTION 17 - Electric Vehicle - Transaxle
359
Lubrication
359
Axle Bearing and Shaft
359
Axle Shaft
359
Axle Bearing
362
Transaxle Removal
363
Transaxle Disassembly, Inspection, and Assembly
365
Transaxle Disassembly and Inspection
365
Transaxle Assembly
367
Transaxle Installation
368
SECTION 18 - Gasoline Vehicle - Transaxle
371
General Information
371
Shifter Lever
371
Maintenance/Operate Switch
371
Governor System
372
Transaxle Service
372
Lubrication
372
Tools Required for this Section
373
Rear Hubs
374
Rear Hub Removal
374
Rear Hub Installation
374
Axle Tubes, Axle Shafts and Wheel Bearings
376
Axle Tube and Axle Shaft Removal
376
Axle Tube and Axle Shaft Installation
377
Rear Wheel Bearing Removal
377
Rear Wheel Bearing Installation
377
Axle Shaft Oil Seal Removal
377
Axle Shaft Oil Seal Installation
378
Transaxle Removal
379
Transaxle Installation
382
Forward/Neutral/Reverse Handle
383
Forward/Neutral/Reverse Handle Removal
383
Forward/Neutral/Reverse Handle Installation
383
Shifter Cable
383
Shifter Cable Removal
383
Shifter Cable Installation
384
Shifter Cable Adjustment
384
SECTION 19 - Kohler ECH400 - Troubleshooting and Electrical System
387
General Information
387
Accessories
387
Features of the Electronic Fuel Injection (EFI) System
387
Ground Locations
387
Low Oil Warning Light
388
Malfunction Indicator Light
388
Troubleshooting Guide
388
Gasoline Powertrain
389
Fuse and Relay Locations
391
Electrical System
392
Test Procedures
393
Testing Basics
393
SECTION 20 - Kohler ECH400 - Electrical Components
419
Battery
419
General Information
419
Preventive Maintenance
420
Self-Discharge
420
Vibration Damage
420
Battery Removal
421
Charging the Battery
421
Battery Installation
421
Battery Storage
422
Charging a Dead Battery
422
Ground Cables
422
Starter/Generator
422
Starter/Generator Removal
422
Disassembly of the Starter/Generator to Service the Brushes
423
Brush Inspection and Replacement
423
Brush Spring Inspection and Replacement
424
Starter/Generator Assembly
424
Disassembly of the Starter/Generator to Service the Armature/Commutator
425
Bearing Cleaning and Inspection
426
Bearing Removal
427
Field Coil Assembly
427
Visual Inspection of Armature
427
Commutator Cleaning and Inspection
428
Armature Ground Test
429
Visual Inspection of Field Coils
430
Starter/Generator Rework
430
Starter/Generator Assembly
430
Starter/Generator Installation
433
Belt Tension Adjustment for EFI Engines
434
Solenoid
436
Solenoid Removal
436
Solenoid Installation
437
Voltage Regulator
438
Voltage Regulator Removal
438
Voltage Regulator Installation
439
Engine Control Unit (ECU)
439
Engine Control Unit Removal
439
Engine Control Unit Installation
440
Fuel Level Sending Unit
440
Maintenance/Operate Switch
440
Maintenance/Operate Switch Removal
440
Maintenance/Operate Switch Installation
441
Accelerator Pedal Limit Switch
441
Kill Limit Switch
442
Multi-Purpose Buzzer Limit Switch
442
Multi-Purpose Buzzer Limit Switch Removal
442
Multi-Purpose Buzzer Limit Switch Installation
443
Neutral Lockout Limit Switch
443
Neutral Lockout Limit Switch Removal
443
Neutral Lockout Limit Switch Installation
444
Transaxle Limit Switch
445
Transaxle Limit Switch Removal
445
Transaxle Limit Switch Installation
445
Brake Light Relay
446
Brake Light Relay Removal
446
Brake Light Relay Installation
447
Fuel Gauge/Hour Meter
447
General Information
447
Fuel Gauge/Hour Meter Removal
448
Fuel Gauge/Hour Meter Installation
448
Advertisement
Club Car Tempo 2+2 2020 Maintenance And Service Manual (392 pages)
Lithium-Ion Vehicle
Brand:
Club Car
| Category:
Electric Vehicles
| Size: 24.39 MB
Table of Contents
Table of Contents
7
SECTION 1 - Safety Information
15
General Safety Information
15
Practice Safety
15
Safety Signal Words
15
Safety Committee
15
Vehicle Safety Information
16
Disable the Vehicle
17
High Voltage Interlock Fuse
18
Battery International Safety Symbols
19
SECTION 2 - Vehicle Specifications
21
Dimensions
21
Performance
21
Tires
21
Electric Motor
22
Battery
22
Noise and Vibration
22
Transaxle
22
Vehicle Weights and Load Capacities
23
SECTION 3 - Extended Storage
