EZGO ELECTRIC DCS TXT VEHICLES REPAIR AND SERVICE MANUAL

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TECHNICIAN'S REPAIR AND SERVICE MANUAL

ELECTRIC & DCS TXT VEHICLES

MANUAL: 28407-G01

MODEL YEAR: 1997

ISSUED: 08/96

SAFETY Read and understand all labels located on the vehicle. If there are questions on any of the information, contact an E-Z­ GO representative for clarification.

Always replace any damaged or missing labels.

On steep hills it is possible for vehicles that are not equipped with DCS to coast at greater than normal speeds encoun­ tered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. (See vehicle specification.) Limit speed by applying the service brake.

Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered abuse and will not be covered under warranty.

If the vehicle is to be used in a commercial environment, signs similar to the one illustrated should be used to warn of hills that could result in an unsafe coasting condition.

Use extra caution when towing the vehicle(s). Do not tow a single vehicle at speeds in excess of 12 mph {19.3 kph). Do not tow multiple vehicles at speeds in excess of 5 mph (8 kph). Towing the vehicle at above the recommended speed may result in personal injury and/or damage to the vehicle and other property. Vehicles equipped with DCS must be towed with the Run-Tow/Maintenance switch located under the passenger seat in the ''TOW" position.

Be sure that this manual remains as part of the permanent service record should the vehicle be re-sold.

NOTES, CAUTIONS AND WARNINGS T hroughout this guide [R!]@'IT'(§, CAUTION and WARNING will be used.

A note indicates a condition that should be observed.

CAUTION A CAUTION INDICATES A CONDIT ION THAT MAY RESULT IN DAMAGE T O THE VEHICLE.

A_ WARNING A_ A WARNING INDICATES A HAZARDOUS CONDITION WHICH COULD RESULT IN SEVERE INJURY OR DEATH.

Please observe these [R!]@'IT'[§®, CAUTIONS and WARN· INGS; be aware that servicing a vehicle requires

mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

TECHNICIAN'S REPAIR AND SERVICE MANUAL TXT ELECTRIC AND DCS VEHICLES

VEHICLES TXT FLEET TXT FLEET DCS TXT FREEDOM TXT FREEDOM DCS TXT4CADDY

E-Z-GO DIVISION OF T E XT RON, INC., P.O.BOX 388, AUGUSTA, GEORGIA 30903-0388

Repair and Service Manual

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LIMITED WARRANTY

TO OBTAIN A COPY OF THE LIMITED WARRANTY APPLICABLE TO THE VEHICLE, CALL OR WRITE A LOCAL DISTRIBUTOR, E-Z-GO BRANCH OR THE E-Z-GO WARRANTY DEPARTMENT WITH VEHICLE SERIAL NUMBER AND MANUFACTURER CODE. THE USE OF NON E-Z-GO PARTS MAY VOID THE WARRANTY. OVERFILLING BATTERIES MAY VOID THE WARRANTY. BATTERY PROLONGED STORAGE: ALL BATTERIES WILL SELF DISCHARGE OVER TIME. THE RATE OF SELF DISCHARGE VARIES DEPENDING ON THE AMBIENT TEMPERATURE. A FULLY CHARGED BATTERY WILL NOT FREEZE IN WINTER TEMPERATURES. FOR WINTER STORAGE, THE BATTERIES MUST BE CLEAN, FULLY CHARGED AND DISCONNECTED FROM ANY SOURCE OF ELECTRICAL DRAIN. THE BATTERY CHARGER AND THE CONTROLLER MODULE ARE BOTH SOURCES OF ELECTRICAL DRAIN. UNPLUG THE BATTERY CHARGER DC PLUG FROM THE VEHICLE RECEPTACLE. DISCONNECT THE CONTROLLER FROM THE BATTERY SET BY SELECTING THE 'TOW/ MAINTENANCE' POSITION ON THE RUN-TOW/MAINTENANCE SWITCH LOCATED UNDER THE PASSENGER SEAT AS WITH ALL ELECTRIC VEHICLES, THE BATTERIES MUST BE CHECKED AND RECHARGED AS REQUIRED AT 30 DAY INTERVALS. REFER TO THE PROLONGED STORAGE SECTION WITHIN THE BATTERIES AND CHARGING SECTION OF THIS MANUAL.

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TABLE OF CONTENTS

I

TITLE

PAGE

Safety ........................................................................................................................... Inside Covers Limited Warranty ............................................................................................................................... ii Safety Information ............................................................................................................................ v

TITLE

SECTION

General............................................................................................................................................. A Safety ............................................................................................................................................... 8 Body .................................................................................................................................................C Wheels and T ires ............................................................................................................................. D Electronic Speed Control - DCS ....................................................................................................... E Front Suspension and Steering ........................................................................................................ F Electronic Speed Control................................................................................................................. G Motor ................................................................................................................................................ J Batteries and Charging .................................................................................................................... K Battery Charger (PowerwiseTM and PowerwiseTM +) ........................................................................ L Brakes ............................................................................................................................................. M Horn and Accessory Wiring.............................................................................................................. N Rear Suspension .............................................................................................................................. P Rear Axle.......................................................................................................................................... R Paint ................................................................................................................................................. 8 Troubleshooting ................................................................................................................................ T Lightning Protection and Grounding................................................................................................. U General Specifications ..................................................................................................................... V

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NOTES

Notes: _________________________________

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SAFETY INFORMATION T he Repair and Service Manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by E-Z-GO. Adherence to these procedures and trouble-shooting tips will ensure the best possible service from the product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed:

GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the place of good common sense and prudent driving practices.

Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. E-Z-GO strongly suggests that the owner-operator read this entire Owner's Guide and the Technician's Repair and Service Manual paying particular attention to the C AUT IONS and WARNINGS contained therein. It is further recommended that employees and other operators be encouraged to do the same.

If you have any questions, contact your closest E-Z-GO representative, call the E-Z-GO Customer Service Department at 1-800-241-5855 or write to the address on the back cover of this publication.

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E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

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E-2-GO Division of Textron reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.

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T his vehicle conforms to the current applicable standard for safety and performance requirements.

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T hese vehicles are designed and manufactured for off-road use. T hey do not conform to Federal Motor Vehicle Safety Standards or EPA regulations and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances.

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With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery(-) post.

NEVER USE THE CHASSIS OR BODY AS A GROUND CONNECTION.

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Vehicle capacity is limited to a maximum of two persons per seat.

•

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, its stability or increases the speed beyond the factory specification. Such modifications can cause serious personal injury or death. Modifications that increase the speed and or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle. Do not make any such modifications or changes. E-Z­ GO prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

Some vehicles may exceed the 15 mph maximum normally associated with golf course use. Higher speeds will result in increased stopping distances and less stability than similar slower vehicles. Vehicles that are capable of higher speeds must limit their speed substantially to no more than the speed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense.

GENERAL OPERATION •

Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.

•

Always read and observe all warnings and operation instruction labels affixed to the vehicle.

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SAFETY INFORMATION •

Always follow all safety rules established in the area where the vehicle is being operated.

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Always reduce speed to compensate for poor terrain or conditions.

•

Always apply service brake to control speed on steep grades.

•

Always maintain adequate distance between vehicles.

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Always reduce speed in wet areas.

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Always use extreme caution when approaching sharp or blind turns.

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Always use extreme caution when driving over loose terrain.

•

Always use extreme caution in areas where pedestrians are present.

MAINTENANCE •

Always maintain your vehicle in accordance with the manufacturer's periodic service schedule.

•

Always ensure that mechanics performing repairs are trained and qualified to do so.

•

Always follow the manufacturer's directions if you do any maintenance on your vehicle. Be sure to disable the vehi­ cle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

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Always insulate any tools used to remove the battery from its wiring in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the batteries or cover exposed terminals with an insulating material.

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Always check the polarity of each battery terminal and be sure to rewire the batteries correctly.

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Always use specified replacement parts. Never use replacement parts of lesser quality.

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Always use recommended tools.

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Always determine that tools and procedures not specifically recommended by the manufacturer will not compro­ mise the safety of personnel nor jeopardize the safe operation of the vehicle.

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Never get under a vehicle that is supported by a jack.

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Always support the vehicle using wheel chocks and safety stands. Lift the vehicle in accordance with the manufacturer's instructions.

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Always empty the fuel tank or plug fuel hoses to prevent fuel leakage.

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Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.

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Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.

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The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury, refer the repair or maintenance to a qualified mechanic.

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Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic.

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SAFETY INFORMATION •

Always replace damaged or missing warning, caution or information labels.

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Always keep complete records of the maintenance history of the vehicle.

VENTILATION •

Hydrogen is explosive in concentrations as low as 4% and is generated in the charging cycle of electric vehicles.

Because it is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Air exchanges of 5 changes per hour is considered the minimum requirement.

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Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.

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Never charge or fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural or pro­ pane water heaters and furnaces.

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Always use a dedicated 15 amp circuit for each battery charger. Do not permit other appliances to be plugged into the receptacle when the charger is in operation.

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SAFETY INFORMATION

Notes: _________________________________

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Section TABLE OF CONTENTS FOR SECTION 'A' SECTION TITLE SERIAL NUMBER PLATE LOCATION

PAGE NO. A- 1

CONTROLS A- 1 Key/Headlight Switch ............................................................................................................A- 1 Direction Selector .................................................................................................................. A- 1 Accelerator Pedal ..................................................................................................................A- 2 Combination Brake and Parking (PARK) Brake Pedal .......................................................... A- 2 Run- Tow/Maintenance Switch (on DCS vehicles only) ....................................................... A- 2 A- 2 FEATURES All Vehicles ............................................................................................................................ A- 2 DCS Vehicles ........................................................................................................................A- 3 BEFORE ENTERING VEHICLE

A-3

BEFORE STARTING

A-3

ADDITIONAL WARNINGS AND CAUTIONS (APPLY TO DCS MODELS)

A-4

STARTING THE ELECTRIC VEHICLE

A- 4

COASTING

A-5

TOWING

A-5

SERVICING THE ELECTRIC VEHICLE

A- 5

A-6 SEATS Preparation of Seats for Service ........................................................................................... A-6 ROUTINE MAINTENANCE

A-6

A-6 REAR AXLE Checking the Lubricant Level ................................................................................................A-6 A-6 GENERAL PREVENTATIVE MAINTENANCE Daily Check List.. ................................................................................................................... A-6 Owner/Operator ..................................................................................................................... A-7 Mechanic ............................................................................................................................... A-7 TIRES

A-7

CARE AND CLEANING OF THE VEHICLE

A-7

A -8 WINDSHIELD (IF EQUIPPED) Cleaning ..........................................................................:..................................................... A-8 Trailering................................................................................................................................ A-8 TORQUE SPECIFICATIONS FOR UNSPECIFIED HARDWARE

A- 9

LIST OF ILLUSTRATIONS Fig. A-1 Serial No. Plate Location ................................................................................................... A- 1 Fig. A-2 Key/Headlight Switch ......................................................................................................... A- 1 Fig. A-3 Direction Selector .............................................................................................................. A- 1 Fig. A-4 Accelerator and Brake Controls ......................................................................................... A- 2 Fig. A-5 Run-Tow/Maintenance Switch ........................................................................................... A- 2 Fig. A-6 Rear Axle Lubricant Check/Fill .......................................................................................... A-6 Fig. A-7 Torque Specifications ........................................................................................................ A- 9 Fig. A-8 Bolt Grades ........................................................................................................................ A- 9 Fig. A-9 Lubrication Points ............................................................................................................ A- 10 Fig. A-10 Periodic Service Schedule............................................................................................. A- 11 Fig. A-11 Periodic Service Schedule (Continued) ......................................................................... A- 12

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GENERAL

Notes: _________________________________

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GENERAL

Section

SERIAL NUMBER PLATE LOCATION (See Fig. A-1 "Serial No. Plate Location" on page A-1)

The serial and manufacturing numbers are stamped on a plate on the passenger side of the dash housing of the vehicle. Always provide these numbers to the dealer when ordering parts for the vehicle.

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Fig. A-2 Key/Headlight Switch

Direction Selector (See Fig. A-3 "Direction Selector" on page A-1)

Fig. A-1 Serial No. Plate Location

CONTROLS The controls on the vehicle consist of a key/headlight switch, direction selector, accelerator pedal, combination service brake and parking (PARK) brake pedal and on DCS model vehicles, a Run-Tow/Maintenance switch located under the passenger seat.

Key/Headlight Switch (See Fig. A-2 "Key/Headlight Switch" on page A-1)

Located on the console, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key. If the vehicle is equipped with lights, this switch also has a position for operating the lights.

Located on the seat support panel, this lever permits the selection of forward, neutral or reverse.

Neutral � �

or Reverse

For added security when the vehicle is left unattended, the key should be removed while in the 'OFF' position, preventing inadvertent operation of the vehicle.

Fig. A-3 Direction Selector

CAUTION

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If the vehicle is equipped with E-Z-GO installed custom accessories, some accessories remain operational with the key switch in the 'OFF' position.

Forward

THE VEHICLE MUST BE COMPLETELY STOPPED BEFORE MOVING THE DIRECTION SELECTOR.

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GENERAL Accelerator Pedal (See Fig. A-4 "Accelerator and Brake Controls" on page A-2)

Depressing the accelerator will release the parking (PARK) brake if it is engaged. This is a feature to assure that the vehicle is not driven with the parking (PARK) brake engaged.

The DCS vehicle will operate only if this switch is in the 'RUN' position. For detailed information on the operation and function of this switch, refer to Section E (Electronic Speed Control - DCS) in this manual.

Depressing the vehicle accelerator pedal starts the motor. When the pedal is released, the motor will stop.

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A.WARNING A.

Depressing the bottom of the brake pedal is the preferred method of releasing the parking (PARK) brake to assure the longest service life of brake components.

Fig. A-4 Accelerator and Brake Controls

Combination Brake and Parking (PARK) Brake Pedal

Enclosure

(See Fig. A-4 "Accelerator and Brake Controls" on page A-2)

The brake pedal incorporates a parking (PARK) brake feature. To engage, push down on the top section of the pedal until it locks in place. The parking (PARK) brake will release when the brake pedal is depressed. Use the BOTTOM section of the brake pedal to operate the ser­ vice brake system.

