Hauler Pro 72V (2014+) - Repair, Service Manual and Electrical Wiring Diagrams

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HAULER PRO 72V (2014+) - SERVICE MANUAL / REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual / Repair Manual and Wiring Diagrams, for Electric Powered Utility Vehicle Hauler Pro 72V from year 2014.

CONTENTS:

SAFETY INFORMATION
- General Iii
- General operation Iii
- Maintenance. Iv
- Ventilation Iv

GENERAL INFORMATION AND ROUTINE MAINTENANCE
- Serial number label location . 1
- Transporting vehicle . 1
- Towing  1
- Hauling . 1
- Servicing the electric vehicle . 1
- Routine maintenance. 2
- Rear axle 2
- Brakes 2
- Tires 2
- Recommended tire pressures  2
- Light bulb replacement . 2
- Vehicle cleaning and care 3
- Vehicle care products. 3
- Sun top and windshield  3
- Hardware . 4

SAFETY
- Notices, cautions, warnings and dangers  5
- Important safety warning 5
- Modifications to vehicle . 5
- General maintenance 5
- Before servicing the vehicle  6
- Additional warnings specific to electrical system . 6
- Battery removal and installation 7
- Lifting the vehicle 8

BODY
- General. 11
- Body component replacement 11
- Instrument panel replacement  12
- Center compartment replacement 13
- Cowl replacement 13
- Brush guard replacement .13
- Rocker panel replacement 14
- Side panel replacement 14
- Rear fender replacement 14
- Rear body panel replacement .15
- Painting 16
- Minor scratches 16
- Larger scratches .16
- Complete panel repair .16

WHEELS AND TIRES
- Wheel and tire service 17
- Tire repair 17
- Wheel installation 18

FRONT SUSPENSION AND STEERING
- Maintenance. 20
- Lubrication 20
- Wheel bearing and king pin bushing inspection 20
- Wheel bearing packing .20
- Wheel bearing adjustment .21
- Wheel alignment .21
- Front suspension 23
- Front shock absorber replacement .24
- Front axle replacement .24
- Axle linkage rod replacement 24
- Front spring replacement 25
- Hub replacement .26
- Wheel bearing and race replacement 27
- Steering. 28
- Rack ball joint replacement 28
- Tie rod inspection/replacement 29
- Bellows replacement .30
- Pinion seal replacement 30
- Spindle replacement 31
- Rack and pinion unit disassembly and inspection  32
- Rack and pinion unit replacement . 33
- Checking/adjusting rack extension-to-rack and pinion unit clearance  33
- Steering wheel replacement  34
- Steering shaft and column replacement  35

ELECTRONIC SPEED CONTROL
- Speed sensor 39
- Controller 39
- Controller replacement 39
- Solenoid replacement 40

MOTOR
- General. 43
- Motor replacement  43
- Motor tests  44

BATTERIES AND CHARGING
- Safety  45
- Battery 45
- Battery maintenance  46
- At each charging cycle . 46
- Monthly . 46
- Electrolyte level and water . 46
- Cleaning batteries  47
- Battery replacement  48
- Prolonged storage . 48
- Battery charging  49
- Ac voltage . 49
- Fault diagnosis 49
- Hydrometer  50
- Using a hydrometer . 50

ELECTRICAL SYSTEM
- Awg to metric conversions . 56
- Voltage test for batteries . 56
- Main harness. 56
- Power supply . 56
- Accessory wiring 58
- Faulty wire replacement 58
- Headlight replacement .58
- Taillight replacement .59
- Fault diagnosis. 60
- General .60
- Testing battery voltage .60
- Continuity check .60
- Testing a switch for continuity .61
- Testing a solenoid for continuity 61

BRAKES
- Brake system overview. 65
- General description 65
- How the service brake works 65
- Equalizer link .66
- Automatic adjuster mechanism 66
- How the park brake works .66
- Kick-off actuating linkage 66
- Compensator assembly 66
- Fault diagnosis flowchart. 67
- Fault diagnosis table  69
- Fault diagnosis and inspection. 70
- New vehicle 70
- Fault diagnosis and inspection procedures .70
- Brake pedal and linkage inspection 71
- Periodic brake performance test (pbpt) 73
- Aggressive stop test 74
- Wheel brake inspection 74
- Maintenance and repairs . 76
- Adjusting brake pedal free travel .77
- Brake drum removal and installation 78
- Wheel brake service 78
- Backing plate/entire wheel brake assembly removal and installation .79
- Brake shoe removal 80
- Brake shoe installation .81
- Brake cable and equalizer assembly removal and installation . 82
- Compensator assembly, removal and installation  82
- Brake pedal removal and installation . 82
- Park brake catch bracket removal and installation . 83
- Park brake pedal removal and installation . 83
- Pedal bumper adjustment . 83
- Park brake release linkage removal and replacement . 84
- Park brake kick-off cam removal, replacement and installation . 84

OPTIONAL FRONT HYDRAULIC BRAKES
- System description 85
- Master cylinder replacement 85
- Remove master cylinder  85
- Install master cylinder  85
- Brake master cylinder fluid . 86
- Flush hydraulic brake system . 86
- Check brake fluid  86
- Routine maintenance. 86
- Replacement of wear items . 86
- Brake pad replacement  86
- Rotor replacement  87
- Spindle replacement . 87
- Actuator linkage bushings  87
- Actuator pivot bushings . 87
- Bleeding brakes  87
- General information about bleeding brakes  87
- Brake bleeding procedure . 88

BATTERY CHARGER
- Charger description. 89
- Portable charger option . 89

REAR SUSPENSION
- Rear suspension 91
- General  91
- Shock absorber removal  91
- Shock absorber installation . 91
- Rear spring removal 91
- Rear spring installation .92
- Rear axle assembly removal 92
- Rear axle assembly installation .92

REAR AXLE
- Rear axle maintenance 95
- Checking the lubricant level 95
- Rear axle disassembly  95
- Axle shaft removal and disassembly 95
- Axle shaft seal removal and replacement .96
- Axle shaft replacement .97

WEATHER PROTECTION
- Sun top and windshield. 101
- Transporting vehicle .101
- Sun top. 101
- Rear support installation 101
- Front struts .101
- Sun top 101
- Split windshield . 103
- Full windshield. 104

HANDHELD DIAGNOSTICS
- How to use the handheld programmer. 105
- Primary connection: 4-pin tyco .105
- Alternate connection: 4-pin molex .105
- Navigation .106
- Changing data value 106
- Bookmark 106

TROUBLESHOOTING
- Electrical system  111
- Basic electrical power system troubleshooting .111
- Basic electrical troubleshooting for accessories .111
- Suspension and steering  112

GENERAL SPECIFICATIONS
- Vehicle dimensions. 116
- Incline and turning clearance. 117

PERIODIC SERVICE SCHEDULE
- Periodic service schedule . 119

APPENDIX A
- Delta-q user’s guide A