25
Extended Storage Preparation
25
Return to Service from Extended Storage
26
SECTION 4 - Body and Trim
27
Cleaning the Windshield
27
Cleaning the Vehicle Exterior
27
Cleaning the Vehicle Interior
27
Body Repair
28
Stress Lines or Streaks
28
Minor Impact Damage/Deformations
28
Minor Scratches and Surface Blemishes
28
Gouges, Punctures, Tears, Large Scratches, and Abrasions
29
Seat Hinge
30
Seat Hinge Removal
30
Seat Hinge Installation
30
Hip Restraint
31
Hip Restraint Removal
31
Hip Restraint Installation
31
Front Body
32
Front Body Removal
33
Front Body Installation
33
Front Bumper
34
Front Bumper Removal
34
Front Bumper Installation
34
Underbody Bracket
35
Underbody Bracket Removal
35
Underbody Bracket Installation
35
Headlights
36
Headlight Removal
36
Headlight Installation
36
Instrument Panel
37
Instrument Panel Removal
37
Instrument Panel Installation
37
Dash Assembly
38
Dash Assembly Removal
38
Dash Assembly Installation
38
Floor Mat and Retainers
39
Floor Mat Removal
39
Floor Mat Installation
39
Floor Mat Retainer Removal
39
Floor Mat Retainer Installation
39
Kick Plate and Charger Receptacle Bezel
40
Kick Plate and Charger Receptacle Bezel Removal
40
Kick Plate and Charger Receptacle Bezel Installation
42
Access Panel
43
Access Panel Removal
43
Access Panel Installation
43
Visage Display Unit Overhead Baskets
44
Overhead Basket Removal
44
Overhead Basket Installation
44
Overhead Speaker Basket Removal
45
Overhead Speaker Basket Installation
45
Two-Passenger - Canopy
46
Two-Passenger Canopy Removal
46
Two-Passenger Canopy Installation
47
Two-Passenger Canopy with Visage Display Unit Removal
47
Two-Passenger Canopy with Visage Display Unit Installation
49
Two-Passenger Front Canopy Strut Removal
51
Two-Passenger Front Canopy Strut Installation
52
Two-Passenger Rear Canopy Support Removal
53
Two-Passenger Rear Canopy Support Installation
54
Two-Passenger - Rear Body
54
Universal Accessory Mounting
54
Structural Accessory Module (SAM)
55
Seat Back
56
Bag Rack Assembly
57
Bag Strap
58
Sweater Basket
59
Rear Beauty Panel
60
Rear Underbody
61
Rear Crossmember
62
2+2 - Monsoon Canopy
63
Monsoon Canopy Removal
63
Monsoon Canopy Installation
64
2+2 Front Canopy Strut Removal
65
2+2 Front Canopy Strut Installation
66
2+2 Rear Canopy Support Removal
67
2+2 Rear Canopy Support Installation
68
2+2 - Rear Body
69
Seat Backs
69
Fixed Rear Seat
71
Fold-Down Rear Seat
74
Seat Support
78
Foot Deck - 2+2
79
Rear Beauty Panel (2+2 Vehicles)
83
Rear Underbody
84
SECTION 5 - Accelerator and Brake Pedal Group
85
Pedal Group Removal
85
Pedal Group Installation
87
Debris Shields
89
Debris Shields Removal
89
Debris Shields Installation
89
Accelerator Pedal
90
Accelerator Pedal Removal
90
Accelerator Pedal Installation
90
Brake Pedal
91
Brake Pedal Removal
91
Brake Pedal Installation
91
SECTION 6 - Wheel Brake Assemblies
93
General Information
93
Brake Shoe Removal
93
Brake Assembly Cleaning
96
Brake Shoe Installation
99
Brake Cable Equalizer Adjustment
102
Brake Cluster
104
Brake Cluster Removal
104
Brake Cluster Installation
106
Brake Cable
108
Brake Cable Removal
108
Brake Cable Installation
111
SECTION 7 - Steering and Front Suspension
113
General Information
113
Steering Wheel
113
Steering Wheel Removal
113
Steering Wheel Installation
114
Steering Column
115
Steering Column Removal
115
Steering Column Installation
116
Rack and Pinion
116
Rack and Pinion Inspection
117
Rack and Pinion Removal
117
Rack and Pinion Installation
118
Front Suspension
119
Lubrication
119
Wheel Alignment
119
Front Suspension Components
122
Tie Rod End Removal
122
Tie Rod Installation
123
Leaf Spring Removal
124
Leaf Spring Installation
125
Kingpin and Steering Spindle Removal
126
Kingpin and Steering Spindle Installation
127
Control Arm Removal
129
Control Arm Installation
130
Front Shock Absorber Inspection
131
Front Shock Absorber Removal
131
Front Shock Absorber Installation
132
Front Wheel Hubs
133
Front Wheel Free Play Inspection
133
Front Wheel Hub Removal
133
Front Wheel Hub Installation
134
SECTION 8 - Wheels and Tires
135
General Information
135