Run - Tow/Maintenance Switch (on DCS vehicles only) (See Fig. A-5 "Run-Tow/Maintenance Switch" on page A-2)

The vehicle is equipped with a two position switch mounted to the environmental cover of the controller that controls the operation of the electronic speed control.

Page A-2

Fig. A-5 Run-Tow/Maintenance Switch

FEATURES All Vehicles All vehicles are equipped with a charging interlock sys­ tem that disables the controller and prevents the vehicle from being operated while the charger plug is connected to the vehicle receptacle. The interlock functions even if the plug is not fully connected in the receptacle.

Repair and Service Manual

GENERAL DCS Vehicles DCS models are equipped with a regenerative motor control system. At a factory preset speed, the system will sense an over the recommended speed situation and the motor will apply an electronic braking force to slow the vehicle until it is within the designed speed range.

A

WARNING

A

CAUTION IMPROPER USE OR OPERATION OF THE VEHICLE OR THE LACK OF PROPER MAINTENANCE MAY RESULT IN DECREASED PERFORMANCE OR DAMAGE TO THE VEHICLE. BEFORE INITIAL USE, REMOVE CLEAR PLASTIC SEAT COVERINGS. (SEE SEATS, PG. A-6)

THE DCS SYSTEM IS NOT A SUBSTITUTE FOR THE SERVICE BRAKE WHICH SHOULD BE USED TO CONTROL SPEED. If the DCS senses the vehicle may not be under the oper­ ators control (the accelerator has been released in excess of one second) and at the same time senses the vehicle is moving in excess of 2 mph, it will do the follow­ ing: The motor will apply an electronic braking force until the vehicle speed is approximately 2 mph or less and will be accompanied by a beeping sound to indicate the vehicle is moving. Any unusual situation sensed by the DCS sys­ tem will cause a similar response. The system functions in all key switch positions.

The warning beeper and braking effect will be overridden when the unusual situation is rectified by the accelerator pedal being depressed indicating that the operator has control of the vehicle.

The DCS is a low power consumption unit but it will drain the vehicle batteries over a period of time. If the vehicle is to be stored for a prolonged period of time, the DCS should be disconnected from the batteries by selecting the 'TOW/MAINTENANCE' position on the Run-Tow/ Maintenance switch located under the passenger seat.

BEFORE ENTERING VEHICLE

Read and understand the following warnings before attempt­ ing to operate the vehicle:

A

WARNING

A

WHEN VEHICLE IS TO BE LEFT UNATTENDED, TURN KEY TO THE 'OFF' POSITION, REMOVE THE KEY AND ENGAGE THE PARKING (PARK) BRAKE, PLACE THE DIRECTION SELECTOR IN THE NEUTRAL POSITION. DRIVE THE VEHICLE ONLY AS FAST AS TERRAIN AND SAFETY CONSIDERATIONS ALLOW. CONSIDER THE TERRAIN AND EXISTING TRAFFIC CONDITIONS. CONSIDER THE ENVIRONMENTAL FACTORS WHICH EFFECT THE TERRAIN AND YOUR ABILITY TO CONTROL THE VEHICLE. AVOID DRIVING FAST DOWN HILL. A SUDDEN STOP OR CHANGE OF DIRECTION MAY RESULT IN LOSS OF CONTROL. USE BRAKE TO CONTROL SPEED WHEN TRAVELING DOWN AN INCLINE. KEEP FEET, LEGS, HANDS AND ARMS INSIDE THE VEHICLE AT ALL TIMES.

1. Check for correct tire inflation.

2. Inspect for fluid leaks.

3. Be certain that everything is properly stored and secured.

USE EXTRA CARE AND REDUCED SPEED WHEN DRIVING ON POOR SURFACES, SUCH AS LOOSE DIRT, WET GRASS, GRAVEL, ETC.

4. Check to see that the Run - Tow/Maintenance switch is in the 'RUN' position on DCS model vehicles.

ALL TRAVEL SHOULD BE DIRECTLY UP OR DOWN HILLS.

BEFORE STARTING

USE EXTRA CARE WHEN DRIVING THE VEHICLE ACROSS ANY INCLINE.

Be sure you understand the vehicle, its equipment and how to use it safely. Although E-Z-GO vehicles have been designed to provide safe and reliable operation, maintaining good performance depends to a large extent on the operator.

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CHECK AREA BEHIND THE VEHICLE BEFORE OPERATING IN REVERSE.

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A_ WARNING A_

STAY IN DESIGNATED AREAS AND AVOID STEEP SLOPES. USE THE PARKING (PARK) BRAKE WHENEVER THE VEHICLE IS PARKED. AVOID EXTREMELY ROUGH TERRAIN. SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. ALWAYS BRING THE VEHICLE TO A COMPLETE STOP BEFORE SHIFTING DIRECTION SELECTOR.

A_ WARNING A_

PERMITTING THE VEHICLE TO COAST DOWN AN INCLINE AT SPEEDS IN EXCESS OF 2 MPH WITH THE ACCELERATOR PEDAL RELEASED AFTER BRINGING THE VEHICLE TO A COMPLETE STOP WILL CAUSE AN ELECTRONIC BRAKING FORCE TO BE APPLIED AND A BEEPING FROM THE THE DEVICE. WARNING DEPRESSING ACCELERATOR PEDAL WILL RETURN CONTROL TO THE OPERATOR AND DEACTIVATE THE WARNING BEEPER.

THE STANDARD VEHICLE IS LIMITED TO TWO OCCUPANTS MAXIMUM PER SEAT. ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION. DO NOT ALLOW VEHICLE TO COAST. BEFORE ATTEMPTING ANY TYPE OF SERVICING OPERATIONS, READ AND UNDERSTAND ALL NOTES, CAUTIONS AND WARNINGS IN THIS MANUAL. WEAR EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE THE EYES TO POTENTIAL INJURY. IN PARTICULAR, USE CARE WHEN WORKING AROUND THE BATTERIES, WHEN USING SOLVENTS OR COMPRESSED AIR.

CAUTION BEFORE ATTEMPTING TO TOW THE VEHICLE MOVE THE RUN-TOW/MAINTENANCE SWITCH TO THE 'TOW/MAINTENANCE' POSITION. BEFORE DISCONNECTING OR CONNECTING A BATTERY OR ANY OTHER WIRING, MOVE THE RUN - TOW/MAINTENANCE SWITCH TO THE 'TOW/ MAINTENANCE' POSITION. AFTER CONNECTING A BATTERY OR ANY WIRING, WAIT A MINIMUM OF 30 SECONDS BEFORE MOVING THE RUN - TOW/MAINTENANCE SWITCH TO THE 'RUN' POSITION.

STARTING THE ELECTRIC VEHICLE To start the electric vehicle: A pply the service brake, place the key in the key switch and turn to the 'ON' posi­ tion. M ove the direction selector to the direction desired release the service brake pedal and depress the acceler� ator pedal to start the motor.

ADDITIONAL WARNINGS AND CAUTIONS (APPLY TO D CS MODELS)

A_ WARNING A_

MOVING THE DIRECTION SELECTOR WHILE THE VEHICLE IS IN MOTION WILL RESULT IN A SUDDEN SLOWING OF THE VEHICLE AND THE BEEPING OF A WARNING DEVICE.

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T he motor stops when the accelerator pedal is released.

To stop the vehicle more quickly, depress the BOTTOM OF THE SERVICE BRAKE PEDAL.

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When the direction selector is in the reverse position, a warn­ ing signal will sound. This is a device to indicate that the vehi­ cle is ready to start and run in reverse.

W hen leaving the vehicle unattended, engage the park­ ing (PARK) brake by depressing the TOP of the brake pedal until it locks in place. To release the parking

Repair and Service Manual

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GENERAL (PARK) brake, depress the BOTTOM part of the brake pedal.

CAUTION

CAUTION

A MAXIMUM OF FOUR VEHICLES (INCLUDING THE TOW VEHICLE} MAY BE TOWED AT A TIME .

TO AVOID COMPONENT DAMAGE, THE VEHICLE MUST BE BROUGHT TO A COMPLETE STOP BEFORE SHIFTING THE DIRECTION SELECTOR.

TOW BARS ARE NOT INTENDED FOR OFF ­ COURSE USE .

ON DCS MODELS, IF THE DIRECTION SELECTOR IS SHIFTED BEFORE THE VEHICLE COMES TO A COMPLETE STOP, A WARNING BEEPER WILL ACTIVATE.

COASTING C oasting will not be a problem with DCS model vehicles because the DCS controls the speed of the vehicle while moving down hill. H owever, the DCS is not a substitute for the service brake which should be used to control the speed of the vehicle.

O n steep hills, it is possible for non DCS vehicles to coast at faster than normal speeds encountered on a flat sur­ face. To prevent loss of vehicle control, speeds should be limited to no more than the maximum speed on level ground (see vehicle specification). L imit speed by apply­ ing service brake. S evere damage to the drive train com­ ponents due to excessive speed may result from driving the vehicle above specified speed. D amage caused by excessive speed may cause a loss of control, is costly, is considered abuse and will not be covered under war­ ranty.

TOWING Tow bars to fit vehicles are available from the E-Z-GO S ervice Parts D epartment.

DCS models are equipped with a Run - Tow/M aintenance switch which, when in 'TOW' position allows the vehicle to roll freely without activating the warning beeper. C heck to see that vehicles to be towed are in this mode.

CAUTION

USE EXTRA CAUTION WHEN TOWING VEHICLE(S). DO NOT TOW A SINGLE VEHICLE AT SPEEDS IN EXCESS OF 12 MPH DO NOT TOW MULTIPLE VEHICLES AT SPEEDS IN EXCESS OF 5 MPH TOWING VEHICLES ABOVE RECOMMENDED SPEED MAY RESULT IN DAMAGE TO VEHICLE AND OTHER PROPERTY .

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DO NOT RIDE ON TOWED VEHICLES.

SERVICING THE ELECTRIC VEHICLE

_A WARNING _A BEFORE SERVICING THE ELECTRICAL SYSTEM, TURN OFF ALL ELECTRICAL LOADS FROM THE BATTERIES BEFORE REMOVING ANY HEAVY GAUGE BATTERY WIRES.

CAUTION IN THE BEST INTEREST OF BOTH VEHICLE OWNER AND SERVICING DEALER, CAREFULLY FOLLOW THE PROCEDURES RECOMMENDED IN THIS MANUAL . ADEQUATE PREVENTATIVE AT MAINTENANCE, REGULAR APPLIED INTERVALS, IS THE BEST GUARANTEE FOR KEEPING THE E-Z-GO VEHICLE BOTH DEPENDABLE AND ECONOMICAL .

BEFORE ANY ELECTRICAL SERVICE IS PERFORMED, THE RUN - TOW/MAINTENANCE SWITCH MUST BE PLACED IN THE 'TOW/ MAINTENANCE' POSITION (DCS MODELS ONLY).

IF A POWER WIRE (BATTERY, MOTOR OR CONTROLLER) IS DISCONNECTED FOR ANY REASON, THE RUN - TOW/MAINTENANCE SWITCH MUST BE LEFT IN THE 'TOW/MAINTENANCE' POSITION FOR AT LEAST 30 SECONDS AFTER THE CIRCUIT IS RESTORED (DCS MODELS ONLY).

B efore a new vehicle is put into operation, it is recom­ mended that the items shown in the INITIAL SERVICE CHART be inspected.

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P age A-5

INITIAL SERVICE CHART SERVICE OPERATION

ITEM

Batteries

Check charge condition

Seats

Remove protective plastic covering

Brakes

Check operation and adjust if necessary

Tires

Check pressure

SEATS Preparation of Seats for Service Remove the protective plastic coverings from the seats before placing the vehicle in service. The ONLY function of the plastic covering is to protect the seat bottom and back rest during shipping. If the plastic covering is left on the seat and becomes torn, dirt may get under the plastic covering and be ground into the cover material. Water getting under the plastic covering can become trapped and eventually will damage the seat assembly.

ROUTINE MA INTENANCE This vehicle will give years of satisfactory service provid­ ing it receives regular maintenance. Refer to the Periodic Service Schedule and Lubrication Points at the end of this section for appropriate service intervals.

LJ\D@'IT�

Some maintenance items must be serviced more frequently on cars used under severe driving conditions.

REAR AXLE (See Fig. A-6 "Rear Axle Lubricant Check/Fil/" on page A-6)

The only maintenance required for the first five years is the periodic inspection of the lubricant level. The rear axle is provided with a lubricant level check/fill plug located on the passenger side at the rear of the housing.

Unless leakage is evident, the lubricant should only be checked at 500 hour intervals or after five years, which­ ever comes first.

Checking the Lubricant Level Clean the area around the check/fill plug. The check/fill plug should be removed using a 13mm wrench; the cor­ rect lubricant level is just below the bottom of the threaded hole. If lubricant is to be added, remove the Page A-6

Check/Fill Plug

Fig. A-6 Rear Axle Lubricant Check/Fill

check/fill plug and add lubricant using a funnel. Add lubri­ cant slowly until lubricant starts to seep from the plug.

Install the check/fill plug. In the event that the lubricant is to be replaced, the vehicle is elevated with the plug at the lowest point.

GENERAL PREVENTATIVE MAINTENANCE WEEKLY, QUARTERLY, SEMI-ANNUAL AND ANNUAL

service requirements are detailed in the 'Periodic Service Schedule'.

Daily Check List After the vehicle has been put into service, it is recom­ mended that the following items be checked daily. The driver can be a great asset to a proper maintenance pro­ gram if he makes it a point to ·Iook, listen and feel for an unusual situation. This practice can be a great help in solving many maintenance problems in the minor stages while they can be corrected by simple adjustments.

Some maintenance items must be serviced more frequently on cars used under severe driving conditions.

1. Perform the DAILY BRAKING PERFORMANCE TEST. To determine the adequacy of the vehicles brake system, the following test should be performed daily:

Repair and Service Manual

GENERAL

A

WARNING

A

ALL DRIVING BRAKE TESTS MUST BE DONE IN A SAFE LOCATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL.

Owner/Operator The recommended way of performing the daily brake test and determining a vehicle's braking performance is to latch the park brake at a COMMON P OINT on a paved surface while traveling at maximum speed. The vehicle stopping location must be observed. If the vehicle stops in a significantly greater distance, or pulls to one side, the vehicle should IMMEDIATELY be removed from service and inspected by a qualified mechanic.

Mechanic The mechanic should perform a 'panic' stop on the sus­ pect vehicle(s) by applying maximum force and travel to the brake pedal while traveling at full speed. He should observe if either of the rear wheels fail to 'lock up'. If one wheel fails to lock, it is reasonable to expect that a prob­ lem exists with the service brake system and the BRAKE MAINTENANCE as described in the Operation and Ser­ vice Manual, must be performed in its entirety. If both wheels lock, the parking (PARK) brake must be adjusted and the vehicle re-tested per the DAILY BRAKE TEST. 2. DCS VEHICLES ONLY • At monthly intervals, test the DCS system by allowing the vehicle to roll down an incline at speeds exceeding 2 mph with the accelerator pedal released. Braking force should be felt at approximately 2 mph indicating that the DCS sys­ tem is functioning. If the vehicle speed continues to rise, apply the service brake and have vehicle inspected by a trained mechanic.

If the vehicle is to be used commercially we suggest that you also follow lists 3 and 4.

3. INSPECT THE FOLLOWING:

•

Check the tires for cuts, wear and proper air pres­ sure.

•

Be sure that the engaged parking (PARK) brake will hold on a hill and when disengaged, does not drag or prevent the vehicle from rolling freely.

•

Ensure that all switches are operating normally.

•

Listen for unusual noises, such as rattles due to loose hardware, scraping sounds such as brakes

dragging, unusual engine noises and be sensitive to abnormal performance.

•

Damaged or missing equipment.

•

Mechanical damage.

•

Torn seat.

4. CLEAN THE VEHICLE • Wipe seat.

•

Clean floormat.

•

Remove trash from dash tray.

•

Visually check the appearance of the vehicle for dents, scratches, loose equipment.

• Wash accumulated dirt from motor compartment and underbody.

TIRES Tire condition should be inspected on a daily basis. Infla­ tion pressures should be checked on a weekly basis when the tires are cool.

Tire inflation should be governed by the condition of the terrain. For outdoor applications with major use on grassy areas, the following should be considered: On hard turf, it is desirable to have a slightly higher inflation pressure. On very soft turf, a lower pressure prevents tires from cutting into the turf. All tires should have the same pressure for optimum handling characteristics. Be careful not to overinflate. Due to the low volume of these small tires, overinflation can occur in a matter of sec­ onds. Be sure to install the valve dust cap after checking or inflating.

WEEKLY, QUARTERLY, SEMI-ANNUAL AND ANNUAL service requirements are detailed in the 'Periodic Service Schedule'.

CARE AND CLEANING OF THE VEHICLE It is important that proper techniques and cleaning mate­ rials be used.

Normal cleaning of vinyl seats and plastic or rubber trim require the use of a mild soap solution applied with a sponge or soft brush and the subsequent removal of the material with a damp cloth.

Removal of oil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber cleaner.

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 those painted surface.

Repair and Service Manual

P age A-7

Do not use hot water, strong soap or harsh chemical detergents.

Rubber parts should be cleaned with non-abrasive household cleaner.

Occasional cleaning and waxing with non-abrasive prod­ ucts designed for 'clear coat' automotive finishes will enhance the appearance and durability of the painted surfaces.

Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle. These mate­ rials will accelerate corrosion of underbody parts. It is recommended that the underbody be flushed occasion­ ally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to ease its removal, taking care not to chip or otherwise damage paint.

Page A-8

WINDSHIELD (IF EQUIPPED) Cleaning Clean with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish.

CAUTION

DO NOT USE ANY ABRASIVE OR VOLATILE SOLVENTS TO CLEAN PLASTIC PARTS.

Trailering If the vehicle is to be transported on a trailer at highway speeds, it is recommended that the windshield be removed and the seat bottom secured. Always check that the vehicle and contents are adequately secured before trailering the vehicle.

Repair and Service Manual

GENERAL TORQUE SPECIFICATIONS FOR UNSPECIFIED HARDWARE

ALL TORQUE FIGURES ARE IN FT.LBS. Unless otherwise noted in the text, tighten all hardware in accordance with this chart BOLT SIZE

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

5/8"

3/4"

7/8"

1"

Grade 2

4

8

15

24

35

55

75

130

125

190

Grade 5

6

13

23

35

55

80

110

100

320

480

Fig. A-7 Torque Specifications

In general two grades of hardware are used in the vehi­ cle. Grade 5 hardware can be identified by the three marks on the hexagonal head. Unmarked hardware is Grade 2.

ow Grade 2

IT;D@u�

The table above specifies 'lubricated' torque figures. Fasten­ ers that are plated or lubricated when installed are consid­ ered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.

Grade 5

Fig. A-8 Bolt Grades

E.ZlaDiiUM•):I

Repair and Service Manual

Page A-9

(2) Ball Joint

--- Ball Joint

Ball Joint ---

Steering Unit Ball Joint on Rack and Rod

Use maximum of three pumps of grease for each grease fitting - Overgreasing may impair vehicle operation

Fig. A-9 Lubrication Points

Page A-10

Repair and Service Manual

E.ZGDii=f:foM�i

GENERAL S YSTEM

DAILY

WEEKLY

MONTH 20 HRS.

3MONTH 50 HRS.

SEMI-A NNUAL A NNUAL 125 HRS. 250-30 0 HRS.

• Check for smooth operation and correct free travel • Check brake performance and adjust if required • Check brake performance and adjust if required • Check operation when direction selector is in reverse . • Examine for inflation, cuts and excessive wear . • Check for bent rims, missing/loose lug nuts ·: • Recharge to full charge state after each day's use • Inspect connector system at each charge . • Check operation of DCS • Inspect and clean as required • Check electrolyte level - correct if required • Check for smooth movement • Check and tighten wire connections as required. Keep receptacles free of dirt and foreign matter + Check attachment, adjust as required - Lubricate linkage with light oil • Check for abnormal play, tightness of all hardware • Check for excessive play, bent components or loose connections • Check pressure, see specifications • Check all wiring for loose connections and broken/missing insulation • Check for damage to axle and loose or missing hardware • Check for oil leakage and loose fasteners • Check for loose hardware, cracks at attachment points • Check if tire wear is unusual, align per Service Manual • Check for bent/binding linkage rod and damage or wear to latch arm or catch bracket + Lubricate, use light oil - D O NOT L UBRICATE CABLES OR BRAKE LATCH Clean body components and wax all painted surfaces + Check for wear and smooth movement (lubricate shafts and ball joints if required) •. �.:.,..

• Check for excessive play and tightness of ·· · · retaining nuts + Lubricate, use Shell Alvania® EP-2 . + Lubricate linkage, use Shell Alvania® EP-2 .,; ...... + Lubricate, use Shell Alvania® EP-2 • Check

+Clean, Adjust etc.

.&. Replace

Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.

Fig. A-10 Periodic Service Schedule

E�Gitni½:iilM:I

Repair and Service Manual

Page A-11

GENERAL DAILY

WEEKLY

MONTH 20HRS

3 MONTH 50HRS

SEMI-ANNUAL ANNUAL 125 HRS 250-300HRS + Adjust, see Service Man­ ual + Pack, use Shell Alvania® EP-2 + Check brake shoe linings, wear limit .06" (1.5 mm)

• Check

+Clean, Adjust etc.

.&. Replace

Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.

Fig. A-11 Periodic Service Schedule (Continued)

Page A-12

Repair and Service Manual

E�laDii:f:iid•]:I

Section

SAFETY

TABLE OF CONTENTS FOR SECTION 'B' SECTION TITLE

PAGE NO.

GENERAL

8-1

GENERAL MAINTENANCE

8-4

IMPORTANT SAFETY WARNING 8-4 NOTES, CAUTIONS and WARNINGS .................................................................................. 8 - 4 8-4 BEFORE SERVICING THE VEHICLE Battery Removal .................................................................................................................... B - 6 Battery lnstallation ................................................................................................................. 8 - 6

LIFTING THE VEHICLE

8-6

LIST OF ILLUSTRATIONS Fig. 8-1 Battery Connections .......................................................................................................... 8 - 6 Fig. 8-2 Lifting the Vehicle .............................................................................................................. 8 - 7

Repair and Service Manual

Page B-i

SAFETY Notes: _________________________________

Page 8-ii

Repair and Service Manual

GENERAL

5.2.1. Steep Grade

The following text is provided as recommended by part II of ANSI / GCMA 2130.1 - 1993. E-Z-GO as a member of the Golf Car Manufacturers Association (GCMA) strongly endorses the contents of this specification.

PART II MAINT ENANCE AND OPERATIONS 5.

GENERAL SAFE TY PRACTICE S

5.1.

Introduction

Like other machines, golf cars can cause injury if improp­ erly used or maintained. This section contains broad safety practices recommended for safe golf car opera­ tions. Before operation, the controlling party should establish such additional specific safety practices as may be reasonably required for safe operations.

Experience has shown that golf cars which comply with the provisions stated in Part Ill of this Standard are safe when properly operated in accordance with the safety and operation warnings affixed to every golf car. The safe operation is enhanced when the golf cars are operated within a specific set of operation instructions, safety rules and practices established to meet actual operating ter­ rain and conditions.

The safety information contained in Part II is intended to provide the controlling party with basic safety information and to encourage the controlling party to implement a golf car safety program.

It is suggested and recommended that Part II be reprinted in the golf car manufacturer's operation and service manuals to encourage safe operations and prac­ tices at the controlling party's facility.

5.2.

Safety Survey

The controlling party shall perform a safety survey peri­ odically, and as conditions warrant to their premises, to identify areas where golf cars should not be operated and to identify possible hazards.

E�ISClii:f:tid•l:I

In areas where steep grades exist, golf car operations should be restricted to the designated golf car pathways where possible, and shall be identified with a suitable warning giving the following information: 'Warning, steep grade, descend slowly with one foot on brake:' 5.2.2. Wet Areas Wet grassy areas may cause a golf car to lose traction and may affect stability. Wet areas shall be chained or roped off to prevent golf car operations or be identified by a suitable warning not to operate golf cars in this area due to wet terrain.

5.2.3. Sharp Approaches

Turns,

Blind

Corners,

Bridge

Sharp turns, blind spots, bridge approaches and other potentially hazardous areas shall be either chained or roped off to prevent golf car operations or identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard.

5.2.4. Loose Terrain Loose terrain may cause a golf car to lose traction and may affect stability. Areas of loose terrain should be repaired if possible, or chained or roped off to prevent golf car operation or identified by a suitable warning to operators not to operate golf cars in this area due to loose terrain or possible hazardous conditions.

5.2.5. Golf Car/Pedestrian Interference Areas Areas where pedestrians and golf cars interfere shall be avoided whenever possible by rerouting the golf car traf­ fic or the pedestrian traffic to eliminate the interference. If elimination of the interference is not possible or is highly impractical, signs shall be erected warning pedestrians of the golf car traffic and golf car operators of the pedes­ trian traffic and to drive slowly and use extreme caution.

Repair and Service Manual

Page B-1

SAFETY 6.

MAINTENANCE

6.1. Introduction 6.1.1. Golf cars may become hazardous if maintenance is neglected or improperly performed. Therefore mainte­ nance facilities, trained personnel and procedures in accordance with the manufacturer's recommendations should be provided by the controlling party.

6.2. Preventive Maintenance A regularly scheduled inspection and preventive mainte­ nance program in accordance with the manufacturer's recommendations should be established. Such a pro­ gram will be a valuable tool in providing the golfing patron with a safe, properly operating golf car and thereby help to avoid accidents.

6.2.1. Personnel Only qualified, trained and authorized personnel shall be permitted to inspect, adjust and maintain golf cars.

nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air changes per hour is recommended. The controlling party shall consult applicable fire and safety codes for the spe­ cific ventilation levels required as well as the use of explosion proof electrical apparatus.

6.2.4. Maintenance Procedures All maintenance shall be performed in accordance with the manufacturer's recommended maintenance proce­ dures as outlined in the manufacturer's operation and service manuals.

6.2.5. Maintenance Safety Procedures All maintenance shall be performed in accordance with the manufacturer's recommended safety procedures as outlined in the manufacturer's operation and service manuals. The following list of recommended safety pro­ cedures are general in nature and in no way supersede the manufacturer's specific instructions.

6.2.5.1. Follow manufacturer's instructions for immobi­ lizing golf car before beginning any maintenance.

6.2.2. Parts and Materials Only manufacturer's recommended replacement parts and materials shall be used.

6.2.3. Ventilation Maintenance and storage areas shall be properly venti­ lated to avoid fire hazards in accordance with applicable fire codes and ordinances.

6.2.3.1. Ventilation for gasoline powered golf cars shall be provided to remove flammable vapors, fumes and other flammable materials. Consult applicable fire codes for specific levels of ventilation.

6.2.3.2. Ventilation for electric powered golf cars shall be provided to remove the accumulation of flammable hydrogen gas emitted during the charging process. The amount of hydrogen gas emitted depends upon a num­ ber of factors such as the condition of the batteries, the output rate of the battery charger and the amount of time the batteries are on charge. Hydrogen emissions are generally considered to be in the area of 1 O to 20 cubic liters per car per charge. Because of the highly volatile Page B-2

6.2.5.2. Block chassis before working underneath golf car.

6.2.5.3. Before disconnecting any part of the fuel sys­ tem, drain the system and turn all shut off valves to the 'OFF' position to prevent leakage or accumulation of flammable fuels in the work area.

6.2.5.4. Avoid fire hazards and have fire protection equipment available.

6.2.5.5. Before performing any maintenance on an elec­ tric golf car, disable the electrical system in accordance with the manufacturer's instructions.