Lift the Vehicle
135
Lift the Front of the Vehicle
136
Lower the Front of the Vehicle
136
Lift the Rear of the Vehicle
136
Lower the Rear of the Vehicle
137
Tires
138
Tire Pressure Measurement
138
Tire Removal
138
Tire Repair
139
Tire Installation
139
Wheel Assembly
140
Wheel Assembly Removal
140
Wheel Assembly Installation
141
SECTION 9 - Rear Suspension
143
General Information
143
Shock Absorbers
143
Rear Shock Absorber Inspection
143
Rear Shock Absorber Removal
144
Rear Shock Absorber Installation
145
Panhard and Bracket
146
Panhard and Bracket Removal
146
Panhard and Bracket Installation
146
Leaf Springs (Two-Passenger)
147
Leaf Spring Removal (Two-Passenger)
147
Leaf Spring Installation (Two-Passenger)
149
Leaf Springs (Four-Passenger)
150
Leaf Spring Removal (Four-Passenger)
150
Leaf Spring Installation (Four-Passenger)
152
Leaf Springs (Four-Passenger - Heavy Duty with Panhard)
153
Leaf Spring Removal (Four-Passenger - Heavy Duty with Panhard)
153
Leaf Spring Installation (Four-Passenger - Heavy Duty with Panhard)
155
SECTION 10 - Vehicle Maintenance
157
General Information
157
Daily Pre-Operational Safety Checklist
157
Daily Vehicle Performance Inspection
157
Maintenance
158
Maintenance Service Schedules
159
Periodic Lubrication Schedules
161
Cleaning the Dynamic Braking Resistor
162
Section 11 - Ccdt
163
Overview
163
Dongle
163
Diagnostic Cable
164
Ccdt-App
164
Connect the Dongle to the Vehicle
165
Connect the CCDT Tool to Mobile Device
165
CCDT-APP Screens
166
Splash Screen
166
Connection Screen
166
Home Screen
168
Screen Layout
168
Car System Screen
169
BMS Screen
170
VCM Screen
171
MCU Screen
172
Custom View Screen
173
Settings Screen
174
Faults Screen
177
Graph Screen
177
Software Update Screen
179
Vehicle Settings Update / Write Screen
181
Setup a Replacement VCM
184
Troubleshooting
185
SECTION 12 - Electrical System Troubleshooting
187
General Information
187
Controller Area Network (CAN)
187
CAN Bus
187
Battery Management System (BMS)
189
Contactor
190
Accessories
190
Diode, Fuse, and Relay Locations
191
Fuse Block Cover
192
Fuse Block Tables
193
Fuses
195
ATO and Mini ATM Fuse Inspection
195
Charger Fast Acting Fuse Test
195
Dynamic Braking Resistor (DBR) Fuse
196
Ground Locations
197
Vehicle Fault Codes
198
Dash Display Messages
198
Vehicle Fault Code Table
200
Basic Troubleshooting Guide
209
Main CAN Bus Test Procedure
211
Electrical Component Test Procedures
219
Testing Basics
220
Charger Interlock Test Procedure
220
Dash Display Test Procedure
222
Dynamic Braking Resistor (DBR) Test Procedure
222
Forward/Neutral/Reverse Switch (FNR) Test Procedure
224
Key Switch Test Procedure
225
Main Solenoid Test Procedure
227
MCOR Accelerator Position Test Procedure
229
MCOR Limit Switch Test Procedure
232
Multi-Purpose Buzzer Test Procedure
234
Run/Tow-Stow Test Procedure
235
Solenoid Activating Coil Test Procedure
236
Main Harness Connector Pinouts
237
Auxiliary CAN Connector
237
Battery 19-Pin Connector
237
Charger Receptacle 3-Pin Connector
238
Charger Receptacle 2-Pin Connector
238
DBR Blue Connector
239
DBR Temperature Switch Connector
239
DC-DC 3-Pin Connector
240
DC-DC 2-Pin Connector
240
Forward Lighting Connector
241
IP 12-Pin Connector
241
Lighting Control Connector
242
MCOR 3-Pin Connector
243
MCOR 2-Pin Connector
243
MCU 35-Pin Connector
244
Motor Speed Sensor Connector
245
Motor Temperature Sensor Connector
245
Left Taillight Connector
246
Right Taillight Connector
246
VCM 81-Pin Connector
247
VCM 40-Pin Connector
248
VDU Strut Connector
249
Visage Harness Connector Pinouts
250
14-Pin Connector
250
SECTION 13 - Electrical Components
251
Dash Display
251
Dash Display Removal
251
Dash Display Installation
251
Headlight Switch
252
Headlight Switch Removal
252
Headlight Switch Installation
252
Key Switch
253
Key Switch Removal
253
Key Switch Installation
253
Multi-Purpose Buzzer
254
Multi-Purpose Buzzer Removal
254
Multi-Purpose Buzzer Installation
254
Hazard Light Switch
255
Hazard Light Switch Removal
255
Hazard Light Switch Installation
255
USB Receptacle
256
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