6.2.5.6. Use only properly insulated tools when working on electrically powered golf cars or around batteries.

6.2.5.7. Brakes, steering mechanisms, warning devices, governors and all other safety devices shall be inspected and maintained in a safe and proper operating condition

Repair and Service Manual

E:ZE:iD ii=f:U 1t•):•

shall not be modified as supplied by the manufacturer.

6.2.5.8. After each maintenance or repair the golf car

shall be driven by qualified, trained and authorized per­ sonnel to ensure proper operation and adjustment.

6.2.5.9. Driving golf car to check for proper operation

and adjustment after repair shall be performed in an area that is free of vehicular and pedestrian traffic.

6.2.5.1O. Record all maintenance performed in a mainte­

nance record log by date, name of person performing maintenance and type of maintenance. Controlling party management should periodically inspect maintenance log to ensure currency and completeness of entries.

6.2.5.11. Provide operator comment cards to assist in

identifying non-periodic maintenance needs for specific golf cars.

6.2.6. The controlling party shall maintain in a legible

condition all nameplates, warnings and instructions which are supplied by the manufacturer.

6.2.7. The controlling party shall not perform any modifi­

cation or addition which affects capacity or safe opera­ tion, or make any change not in accordance with the owner's manual without the manufacturer's prior written authorization. Where authorized modifications have been made, the controlling party shall ensure that capacity, operation, warning and maintenance instruction plates, tags or decals are changed accordingly.

6.2.8. As required under paragraphs 6.2.6 and 6.2.7 the

manufacturer shall be contacted to secure new name­ plates, warnings or instructions which shall then be affixed in their proper place on the golf car.

7. FUELS HANDL ING AND STORAGE/ BATTERY CHARGING The controlling party shall supervise the storage and handling of liquid fuels in accordance with applicable fire and safety requirements.

7.1.

Storage and handling of liquefied petroleum gas fuels shall be in accordance with American Gas Associa­ tion recommendations and applicable fire safety require­ ments.

7.2.

The controlling party shall require battery chang­ ing and charging facilities and procedures to be in accor­ dance with applicable ordinances or regulations (also see paragraph 6.2.3.2).

7.3.

The controlling party shall periodically inspect facilities and review procedures to be certain that the procedures in paragraphs 6.2.3.2 and 7.3 are being fol­ lowed.

7.4.

8. OP ERATING SAFETY RUL ES AND PRACTICES 8.1. Operator Qualifications 8.1.1. Only authorized persons shall be allowed to oper­

ate golf cars. It is recommended that no persons be allowed to operate golf cars except those persons who posses a valid motor vehicle driver's license.

8.1.2. The controlling party shall display the operation

and safety instructions as recommended by the golf car manufacturers and the golf course safety rules in a con­ spicuous place near the golf car rental area or golf car pick-up area. It is also recommended, as with all motor vehicles, that the warning "Do not operate golf cars when under the influence of alcohol or drugs." be posted in a conspicuous location.

Repair and Service Manual

Page B-3

GENERAL MAINTENANCE When any maintenance procedure or inspection is per­ formed, it is important that care be exercised to insure the safety of the technician/mechanic or bystanders and to prevent damage to the vehicle.

Always read and observe all of the [R!]@'IT'�®, CAUTIONS and WARNINGS that are detailed in this manual.

Always read and understand the entire relevant manual section before attempting any inspection or service.

It is impossible to anticipate all situations that may arise, therefore it is important that all personnel servicing the vehicle be trained and aware of the safety issues perti­ nent to servicing an electric powered vehicle.

IMPORTANT SAFETY WARNING In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

It is virtually impossible to anticipate all possible compo­ nent failures or the manner in which each component may fail.

Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there­ fore may be considered potentially hazardous. Use extreme care when working on any vehicle. When diag­ nosing, removing or replacing any components that are not operating correctly, take the time to consider the safety ramifications if the component should move unex­ pectedly.

Some components are heavy, spring loaded, highly cor­ rosive, explosive or may produce high amperage or reach high temperatures. Battery acid and hydrogen gas could result in serious bodily injury to the technician/ mechanic and bystanders if not treated with utmost cau­ tion. Be careful not to place hands, face, feet or body in a location that could expose them to injury should an unforeseen situation occur.

NOTES, CAUTIONS and WARNINGS Throughout this manual, the following [R!]@'u'�®, CAU· TIONS and WARNINGS are used. For the protection of

CAUTION

A CAUTION INDICATES A CONDITION THAT MAY RESULT IN DAMAGE TO THE VEHICLE.

A_ WARNING A_ A WARNING INDICATES A HAZARDOUS CONDITION WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.

BEFORE SERVICING THE VEHICLE [N]@lf�

Only trained personnel should be authorized to service E-Z­ GO vehicles.

Before attempting to inspect or service a vehicle, be sure to read and understand the following warnings:

A_ WARNING A_ SET THE 'PARK' BRAKE BEFORE PERFORMING ANY WORK ON THE VEHICLE. HYDROGEN GAS IS FORMED WHEN CHARGING BATTERIES. DO NOT CHARGE BATTERIES VENTILLATION. WITHOUT ADEQUATE 4% ARE OF CONCENTRATIONS HYDROGEN EXPLOSIVE KEEP ALL SMOKING MATERIALS, OPEN FLAME OR SPARKS AWAY FROM THE BATTERIES. WRAP WRENCHES WITH VINYL TAPE TO PREVENT THE POSSIBILITY OF A DROPPED WRENCH FROM 'SHORTING OUT' A BATTERY, WHICH COULD RESULT IN AN EXPLOSION AND SEVERE PERSONAL INJURY.

all personnel and the vehicle, be aware of and observe the following:

A note indicates a condition that should be observed.

Page B-4

BEFORE WORKING ON VEHICLE, REMOVE ALL JEWELRY (RINGS, WATCHES, ETC.)

Repair and Service Manual

E�laDii:f:tid•]:I

A

WARNING

A

BE SURE THAT NO LOOSE CLOTHING OR HAIR CAN BECOME CAUGHT IN THE MOVING PARTS OF THE POWERTRAIN. WEAR O.S.H.A. APPROVED CLOTHING AND EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE THE BODY OR EYES TO POTENTIAL INJURY. IN PARTICULAR USE CARE WHEN WORKING WITH OR AROUND BATTERIES, USING SOLVENTS OR COMPRESSED AIR. BE SURE THAT THE KEY SWITCH IS OFF AND ALL ELECTRICAL ACCESSORIES ARE TURNED OFF BEFORE STARTING WORK ON VEHICLE. NEVER DISCONNECT A CIRCUIT UNDER LOAD AT A BATTERY TERMINAL.

A

WARNING

A

USE CARE NOT TO TIP BATTERIES WHEN REMOVING OR INSTALLING THEM; SPILLED ELECTROLYTE CAN CAUSE BURNS AND DAMAGE. THE ELECTROLYTE IN A STORAGE BATTERY IS A DILUTE ACID WHICH CAN CAUSE SEVERE BURNS TO THE SKIN AND EYES. TREAT ALL ELECTROLYTE SPILLS TO THE BODY AND EYES WITH EXTENDED FLUSHING WITH CLEAR WATER. CONTACT A PHYSICIAN IMMEDIATELY. ALWAYS WEAR A SAFETY SHIELD OR APPROVED SAFETY GOGGLES WHEN ADDING WATER OR CHARGING BATTERIES.

WHEN CONNECTING BATTERY CABLES, PAY PARTICULAR ATTENTION TO THE POLARITY OF THE BATTERY TERMINALS. NEVER CONFUSE THE POSITIVE AND NEGATIVE CABLES AEROSOL CONTAINERS OF BATTERY TERMINAL PROTECTANT MUST BE USED WITH EXTREME CARE. INSULATE THE METAL CONTAINER TO PREVENT THE METAL CAN FROM CONTACTING BATTERY TERMINALS WHICH COULD RESULT IN AN EXPLOSION. BATTERIES ARE HEAVY. USE PROPER LIFTING TECHNIQUES WHEN MOVING THEM. ALWAYS LIFT THE BATTERY WITH A COMMERCIALLY AVAILABLE BATTERY LIFTING DEVICE.

ANY ELECTROLYTE SPILLS SHOULD BE NEUTRALIZED WITH A SOLUTION OF 1/4 CUP OF SODIUM BICARBONATE (BAKING SODA) DISSOLVED IN 1 1/2 GALLONS OF WATER AND FLUSHED WITH WATER. OVERFILLING BATTERIES MAY RESULT IN ELECTROLYTE BEING EXPELLED FROM THE BATTERY DURING THE CHARGE CYCLE. ELECTROLYTE MAY CAUSE PERSONAL INJURY AND DAMAGE TO THE VEHICLE AND STORAGE FACILITY.

Repair and Service Manual

Page B-5

LIFTING THE VEHICLE

Battery Removal Qty. Required

Tool List

Insulated wrench, 1/2" ................................................. 1 Socket, 1/2", 3/8" drive ................................................ 1 Extension, 12", 3/8" drive ............................................ 1 Ratchet, 3/8" drive ....................................................... 1 Battery carrier.............................................................. 1 Using an insulated wrench, remove all wires from the vehicle batteries. Remove the battery hold downs by removing the hardware and lifting the retainer from the batteries.

Remove the batteries using a commercial battery carrier.

Battery Installation

Some servicing operations may require the rear wheels or the entire vehicle be raised.

CAUTION WHEN LIFTING THE VEHICLE, POSITION JACKS AND JACK ST ANDS ONLY ON THE AREAS INDICATED. Tool List

Qty. Required

Floor jack ..................................................................... 1

(See Fig. B-1 "Battery Connections" on page B-6)

If the batteries have been cleaned and any acid in the battery rack area neutralized, no corrosion to the battery racks or surrounding area should be present. If any cor­ rosion is found, it should be immediately removed with a putty knife and a wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint.

The batteries should be placed into the battery racks and the battery hold downs tightened snugly (25 - 30 in. lbs. torque), to prevent movement, but not tight enough to cause distortion of the battery cases.

Inspect all wires and terminals and clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate (baking soda); wire brush if required.

Use care to connect the battery wires as shown in the fol­ lowing illustration and tighten the battery post hardware securely. Protect the battery terminals and battery wire terminals with a commercially available protective coat­ ing.

BL+

BL-

Front of Vehicle

Jack stands .................................................................. 4 Wheel chocks .............................................................. 4

A_ WARNING A_ BE SURE THE VEHICLE IS ON A FIRM AND LEVEL SURFACE. NEVER GET UNDER A VEHICLE WHILE IT IS SUPPORTED BY A JACK. USE SAFETY STANDS AND TEST THE STABILITY OF THE VEHICLE ON THE STANDS. ALWAYS PLACE CHOCKS IN FRONT AND BEHIND THE WHEELS THAT ARE NOT TO BE RAISED. USE EXTREME CARE SINCE THE VEHICLE IS EXTREMELY UNSTABLE DURING THE LIFTING PROCESS. Install chocks in front and behind each front wheel. Cen­ ter the jack under the rear bumper. Raise the vehicle, and locate a jack stand under the outer end of each rear axle.

Lower the jack and test the stability of the vehicle on the two jack stands.

Place the jack at the center of the front axle. Raise the vehicle and position jack stands under the frame cross­ member as indicated.

Lower the jack and test the stability of the vehicle on the four jack stands.

If only the front or rear of the vehicle is to be raised, place the chocks in front of and behind each wheel that is not to be raised in order to stabilize the vehicle.

Fig. B-1 Battery Connections

Page B-6

(See Fig. B-2 "Lifting the Vehicle" on page B-7)

Lower the vehicle by reversing the lifting sequence.

Repair and Service Manual

E�GDii:f:;id•HI

SAFETY

0 0 0

Fig. B-2 Lifting the Vehicle

Repair and Service Manual

Page B-7

��---=��-

BI

Notes: _________________________________

Page B-8

Repair and Service Manual

Section

BODY

TABLE OF CONTENTS FOR SECTION 'C' SECTION TITLE BODY

PAGE NO.

C-1 General ................................................................................................................................. C • 1 Body Component Differences .............................................................................................. C - 5 Instrument Panel Removal/Installation ................................................................................. C - 5 Rear Body Removal/Installation ........................................................................................... C - 6 Body Panel Installation ......................................................................................................... C - 7 Sound Insulation Foam Installation ...................................................................................... C - 7 Fender Scuffguard Replacement ......................................................................................... C - 7 Bagwell Scuffguard Replacement ........................................................................................ C - 7 Rear Bumper Removal ......................................................................................................... C - 7 Rear Bumper Installation ...................................................................................................... C - 7 Front Shield Replacement .................................................................................................... C - 7 Rocker Panel Replacement.................................................................................................. C - 7

LIST OF ILLUSTRATIONS Fig. C-1 Fig. C-2 Fig. C-3 Fig. C-4 Fig. C-5 Fig. C-6 Fig. C-7

Drill Out Metal Rivet.......................................................................................................... C - 1 Drive Rivet Removal......................................................................................................... C - 1 Removing 'Christmas Tree' Fasteners ..........•.................................................................. C - 1 Body Components (Front) ................................................................................................ C - 2 Body Components (Rear) ................................................................................................. C - 3 Electric and Gasoline Body Component Differences ....................................................... C - 4 Front Shield Replacement ................................................................................................ C - 7

Repair and Service Manual

Page C-i

BODY Notes: ________________________________

Page C-ii

Repair and Service Manual

Section

BODY �@u@

This section contains references to components that may be applicable to either gasoline or electric vehicles and may not be appropriate to both.

/_

DrillOut Rivet HeadOnly

BODY

r:.

Fig. C-1 Drill Out Metal Rivet

�@u@

In the following text, there are references to removing/install­ ing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in their original posi­ tions unless otherwise specified. Non-specified torques are as shown in the table in Section A.

0i }

t==r:==,�

\ =-

General

I

Push Pin with Screwdriver from Rear Side

(See Fig. C-1 "Drill Out Metal River on page C-1)

., u

d

-

[ 0

-t

""

OR

(See Fig. C-2 "Drive Rivet Removal" on page C-1)

Drive Pin through with Punch from Front

(See Fig. C-3 "Removing 'Christmas Tree' Fasteners" on page C-1)

A.

WARNING

I

, '

A.

, '

BATTERIES SHOULD ALWAYS BE REMOVED BEFORE ANY SERVICING THAT COULD RESULT IN SPARKS BEING GENERATED. THE FUEL TANK MUST ALWAYS BE PROTECTED TO PREVENT IT BEING PUNCTURED BY A DRILL BIT. In general, body component replacement can be accom­ plished with a minimum of specialized tools. Most body components are held in place with conventional remov­ able hardware (nuts, bolts, washers and screws). Some components are mounted with 'pop' rivets which require that the rivet head be removed in order to push out the shank of the rivet. The rivet head is easily removed by drilling into the head with a sharp drill bit that is slightly larger than the shank of the rivet. Care must be exercised when drilling to prevent the drill from being forced through the plastic body components where it could dam­ age components located immediately behind the rivet.

The best way to prevent this occurring is to use a sharp drill bit that requires very little pressure to cut success­ fully and to place a piece of protective sheet metal between the surface being drilled and components directly behind it.

1 'J

I

t

Fig. C-2 Drive Rivet Removal

'Christmas Tree' Fastener �

Remove Rivet with Pry Bar

Fig. C-3 Removing 'Christmas Tree' Fasteners

Repair and Service Manual

Page C-1

BODY

- -

======= ------ 3 kW

•

TYPE

CE

KG

•

E Z GO D v s,on of Textron Inc PO Box 388 Augustn Georgi� USA 30903 0388

� I

�-16

36

Fig. C-4 Body Components (Front)

Page C-2

Repair and Service Manual

EaGDii:f:;id•l:I

BODY

30

Fig. C-5 Body Components {Rear)

Ea!ESC ii:£:;i,t•):I

Repair and Service Manual

Page C-3

Electric Vehicles

Seat Frame �Gas Vehicle Only)

Fig. C-6 Electric and Gasoline Body Component Differences

Page C-4

Repair and Service Manual

BODY Body Component Differences (See Fig. C-6 "Electric and Gasoline Body Component Differences" on page C-4)

Refer to Fig. C-6 and note the differences between the electric and gasoline vehicles.

The seat support frames differ between the electric and gasoline vehicles.

The battery rack is added to the electric vehicle only.

Sound insulation foam is used around the trunk lid and behind the front area of the rear body panel on the gaso­ line vehicle only (not illustrated).

Splash panels differ. The electric vehicle uses the same panel on both sides but installs one with the flanges up and the other with the flanges facing down.

Be sure to consult the Service Parts Manual for specific part numbers and applications.

Instrument Panel Removal/Installation (See Fig. C-4 "Body Components (Front)" on page C-2)

If the instrument panel is to be replaced, the serial number plate and CE plate must be removed from the old instrument panel and reinstalled on the replacement panel.

Tool List

Qty. Required

Electric/air drill ............................................................ 1 Drill bit, 7/32" ............................................................... 1

Socket, 3/8", 3/8" drive ................................................ 1

If the instrument panel (1) is to be replaced, the serial number plate (2) and CE plate (3) must be removed from the old instrument panel and reinstalled on the replace­ ment panel. When installing a replacement instrument panel, a new console safety label (4) MUST be ordered and placed on the new instrument panel. When ordering a replacement instrument panel, provide vehicle serial number to the E-Z-GO Service Parts Representative and they will provide the correct part number for the safety label.

A

WARNING

A

TO PREVENT THE POSSIBILITY OF INJURY DUE TO LACK OF VEHICLE INFORMATION, THE CORRECT SAFETY LABEL MUST BE ON THE INSTRUMENT PANEL AT ALL TIMES. Remove the rocker panel sill plates (5) by removing the hardware (6) securing them to the frame.

Remove the rivet (7) at the front edge of the rocker panel (8). Remove the rivets (34) along the side of the rocker panel. Pull the rocker panel away from the vehicle frame which will release the spacers (35,36) securing the rocker panel to the frame. Be sure to note the location of each length of spacer.

Pull the front of the floor mat (9) up to expose the rivets (10) that secure the instrument panel (1) and cowl (11) to the floor. (See Detail A.) Drill out the rivets (12) located in the floor panels (13,14), and across the top of the instru­ ment panel.

Remove the four screws (15) located within the instru­ ment panel pockets.

Ratchet, 3/8" drive....................................................... 1

The instrument panel may now be pulled away from the cowl by 'rotating' it arounc;:J the steering column.

Rivet gun ..................................................................... 1

Reassembly is the reverse order of disassembly and will require new rivets to be installed.

Punch .......................................................................... 1 Phillips Screwdriver ..................................................... 1

Cowl Removal/Installation (See Fig. C-4 "Body Components (Front)" on page C-2)

Small pry bar ............................................................... 1

Tool List

Socket, 7/16", 1/4" drive .............................................. 1

Electric/air drill ............................................................ 1

Ratchet, 1/4" drive ....................................................... 1

Qty. Required

Drill bit, 7/32" ............................................................... 1 Socket, 3/8", 3/8" drive ................................................ 1 Ratchet, 3/8" drive ....................................................... 1

The instrument panel may be removed without removing the cowl or may be removed as part of the cowl.

E�GDiiUhM:I

Rivet gun ..................................................................... 1 Punch .......................................................................... 1

Repair and Service Manual

Page C-5

BODY Phillips Screwdriver ..................................................... 1

Socket, 9/16", deepwell, 3/8" drive .............................. 1

Small pry bar ............................................................... 1

Socket, 3/8", 3/8" drive ................................................ 1

Socket, 7/16", 1/4" drive .............................................. 1

Ratchet, 3/8" drive ....................................................... 1

Ratchet, 1/4" drive ....................................................... 1

Rivet gun ..................................................................... 1

Duct tape ..................................................................... 1

Punch .......................................................................... 1

Allen key, 3/16" ............................................................ 1

Phillips Screwdriver ..................................................... 1

Allen key, 7/32" ............................................................ 1

Small pry bar ............................................................... 1 Socket, 7/16", 1/4" drive .............................................. 1

If the cowl is to be removed, it is recommended that the instrument panel be left in place until the entire cowl and instrument panel has been removed as an assembly.

Remove the rocker panel sill plates (5) by removing the hardware (6) securing them to the frame.

Remove the rivet (7) at the front edge of the rocker panel (8). Remove the rivets (34) along the side of the rocker panel. Pull the rocker panel away from the vehicle frame which will release the spacers (35,36) securing the rocker panel to the frame. Be sure to note the location of each length of spacer.

Pull the front of the floor mat (9) up to expose the rivets (10) that secure the instrument panel (1) and cowl (11) to the floor. (See Detail A.) Drill out the rivets (12) located in the upper floor panel (13).

Drill out the rivets (16) securing the sides of the cowl to the frame.

Remove the four screws (15} located within the instru­ ment panel pockets.

Remove the bolts (17) and washers (18) from the sides of the cowl and lift the cowl assembly from the vehicle.

Reassembly is the reverse order of disassembly except that the instrument panel should be riveted to the cowl before assembly to the vehicle. The bolts (17) and wash­ ers (18) reinstalled into the cowl should be tightened to 8 - 12 ft. lbs. The bottom of the instrument panel should be temporarily held in place with duct tape until the entire assembly has been riveted in place.

Rear Body Removal/Installation (See Fig. C-4 "Body Components (Front)" on page C-2) (See Fig. C-5 "Body Components (Rear)" on page C-3)

Tool List

Qty. Required

Electric/air drill ............................................................ 1 Drill bit, 7/32" ............................................................... 1 Drill bit, 1/4" ................................................................. 1 Page C-6

Ratchet, 1/4" drive ....................................................... 1 Duct tape ..................................................................... 1 Allen key, 3/16" ............................................................ 1

A_ WARNING A_ IN ELECTRIC VEHICLES, IN ORDER TO ELIMINATE THE POSSIBILITY OF BATTERY EXPLOSION FROM RESULTING SPARKS CREATED BY VARIOUS TOOLS, THE BATTERIES MUST BE REMOVED BEFORE ANY REPAIRS TO THE BODY ARE UNDERTAKEN. Remove the rocker panel sill plates (5) by removing the hardware (6) securing them to the frame.

Remove the rivet (7) at the front edge of the rocker panel (8). Remove the rivets (34) along the side of the rocker panel. Pull the rocker panel away from the vehicle frame which will release the spacers (35,36) securing the rocker panel to the frame. Be sure to note the location of each length of spacer.

To avoid damage to the plastic body component, remove or install the seat support brackets by sliding to the open end of the molded channel. Do not force the seat support brackets into or out of the channels from above. (See Fig. C-5)

Remove the four bolts (19) that secure the seat supports (20) to the vehicle frame.

Remove the rivets (32) located at each end of the bumper securing the bumper to the body panel.

If the trunk lid is to be reused, remove the hardware (21) securing the trunk lid (22} to the body panel. Remove the trunk lid.

Remove the rivets (37) that secure the floor of the bag­ well area to the frame underneath.

Repair and Service Manual

BODY At the front of the rear body panel, remove the rivets (23) securing the body panel (24) to the frame and floorboard area. Drill out the rivets (25) to remove the scuff guards (26). Drill out the heads of the large headed rivets (27) that secure the bottom of the body panel to the side of the vehicle. Remove body panel.

A

WARNING

A

IT IS IMPORTANT TO USE A SHARP DRILL BIT WHEN REMOVING THE RIVETS ON THE PASSENGER SIDE OF THE GAS POWERED VEHICLE. EXTREME CARE MUST BE USED WHEN DRILLING OUT THE RIVETS LOCATED IN THE FRONT OF THE BODY PANEL AND THE BOTTOM SIDE OF THE BODY PANEL. EXCESSIVE PRESSURE COULD RESULT IN THE DRILL BIT BEING FORCED THROUGH THE BODY PANEL AND PENETRATING THE FUEL TANK. AS EXTRA PROTECTION, IT IS RECOMMENDED THAT A PROTECTIVE PIECE OF SHEET METAL BE PLACED BETWEEN THE FUEL TANK AND THE RIVET. USE OF A DRILL DEPTH STOP WILL PROVIDE ADDITIONAL PROTECTION.

Body Panel Installation (See Fig. C-5 "Body Components (Rear)" on page C-3)

Rear Bumper Removal (See Fig. C-5 "Body Components (Rear)" on page C-3)

Remove the plastic snap fasteners (32) located at each end of the rear bumper (33). Carefully remove the plugs (30) with a screwdriver. Remove the shoulder bolts and washers (31) underneath the plugs. Pull the rear bumper downward to disengage bumper clips (36).

Rear Bumper Installation (See Fig. C-5 "Body Components (Rear)" on page C-3)

Engage the top of bumper with the underside of the fend­ ers. Push bumper upward as fender slides between the bumper clips and the bumper. Push plastic snap fastener into the holes at each end of the bumper and through the fender. Insert shoulder bolts with washers and tighten to 9 - 12 ft. lbs. torque. Replace the plugs.

Front Shield Replacement (See Fig. C-7 "Front Shield Replacement" on page C-7)

The front shield (38) does not need to be removed to replace any other body components. If the front shield is damaged, remove hardware (39) securing the front shield and brace (40) to the frame. Install replacement shield in the reverse order of disassembly.

Installation of rear body panel are in the reverse order of disassembly using new rivets. Install the bolts (19) into the seat supports (20) and tighten to 21 - 25 ft. lbs.

39

Sound Insulation Foam Installation

39

@.

On gasoline vehicles, install sound insulation foam (avail­ able through E-Z-GO Service Parts Department-check Service Parts manual for part number) behind the front panel of the body panel and underneath the trunklid. Pull backing off foam to expose adhesive surface. Align and place on dust free surface.

Fender Scuffguard Replacement (See Fig. C-5 "Body Components (Rear)" on page C-3)

Remove the rivets (25) securing the scuffguard (26) to the rear body panel. Align holes in replacement scuff­ guard with existing holes in fender of body panel. Install using new rivets.

40 Fig. C-7 Front Shield Replacement

Bagwell Replacement (See Fig. C-5 "Body Components (Rear)" on page C-3)

Remove the rivets (28 and 37) securing the bagwell (29) to the rear body panel. Install replacement bagwell with new rivets.

E�GDii:£Ud•W

38

Rocker Panel Replacement Remove the rocker panel sill plates (5) by removing the hardware (6) securing them to the frame.

Repair and Service Manual

Page C-7

BODY Remove the rivet (7) at the front edge of the rocker panel (8). Remove the rivets (34) along the side of the rocker panel. Pull the rocker panel away from the vehicle frame which will release the spacers (35,36) securing the rocker panel to the frame. Be sure to note the location of each length of spacer.

Align the replacement rocker panel with spacers in place and install new rivets.

Replace the rocker panel sill plate in reverse order of dis­ assembly.

Page C-8

Repair and Service Manual

e�Gt:n i:f:Utt·m

rl

WHEELS AND TIRES

Section

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I

TABLE OF CONTENTS FOR SECTION 'D' SECTION TITLE

PAGE NO.

WHEEL AND TIRE SERVICE D -1 Tire Service .......................................................................................................................... D - 1 Wheel Installation ................................................................................................................. D - 1

LIST OF ILLUSTRATIONS Fig. D-1 Wheels and Tires .............................................................................................................. D - 2

Repair and Service Manual

Page D-i

WHEELS AND TIRES

Notes: _____________________________

Page D-ii

Repair and Service Manual

�I

WHEELS AND TIRES

rf..k'ttA.tBfk'itt%4/L,:,, . }::?�""''L<:X.cl;,,L, .!.94t¥fu'\\&i:LLL�£ v';,�, v:,;. l'!:l?:' vi:::�:,.L-::o.&1%£h.�7*r�Pdm11Ft:�t:vv;,,:v:t:.&'.�"''A''::,,''.<Z ,

WHEEL AND TIRE SERVICE

CAUTION

Qty. Required

Tools List

Lug wrench, 3/4" end .................................................. 1 Impact Socket, 3/4", 1/2" drive .................................... 1 Impact wrench, 1/2" drive ............................................ 1 Torque wrench, 1/2" drive, ft. lbs. ................................ 1

Tire Service The vehicle is fitted with low pressure tubeless tires mounted on one piece rims.

In general, the most cost effective way to repair a flat tire that is the result of a puncture in the tread portion of the tire, is to use a commercial tire plug.

U\iJ@u�

DO NOT OVERINFLATE TIRES. DUE TO THE LOW VOLUME OF THESE SMALL TIRES, OVERINFLATION CAN OCCUR IN A MATTER OF SECONDS.

A

The decision to remove a worn or non repairable tire from its wheel will vary from location to location.

The minimal cost differential between the cost of a tire alone versus a wheel and tire assembly, is offset by the labor and equipment costs required to replace the tire alone. Some locations may chose to accumulate a num­ ber of wheel and tire assemblies and have a local tire outlet replace the worn/damaged tires, while other large locations may chose to purchase a tire mounting/ demounting machine.

If the tire is to be removed or mounted, the tire changing machine manufacturer's recommendations must be fol­ lowed in order to minimize the possibility of personal injury.

Wheel Installation

WARNING

A

TO PREVENT INJURY CAUSED BY A BROKEN SOCKET, USE ONLY SOCKETS DESIGNED FOR IMPACT WRENCH USE. NEVER USE A CONVENTIONAL SOCKET.

Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring that the tire be removed from the wheel.

Should a tire repair be necessary, proceed as follows: If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire. Immerse the tire in water to locate the leak and mark with chalk.

Insert tire plug in accordance with manufacturer's specifi­ cations.

Section

CAUTION DO NOT TIGHTEN LUG NUTS TO MORE THAN 60 FT. LBS.

A

WARNING

A

TO SEAT BEADS, USE A SMALL AMOUNT OF AIR INTERMITTENTLY AND NEVER EXCEED THE TIRE MANUFACTURER'S RECOMMENDATION. WHEN REMOVING VALVE CORE, KEEP FACE AND EYES AWAY FROM ESCAPING AIR. BE SURE MOUNTING/DEMOUNTING MACHINE IS ANCHORED TO FLOOR. WEAR SAFETY EQUIPMENT WHEN MOUNTING/ DEMOUNTING TIRES. FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS PROVIDED BY THE MOUNTING/ DEMOUNTING MACHINE MANUFACTURER.

(See Fig. D-1 'Wheels and Tires" on page D-2)

Install wheel on vehicle as shown. Inflate to 18-22 psi.

Repair and Service Manual

Page D-1

D ,

Valve Stem is Always to Outside of Wheel

Tighten 4 Tapered Lug Nuts to 50 - 60 Ft. Lbs. Torque

Fig. D-1 Wheels and Tires

Page D-2

Repair and Service Manual

E�GDU:f:ji;M:I

-----E ELECTRONIC SPEED CONTROL • DCS

Section

TABLE OF CONTENTS FOR SECTION 'E' SECTION TITLE

PAGE NO.

GENERAL E-1 Pedal Box .............................................................................................................................. E - 1 Controller ............................................................................................................................... E - 1 Run - Tow/Maintenance Switch ............................................................................................. E - 1 System Test .......................................................................................................................... E - 2 TROUBLESHOOTING E-2 Symptoms ............................................................................................................................. E - 3 Preliminary Tests ................................................................................................................... E - 3 Measuring Battery Voltage .................................................................................................... E - 4 Checking Voltages on the Ten Pin Controller Connector ...................................................... E - 6 General Testing .....................................................................................................................E - 6 Testing Control Circuit ........................................................................................................... E - 6 Power to the Controller .......................................................................................................... E - 7 Inductive Throttle Sensor (ITS) Circuit .................................................................................. E - 8 REPLACING THE CONTROLLER INDUCTIVE THROTTLE SENSOR REPLACEMENT

E-9 E - 10

LIST OF ILLUSTRATIONS Fig. E-1 Pedal Box Assembly .......................................................................................................... E - 1 Fig. E-2 Controller ...........................................................................................................................E - 1 Fig. E-3 Run-Tow/Maintenance Switch ........................................................................................... E - 2 Fig. E-4 Run and Reverse Switch Locations ................................................................................... E - 4 Fig. E-5 Measuring Battery Voltage ................................................................................................ E - 4 Fig. E-6 Ten Pin Connector Troubleshooting Diagram ................................................................... E - 5 Fig. E-7 Checking Voltage on Ten Pin Connector .......................................................................... E - 6 Fig. E-8 Attach Positive Probe to Battery Side of Solenoid ............................................................. E - 7 Fig. E-9 Attach Negative Probe to Battery BL-................................................................................ E - 7 Fig. E-10 Attach Positive Probe to Controller Side of Solenoid ...................................................... E - 8 Fig. E-11 Attach Positive Probe to Red Wire at Controller Ten Pin Connector ............................... E - 8 Fig. E-12 Attach Positive Probe to Black Wire at Controller Ten Pin Connector.............................E - 8 Fig. E-13 ITS and Plunger ............................................................................................................. E - 11 Fig. E-14 ITS Adjustment .............................................................................................................. E - 12 Fig. E-15 ITS Adjustment (Continued) .......................................................................................... E - 13 Fig. E-16 Wiring Diagram .............................................................................................................. E - 14

E�GDiifai1M:1

Repair and Service Manual

Page E-i

Notes: _______________________________

Page E-ii

Repair and Service Manual

E�laCliiJ:;itt·l�I

GENERAL The Electronic Speed Control system consists of three principal components which are the pedal box, the con­ troller and the run - tow/maintenance switch.

Pedal Box (See Fig. E-1 "Pedal Box Assembly'' on page E-1)

The ITS unit and the controller are both solid state units that contain no user serviceable parts. The testing proce­ dures are designed to test the basic functionality of the power and control wiring systems. Once the functionality of the wiring and related components has been con­ firmed, the remaining tests are used to identify which of the components (controller or ITS) must be replaced.

The pedal box assembly is a modularized unit consisting of the accelerator pedal, return spring and an enclosed box that contains the pedal position micro switch and a solid state Inductive Throttle Sensor (ITS) activated by a moving plunger attached to the accelerator pedal. The ITS and plunger are accessed by removing a panel located under the floormat directly behind the accelerator pedal.

Rocker Panel Insert / Access Cover

0

•

0

0

ltzr

Enclosure

Fig. E-2 Controller

Run - Tow/Maintenance Switch (See Fig. E-3 "Run-Tow/Maintenance Switch" on page E-2)

The DCS model vehicles will operate only if this switch is in the 'RUN' position.

Fig. E-1 Pedal Box Assembly

The vehicle is equipped with a two position switch located on the controller enclosure under seat.

Controller (See Fig. E-2 "Controller'' on page E-1)

The controller enclosure contains a solid state speed controller and solenoid. The controller is located under the seat on the passenger side of the vehicle.

The pedal box and controller are connected by a wiring harness and a six pin connector that is located within the controller enclosure. The controller wiring harness is con­ nected to the controller with a ten pin connector.

The controller is wired to the batteries and develops a regulated power supply for the ITS. The plunger position relative to the ITS varies the current which is fed back to the controller which interprets this change in current and then supplies the appropriate power to the motor.

EmGD ii+:;it!•l:I

With the switch in 'TOW/MAINTENANCE' position: • the controller is deactivated • the electronic braking system is deactivated which allows the vehicle to be towed or roll freely • the warning beeper is deactivated • the vehicle will not operate With the switch in 'RUN' position: • the controller is activated • the electronic braking system and warning beeper features are activated • the vehicle will operate

Repair and Service Manual

Page E-1

�1

E

ELECTRONIC SPEED CONTROL. DCS

If a// of the following events occur with the switch in 'RUN' position: the vehicle has been stopped for more than one second and the accelerator pedal has been released for more than one second

J

switch must be replaced (refer to charging section). If one of the charger connectors causes the buzzer to shut off and the other connector does not, the charger connector that will not cause the buzzer to shut off is faulty and must be replaced. (See charger section of this manual.)

and the vehicle begins to roll above 2 mph then the electronic braking will limit speed to approxi­ mately 2 mph and the warning beeper will sound. When the accelerator pedal is depressed, the electronic braking and warning beeper will be overridden and normal vehi­ cle operation resumes.

AWARNINGA

If a// of the following events occur with the switch in 'RUN' position: the vehicle is being driven down a slope and the vehicle speed exceeds the designed speed with the accelerator pedal depressed or released then the electronic braking will limit the speed of the vehi­ cle to the designed speed range (the warning beeper will not sound). When the electronic braking system is acti­ vated by this sequence of events, the motor generates power which is returned to the batteries.

If the operator attempts to override the electronic braking feature by moving the direction selector or key switch to another position, the warning beeper will sound and the vehicle will brake rapidly until it reaches the speed of approximately 2 mph.

System Test 1. At monthly intervals, test the DCS system by allowing the vehicle to roll down an incline (with operator on vehicle) at speeds exceeding 2 mph with the acceler­ ator pedal released. Braking force should be felt and the warning beeper should sound at approximately 2 mph indicating that the DCS system is functioning. If the vehicle speed continues to rise, apply the service brake and have vehicle inspected by a trained mechanic.

2. T he vehicle is equipped with a magnetically actuated ignition interlock switch to prevent the vehicle from being operated during the charge cycle.

Check to see that the interlock switch is working prop­ erly by placing the vehicle in reverse to activate the reverse warning buzzer and insert the battery charger connector into the receptacle. T he reverse warning buzzer should shut off. If the buzzer does not shut off, try using a different charger connector. If the buzzer does not shut off with either connector, the interlock Page E-2

Enclosure

Fig. E-3 Run-Tow/Maintenance Switch

TROUBLESHOOTING Tool List

Qty. Required

Floor jack ..................................................................... 1 Jack stands .................................................................. 2 Wheel chocks ..............................................................4 Digital VOM .................................................................. 1 3/8" Socket, 3/8" drive ................................................. 1 Ratchet, 3/8" drive ....................................................... 1 Torque wrench, in. lbs., 3/8" drive ................................ 1 Torque wrench, ft. lbs., 3/8" drive ................................. 1

Repair and Service Manual

EZl3Dii=f:tid•1:I

:iE

ELECTRONIC SPEED CONTROL. DCS

, ; "' .. <" P½/k:: "<U;(Jt , 3t.."'J'"*'d,.,a�, \:J;,.;,, ,,..,,.,..LYf&ttf§tCL?iiL:'Ltc'.t:O.".tt:d..%�:iW"m'%�41L::...,,�J,,,;�,,,,i.,;,,,;L½��J��%1�L""'..��,,,:J/.£Lf..Jf0J.Jdi.4iJJ.§:G:L:C>,w,,.,,,,,,,,,,�,<.,JiC :y:;;�cti!v,,,,,,,�J\i,!!LJ.tlti\�,, ,, :?Yttff®WS1E8£'.$�

Extension, 6", 3/8" drive .............................................. 1 Insulated wrench, 9/16" ............................................... 1

Wrench, 1/2" ............................................................... 1 Wrench, 7/16" ............................................................. 1 Phillips Screwdriver (#2) ............................................. 1 Phillips Screwdriver (#1) ............................................. 1 Shop towel .................................................................. 1 Allen wrench, 5/64" ..................................................... 1

All tests must be performed with the rear wheels raised in accordance with procedure specified in Section 8.

All VOM tests are done with the negative probe attached directly to the BL- terminal on the battery set.

A

WARNING

A

BEFORE SERVICING ANY PART WITHIN THE CONTROLLER ENCLOSURE, PLACE SWITCH IN THE 'TOW/MAINTENANCE' POSITION AND REMOVE THE BL+ WIRE FROM THE BATTERY USING AN INSULATED WRENCH. REMOVE THE CONTROLLER ENCLOSURE. RECONNECT BL+ AND WAIT A MINIMUM OF 30 SECONDS BEFORE MOVING SWITCH TO THE 'RUN' POSITION. IF THIS PROCEDURE IS NOT FOLLOWED, WHEN LIFTING THE COVER FROM THE CONTROLLER, THERE IS A RISK OF DAMAGING THE WIRING AND/OR CAUSING IRREPARABLE CONNECTORS DAMAGE TO THE CONTROLLER. CONNECTING THE BL+ WITH THE SWITCH IN THE 'RUN' POSITION WILL CAUSE AN ARC AND COULD CAUSE A BATTERY EXPLOSION. BEFORE DISCONNECTING ANY WIRE ON THE MOTOR, MAKE SURE THE BL+ BATTERY WIRE IS DISCONNECTED. IF THE BL+ BATTERY WIRE IS NOT DISCONNECTED WHEN A WIRE IS BEING REMOVED FROM THE MOTOR, A HIGH VOLTAGE ARC WILL BE PRESENT WHICH IS POTENTIALLY HAZARDOUS. NEVER OPERATE VEHICLE AT FULL THROTTLE FOR MORE THE 4 TO 5 SECONDS WHILE VEHICLE IS IN A "NO-LOAD" CONDITION. RAISE BOTH REAR WHEELS {SEE 'SAFETY' SECTION B OF THIS MANUAL) BEFORE PERFORMING ANY TESTS.

E.ZGDiiUitt•W

A

WARNING

A

AFTER REMOVING A BATTERY WIRE, WAIT FOR A MINIMUM OF 30 SECONDS AND DISCHARGE THE CONTROLLER BY SHORTING THE B+ AND B­ TERMINALS WITH A LARGE INSULATED SCREWDRIVER BEING SURE TO HOLD THE INSULATED PORTION OF THE SCREWDRIVER. BE SURE TO DISCHARGE THE CONTROLLER BEFORE DISCONNECTING A WIRE FROM THE MOTOR.

Symptoms If the vehicle does not operate or operates poorly or intermittently, proceed as follows:

A

WARNING

A

TO PREVENT UNEXPECTED MOVEMENT OF THE VEHICLE, ALWAYS RAISE THE REAR WHEELS BEFORE CONDUCTING ANY TESTS.

Preliminary Tests (See Fig. E-4 "Run and Reverse Switch Locations" on page E-4)

Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to the Repair and Service Manual, Lifting Procedure in Section 'B' Safety). Test the vehicle stability before proceeding.

Remove the seat bottom from the vehicle.

Place the direction selector in 'F' and turn the key switch to 'ON'. Depress the accelerator pedal until the micro switch in the pedal box activates which should cause the solenoid to make an audible click. If the solenoid does not click, go to 'Power to the Controller' located later in this section.

Direction is selected by the operation of the reverse switch (Ref. Fig. E-4). T he reverse switch closes before the run switch only in reverse direction. If the vehicle does not run in forward, perform continuity check on the run switch. If the vehicle does not run in reverse only, perform continuity check on the reverse switch.

Repair and Service Manual

Page E-3

E1

� ELECTRONIC SPEED CONTROL • DCS

!t�L:,-11� EY\�f<'ZEt&Jhl:'Jt;z1Y.,;,.<MMO:r:&u::tfui'lt{:> � :,w� J'.YiamAt:h¾.t.:z1.Hi:;,�Biat'*.@t�:t0lJ;,;;;1�&E?».YtiZlt.�'h7&,%,t:,:.�"-:,"'�-�X1%MttUfitftittft!tt<::L).,:L>,L+,.xtt.@&+z®:.t,,,c::,,,,.sd::::-YiY.:&t...dS&,>L·:mtict .·::,::ta�

Reverse Switch Reference Voltage

Fig. E-4 Run and Reverse Switch Locations

Measuring Battery Voltage (See Fig. E-5 "Measuring Battery Voltage" on page E-4)

It is important to determine the condition of the battery set before proceeding with any electrical troubleshooting.

An open voltage test is of little use since a battery that has deteriorated to the point of requiring replacement can still show six volts or higher in an open voltage test. If there is any doubt as to the adequacy of the battery set, charge the batteries and perform a load test using a dis­ charge machine.

With the adequacy of the batteries confirmed, use a VOM connected directly to the battery terminal posts to deter­ mine the open voltage of the set (See Fig. E-5). In the fol­ lowing tests, this voltage level will be used as a reference. Some loss due to resistance of wires and con­ nectors may be indicated by readings that could be up to one volt less than the reference voltage. No reading indi­ cates an 'open' condition and the battery jumper wires should be inspected for a broken or disconnected con­ ductor.

Page E-4

Repair and Service Manual

Fig. E-5 Measuring Battery Voltage

m tlJ

Iii Cl

I

±

-

Charger Receptacle

DCS TROUBLESHOOTING SEQUENCE

B·

B+

ALL TESTS ARE CONDUCTED WITH RUN TOW/MAINTENANCE SWITCH IN RUN POSITION AND WITH BATTERY SET IN ADEQUATE CONDITION

B-

If vehicle operates in forward but not in reverse check the reverse micro switch "T1

cp'

10

RunTow/maintenance

Ignition

I

�

i....

"-t :.:i

a,

9

RED (Logic Power)

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8

Blank Location

7

BLU (Solenoid Coil)

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(') 0 ::I ::I CD

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0 -,

;::s

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.... � (")

� ;::s �

...... :.:i

REDNEL (Aux Power)

Solenoid Coil

-

I I

(")

REVERSE

I

I--------

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0 C

er C"

Reverse Warning

0

&

ca ::I

I

iii'

ca-, 3

I I I I I I I

I I

r----I I

_________ I __,

C

Pedal Switch

I I I

ITS

I

I

6

I YEL (Key Switch)

5

GRN (Pedal Switch)

4

ORN (Reverse)

3

GRN/BLK (Rev. Alarm)

2

BLK (ITS Input)

I I

I I

I I

If vehicle does not have walk away feature or operates after approximately 10 second delay, replace the diode/resistor module at the solenoid Test using the following sequence: Attach VOM negative(·) probe to battery BL- for the following tests 1) At Controller B+ check for ref. battery voltage 2) At Pin 10 Ref. Battery voltage - If not check wiring and Run-Tow/Maintenance switch 3) At Pin 9 4) At Pin 5

I

Refer to Fig. 8 for wiring connections

·-------· I

1

I

WHT (ITS Output)

5) Pin 7

With key switch on, accelerator pedal up and F or R selected - Ref. Battery voltage - If not check wiring or components

6) Pin 2

14 - 15 voe - If not replace controller

7) Pin 1

.4 - 1.5 voe - If not replace ITS

Solenoid Contactor

;;O��

�M B· B+

Ref. Battery voltage - If not check wiring and Run-Tow/Maintenance switch and interlock switch Depress accelerator pedal - Ref. Battery voltage - If not check wiring and pedal switch Depress the accelerator pedal; - If solenoid clicks go to Pins 1 & 2 - If solenoid does not click go to Pin 7

SEE TECHNICIANS REPAIR AND SERVICE MANUAL FOR WIRING AND COMPONENT TROUBLESHOOTING -0

�

CD

m r­ m

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0

2

en

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E

ELECTRONIC SPEED CONTROL· DCS Checking Voltages on the Ten Pin Controller Connector (See Fig. E-6 "Ten Pin Connector Troubleshooting Diagram" on page E5) (See Fig. E-7 "Checking Voltage on Ten Pin Connector' on page E-6)

A_ WARNING A_ BEFORE SERVICING ANY PART OF THE CONTROLLER, PLACE SWITCH IN THE 'TOW/ MAINTENANCE' POSITION AND REMOVE THE BL+ WIRE FROM THE BATTERY USING AN REMOVE INSULATED WRENCH. THE CONTROLLER ENCLOSURE. RECONNECT BL+ AND WAIT A MINIMUM OF 30 SECONDS BEFORE MOVING SWITCH TO THE 'RUN' POSITION. IF THIS PROCEDURE IS NOT FOLLOWED, WHEN LIFTING THE COVER FROM THE CONTROLLER, THERE IS A RISK OF DAMAGING THE WIRING AND/OR CAUSING IRREPARABLE CONNECTORS DAMAGE TO THE CONTROLLER. CONNECTING THE BL+ WITH THE SWITCH IN THE 'RUN' POSITION WILL CAUSE AN ARC AND COULD CAUSE A BATTERY EXPLOSION.

The VOM shown throughout this section is available through the E-Z-GO Service Parts Department as P/N 27481-G01. Any digital VOM may be used; however, the accuracy, controls, displays and features may vary depending on the make and model. Always follow the meter manufacturer's recommendations and instructions for the use and care of the meter. To perform these test­ ing procedures, the service technician must be compe­ tent in the use of the digital VOM.

causing irreparable damage to the controller. Connecting the BL+ with the switch in the 'RUN' position will cause an arc and could cause a battery explosion.

Access the ten pin connector, be sure the Run - Tow/ Maintenance switch is in 'RUN' and proceed with testing as shown in diagram (Ref. Fig. E-6). Place negative (-) probe of the digital VOM on the battery B-. Place the pos­ itive (+) probe at each specified pin as shown. (Ref. Fig. E-7). To test wiring and components, refer to General Testing Section.

(+) Positive Probe

Fig. E-7 Checking Voltage on Ten Pin C onnector

General Testing Examine all wiring of the controller to assure that all wires are without physical damage or corrosion. Check the routing of all wiring and the tightness of each connec­ tion. Repair or replace any suspect wires or connections.

Testing Control Circuit (See Fig. E-5 "Measuring Battery Voltage" on page E-4)

The following testing should only be performed by a techni­ cian skilled in the use of a digital VOM.

(See Fig. E-8 "Attach Positive Probe to Battery Side of Solenoid" on page E-7)

Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to the Repair and Service Manual, Lifting Procedure in Section 'B' Safety). Test the vehicle stability before proceeding.

To test the control circuit, turn the key switch to the 'ON' position. Set the VOM to voe. Touch the black (-) probe to the negative (-) battery BL- and the red (+) probe to the positive(+) battery BL+.

Before servicing any part of the controller, place switch in the 'tow/maintenance' position and remove the BL+ wire from the battery. Remove the controller enclosure and reconnect battery. Wait 30 seconds before placing switch back into 'run' position. If this procedure is not followed, when lifting the controller enclosure from the controller, there is a risk of damaging the wiring and/or connectors

With the direction selector switch in the 'FORWARD' (F) position, remove the red(+) probe from the positive con­ tact of the battery and relocate it to the battery side of the solenoid(Ref. Fig. E-8). A meter reading of the specified battery reference voltage will indicate that the heavy gauge wire (BL+) and terminations between the battery and solenoid positive(+) terminal are in good condition

Page E-6

Repair and Service Manual

E

ELECTRONIC SPEED CONTROL • DCS Observe the Warning and related text on page E-3.

1. Attach the negative probe to battery terminal BL-. The probe will remain in this location throughout the fol­ lowing tests. (Ref. Fig. E-9)

Fig. E-8 Attach Positive Probe to Battery Side of Solenoid

A

WARNING

A

Negative Probe to BL-

FAILURE TO DISCONNECT BL+ BATTERY WIRE MAY RESULT IN AN ARC AND BATTERY EXPLOSION WHEN CONNECTOR IS SEPARATED.

Disconnect battery BL+ wire and unplug the Run - Tow/ Maintenance switch and perform a continuity test between pins 1 (red) and 2 (red/yellow) and between 3 (red/white) and 4 (orange/red). Replace switch if continu­ ity is not present in the 'RUN' position.

Power to the Controller (See Fig. E-9 "Attach Negative Probe to Battery BL-" on page E-7) (See Fig. E-8 "Attach Positive Probe to Battery Side of Solenoid" on page E-7) (See Fig. E-10 "Attach Positive Probe to Controller Side of Solenoid" on page E-8)

TURN THE KEY SWITCH TO 'ON' AND PLACE DIREC­ TION SELECTOR IN 'F' for this test.

The negative probe will remain attached to the battery BL­ terminal throughout the following tests.

Fig. E-9 Attach Negative Probe to Battery BL-

2. Place the positive probe on the battery side of the solenoid (Ref. Fig. E-8). If the reading is below battery voltage, disconnect the battery at BL+ and check the wire and terminals.

3. Place the positive probe to the controller side of the solenoid (Ref. Fig. E-10). The reading should be 0.1 3.0 volts less than reference battery voltage. If the reading is more than 3.0 volts less than reference bat­ tery voltage, the resistor/diode unit is faulty. Replace

Repair and Service Manual

Page E-7

ELECTRONIC SPEED CONTROL· DCS the resistor/diode unit.

At the ten pin connector on the controller:

If the voltage is the same as reference battery voltage (Ref. Fig. E-10), replace the solenoid.

1. Place the positive probe on the red wire terminal of the ten pin connector. The reading should be battery voltage (Ref. Fig. E-11). If battery voltage is not present, the red wire between the Run - Tow/Main­ tenance switch and the ten pin connector at the controller is faulty.

Reference Battery Voltage Initially Recorded Fig. E-11 Attach Positive Probe to Red Wire at Controller Ten Pin Connector Reference Battery Voltage Replace Solenoid

Fig. E-10 Attach Positive Probe to Controller Side of Solenoid

2. Place positive probe on black wire terminal of the ten pin connector. The reading should be slightly above 14 but less than 16 volts (Ref. Fig. E-12). If the volt­ age is below 14 volts the ITS may be faulty. If the volt­ age is above 16 volts, the controller maybe faulty.

Inductive Throttle Sensor (ITS} Circuit (See Fig. E-11 "Attach Positive Probe to Red Wire at Controller Ten Pin Connector" on page E-8) (See Fig. E-12 "Attach Positive Probe to Black Wire at Controller Ten Pin Connector" on page E-8)

[Ri]@u@

As previously stated the rear wheels of the vehicle must be raised during these tests.

In the following ITS tests, measurements are taken with the accelerator pedal depressed JUST enough to cause the solenoid to click.

The negative probe is still attached to the battery BL- post.

WITH THE KEY SWITCH TO 'ON' AND THE DIREC­ TION SELECTOR IN 'F' continue test.

Observe the Warning and related text on page E-3.

Page E-8

Fig. E-12 Attach Positive Probe to Black Wire at Controller Ten Pin Connector

Repair and Service Manual

E.ZGDii:f:ii1M:I

E

ELECTRONIC SPEED CONTROL • DCS

3. Separate the six pin connector (only four pins are used) between the pedal box and the controller. If the voltage goes to 14-16 volts, the ITS is faulty and must be replaced. If the voltage remains below 14 or above 16 volts, the controller is faulty and must be replaced. See "Replacing the C ontroller".

4. Reconnect the six pin connector.

5. Place the positive probe on the white terminal of the ten pin connector. Depress the pedal slowly. T he reading should be 0.45 - 0.53 volts just as the micro switch is energized (clicks). Depress the accelerator slowly to full pedal. T he reading should move smoothly to above 1.5 volts. If the reading is incorrect, the ITS is faulty and must be replaced. See "Induc­ tive T hrottle Sensor Replacement".

When depressing the accelerator, do so for only as long as required to take the reading.

As previously stated the rear wheels of the vehicle must be raised during these tests.

REPLACING THE CONTROLLER Tool List

Qty. Required

Floor jack..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 3/8" Socket, 3/8" drive ................................................. 1 Ratchet, 3/8" drive ....................................................... 1 Extension, 6", 3/8" drive .............................................. 1 Insulated wrench, 9/16" ............................................... 1 Shop towel .................................................................. 1 Wrench, 1/2" ............................................................... 1 Screwdriver, large ....................................................... 1 Torque wrench, 3/8" drive, in. lbs. ............................... 1

A_ WARNING

A.

TO PREVENT THE POSSIBILITY OF BATTERY EXPLOSION WHEN REMOVING HARDWARE CONTROLLER ENCLOSURE, FROM THE DISCONNECT THE BATTERY BL+ TERMINAL USING AN INSULATED WRENCH. Place the Run - T ow/Maintenance switch in the 'TOW/ MAINTENANCE' position. Using an insulated wrench, remove the BL+ wire from the battery.

A.

WARNING

A.

THE BL+ WIRE MUST BE REMOVED BEFORE DISCHARGING THE CONTROLLER. DISCHARGE THE CONTROLLER BY SHORTING THE B+ AND B- TERMINALS OF THE CONTROLLER WITH A LARGE INSULATED SCREWDRIVER. BE SURE TO HOLD THE INSULATED PORTION OF THE SCREWDRIVER. Note the location of the wiring to the controller before unbolting and removing all wiring. Remove the mounting bolts from the controller, loosen the solenoid mounting bracket and slide the controller out.

Install a new controller in the reverse order of disassem­ bly and tighten the controller mounting bolts and solenoid mount to 108 - 132 in. lbs. torque and the terminal bolts to 11 - 14 ft. lbs. Replace the controller enclosure and tighten the mounting bolts to 108 - 132 in. lbs. torque.

A.

WARNING

A.

RECONNECT BL+ AND WAIT A MINIMUM OF 30 SECONDS BEFORE MOVING THE RUN - TOW/ MAINTENANCE SWITCH TO THE 'RUN' POSITION. CONNECTING THE BL+ WITH THE SWITCH IN THE 'RUN' POSITION WILL CAUSE AN ARC AND COULD CAUSE A BATTERY EXPLOSION.

Torque wrench, 3/8" drive, ft. lbs. ................................ 1 Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to T he Repair and Service Manual, Lifting Procedure in Section 'B' Safety). Test the vehicle stability before proceeding.

E2-l!iDii=t:;i;{•l:I

Reconnect the wiring to the controller and battery. After connecting the battery wiring, wait a minimum of 30 sec­ onds before moving the run - tow/maintenance switch to 'run' position.

Repair and Service Manual

Page E-9

ELECTRONIC SPEED CONTROL • DCS

CAUTION

CAUTION

IF THE WARNING BUZZER BEEPS RAPIDLY AFTER THE 'RUN' POSITION IS SELECTED, DO NOT DEPRESS ACCELERATOR PEDAL. THIS BEEPING INDICATES INCORRECT WIRING. DEPRESSING THE ACCELERATOR WITH INCORRECT WIRING WILL CAUSE IRREPERABLE DAMAGE TO THE CONTROLLER. CHECK THE CONTROLLER WIRING AND CORRECT BEFORE OPERATING THE VEHICLE.

THE 'ITS' ATTACHES TO THE PLASTIC PEDAL BOX WITH TWO PLASTIC STUDS AND TWO SPEED NUTS. BE CAREFUL NOT TO OVERTIGHTEN THE NUTS WHICH COULD STRIP THE PLASTIC STUDS. BE SURE TO TIGHTEN THE NUTS ENOUGH TO PREVENT MOVEMENT OF THE 'ITS'.

INDUCTIVE THROTTLE SENSOR REPLACEMENT (See Fig. E-1 "Pedal Box Assembly" on page E-1) (See Fig. E-13 "ITS and Plunger" on page E-11) (See Fig. E-14 "ITS Adjustment"on page E-12) (See Fig. E-15 "ITS Adjustment (Continued)"on page E-13)

Tool List

Qty. Required

Phillips Screwdriver ..................................................... 1 Wrench, 7/16" .............................................................. 1 Nut driver, 7/1611

•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

1

Drill bit, 17/64" ............................................................. 1 Digital VOM ................................................................. 1 Needle nose pliers....................................................... 1 Observe the Warning and related text on page E-3.

Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to The Operation and Ser­ vice Manual, Lifting Procedure in Section 'B' Safety). Test the vehicle stability before proceeding.

Remove the driver's side rocker panel insert and pull the floormat forward to expose the metal cover to the pedal box. Remove the cover and remove the four screws securing the plastic cover to the pedal box (Ref. Fig. E1 }.

Noting the wiring connections, carefully remove the two wires (black and white) that attach to the ITS and remove the nuts securing the ITS to the plastic pedal box studs.

Page E-10

Install a new ITS being careful to align the ITS and not to over tighten the retaining nuts. Attach the wiring making certain the black and white wires are at the correct con­ nection (Ref. Fig. E-13).

With the accelerator pedal in the full up position, insert a 17/64" drill bit between the plunger and the face of the ITS. The drill bit should be used to verify and adjust the distance between the face of the ITS and the face of the plunger (Ref. Fig. E-14). If the plunger needs adjust­ ment, loosen the lock nut and rotate the plunger until the desired dimension is achieved. Firmly tighten the jam nut.

Set the parking 'PARK' brake. Depress the accelerator pedal until the parking brake releases. The micro switch in the pedal box should activate after the parking brake releases.

If the parking (PARK) brake does not release before the micro switch activates, the brake/cam adjustment should be verified per the instructions in the Brake section of the Repair and Service Manual. If the brake adjustment is correct, the micro switch cam must be adjusted by loos­ ening the setscrew and rotating the cam until the correct adjustment is achieved. Do not allow the setscrew holes to align with the micro switch actuator. Tighten the set­ screw.

Replace the plastic cover and press it firmly into place before tightening the cover screws.

Replace the metal cover, floormat and rocker panel insert.

Repair and Service Manual

E�Gtnifii1t•U•

E

ELECTRONIC SPEED CONTROL • DCS

Parking Brake 'Kick Off' Linkage Micro Switch Adjusting Cam Plunger

'ITS' Connect Black Wire to This Terminal

Six Pin Connector

Fig. E-13 ITS and Plunger

EizGDii:f:iid•]:I

Repair and Service Manual

Page E-11

ELECTRONIC SPEED CONTROL • DCS

0

PEDAL PRE-TRAVEL

PEDAL UP Parking brake 'kick off' linkage releases

'2' \.V

Pedal bracket rest against front of pedal frame opening

Micro Switch disengaged Plunger has not entered 'ITS'

To adjust plunger: - Loosen lock nut - Rotate plunger until desired dimension is achieved - Tighten lock nut

Use 17 /64" drill to measure gap between plunger and 'ITS'

Fig. E-14 ITS Adjustment

Page E-12

Repair and Service Manual

Parking brake must disengage before micro switch is activated See Brake Section of this manual

E---------- E L_E_C _T _R O_ _N _C_ S_ _ E_E_D _ C_ O_ _N _T _R O_L ___ D_C_S---, I P

PEDAL ALL THE WAY DOWN

SOLENOID ACTIVATED

0

0

Pedal bracket rests on rear of pedal frame opening Micro Switch activated Plunger enters 'ITS'

Plunger fully activated To adjust micro switch: - Loosen setscrew - Rotate cam until correct adjustment is achieved - Do not allow setscrew hole to contact micro switch actuator - Tighten setscrew

With pedal all the way down: Plunger should be flush with or extend beyond rear of 'ITS'

Fig. E-15 ITS Adjustment {Continued)

EeGDii:f:;i1M:I

Repair and Service Manual

Page E-13

E1

� ELECTRONIC SPEED CONTROL. DCS

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RED/WHT

Run - Tow/Maintenance Switch

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RED

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Key � Switch

REVERSE

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BLK

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YEL BLU

Solenoid

BLU

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O

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ITS

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1 _Pedal ��x__J

GRN/BLK ..J w 0 �

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BLK

8+11-----+--------------

Fig. E-16 Wiring Diagram

Page E-14

+ I

charger : Recep a I � : � :

RED

YEL

1

I

RED

Direction Selector Switch

RED

I

RED

Repair and Service Manual

FRONT SUSPENSION & STEERING

Section

TABLE OF CONTENTS FOR SECTION 'F' SECTION TITLE

PAGE NO.

FRONT SUSPENSION F-1 Front Shock Absorber Removal ............................................................................................ F - 1 Installation of Shock Absorber ............................................................................................... F - 1 Front Axle Removal ............................................................................................................... F - 1 Front Axle Installation ............................................................................................................ F - 3 Front Spring Removal ........................................................................................................... F - 3 Front Spring Installation ........................................................................................................ F - 3 Tie Rod and Spindle Pin Inspection ...................................................................................... F - 3 Tie Rod Removal ................................................................................................................... F - 3 Tie Rod Installation ................................................................................................................ F - 3 STEERING F-4 Steering Wheel Removal ....................................................................................................... F - 4 Steering Wheel Installation .................................................................................................... F - 4 Steering Removal .................................................................................................................. F - 4 Steering Installation ............................................................................................................... F - 4 Rack Tensioner ..................................................................................................................... F - 6 Steering Shaft Removal ........................................................................................................ F - 6 Steering Shaft Pinion Ball Bearing Removal ......................................................................... F - 6 Steering Shaft Bearing Replacement .................................................................................... F - 6 Rack Removal ....................................................................................................................... F - 6 Rack Ball Joint Removal .......................................................................•............................... F - 6 Rack Ball Joint Installation .................................................................................................... F - 6

MAINTENANCE

F-6 Lubrication ............................................................................................................................. F - 7 Packing and Adjusting Wheel Bearings ................................................................................ F - 7 Bearing Inspection ................................................................................................................. F - 7 Seal Installation ..................................................................................................................... F - 7 Bearing Adjustment ............................................................................................................... F - 7 Wheel Alignment ................................................................................................................... F - 8 Spindle Pin Bearing Inspection/Replacement ....................................................................... F - 9

LIST OF ILLUSTRATIONS Fig. F-1 Fig. F-2 Fig. F-3 Fig. F-4 Fig. F-5 Fig. F-6 Fig. F-7 Fig. F-8 Fig. F-9

E.ZlaDii+:tid•l:I

Suspension Components ................................................................................................... F - 2 Front Axle Alignment.......................................................................................................... F - 3 Tie Rod Removal ............................................................................................................... F - 4 Steering Wheel Removal ................................................................................................... F - 4 Steering Components ........................................................................................................ F - 5 Rack Ball Joint Installation ............................................·..................................................... F - 6 Seal Installation ................................................................................................................. F - 7 Front Spindle and Bearing ................................................................................................. F - 8 Front End Alignment .......................................................................................................... F - 8

Repair and Service Manual

Page F-i

Notes: _________________________________

Page F-ii

Repair and Service Manual

FRONT SUSPENSION & STEERING FRONT SUSPENSION

Socket, 9/16", 1/2" drive .............................................. 1 Pliers ........................................................................... 1

�@u�

In the following text, there are references to removing/install­ ing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in their original posi­ tions unless otherwise specified. Non-specified torque speci­ fications are as shown in the table contained in Section A.

For all front suspension repairs, raise the front end using the procedures described in Section 'B' (Safety) of this manual and support the vehicle frame on jack stands.

A_ WARNING A_

TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LIFTING PROCEDURE IN SECTION B OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF AND BEHIND THE REAR WHEELS. CHECK THE STABILITY OF THE VEHICLE ON THE JACK STANDS BEFORE STARTING ANY REPAIR PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE. Tool List

Section

Qty. Required

Floor jack ..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Wrench, 3/8" ............................................................... 1

Internal snap ring pliers ............................................... 1 External snap ring pliers .............................................. 1 Ball joint separator....................................................... 1 Extension, 1O", 1/2" drive ............................................ 1 Internal puller .............................................................. 1 Straight blade screwdriver ........................................... 1 Phillips screwdriver ...................................................... 1 Thread locking adhesive .......................................... AR

Front Shock Absorber Removal (See Fig. F-1 "Suspension Components" on page F-2)

(Ref. Fig. F-1) Remove the nut from the bottom of the shock absorber (1) at the front axle (2).

Bend the tabs that secure the flexible grass shield (3) to the cowl down and pull the grass shield down to provide access to the top of the shock absorber.

Loosen the nut (4) securing the top of the shock absorber to the vehicle frame and then rotate the shock absorber while holding the nut in place with a wrench.

Remove the shock absorber.

Installation of Shock Absorber (See Fig. F-1 "Suspension Components"on page F-2)

The installation of the shock absorber is the reverse of disassembly, except that the mounting nuts should be tightened until the rubber bushings (5) expand to the diameter of the shock absorber washers (6).

Wrench, 5/8" ............................................................... 1

Front Axle Removal

Wrench, 9/16" ............................................................. 1

(See Fig. F-1 "Suspension Components"on page F-2)

Drift punch ................................................................... 1

Remove the front wheels and then the bottom attach­ ment of the shock absorbers. Remove the cotter pin (7) from the spindle pin (8). Loosen the nut (9) until the threaded end of spindle pin is protected. Tap the nut with a plastic faced hammer to loosen the spindle pin.

Pin punch .................................................................... 1 Ball peen hammer ....................................................... 1 Plastic faced hammer .................................................. 1

�@u�

Ratchet, 1/2" drive ....................................................... 1 Torque wrench, 1/2" drive, ft.lbs. ................................. 1 Impact wrench, 1/2" drive ............................................ 1 Impact Socket, 3/4", 1/2" drive .................................... 1 Socket, 1", 1/2" drive ................................................... 1 Socket, 15/16", 1/2" drive ............................................ 1 Socket, 11/16", 1/2" drive ............................................ 1 Socket, 5/8", 1/2" drive ................................................ 1

E.ZGDiiUilM:•

The thrust washer is located on top of the spindle bushing.

Remove the nut (9) and washer (23) from the spindle pin.

Remove the spindle pin (8), washer (21), thrust washer (10) and spindle sleeve (22) from the spindle and swing it to the side.

Remove the hardware (12) that secures the front of the leaf spring to the front axle.

Repair and Service Manual

Page F-1

FRONT SUSPENSION & STEERING

....

Q)

o E t ell ell ....

LL

a..

LO C\I

Fig. F-1 Suspension Components Page F-2

Repair and Service Manual

C\I

FRONT SUSPENSION & STEERING Front Axle Installation (See Fig. F-1 "Suspension Components" on page F-2)

Front axle installation is in the reverse order of disassem­ bly.

Tighten the spindle pin nut to 40 - 50 ft. lbs torque.

Tighten leaf spring hardware to 35 - 50 ft. lbs torque.

Tighten the shock absorber mounting hardware until the rubber bushings expand to the diameter of the shock absorber washer.

Replace the spindle pin cotter pin with new ones.

Equal Distance

Front Spring Removal (See Fig. F-1 "Suspension Components" on page F-2)

Remove the front wheel on the side of the vehicle that is to have the spring replaced.

Remove the hardware (12) securing the front of the leaf spring to the axle.

2

Pull the top of the floor mat down and locate and remove the hardware (13) securing the rear of the spring to the vehicle frame.

Front Spring Installation

Fig. F-2 Front Axle Alignment

Tie Rod Removal

(See Fig. F-1 "Suspension Components" on page F-2) (See Fig. F-2 "Front Axle Alignmenr' on page F-3)

(See Fig. F-3 "Tie Rod Removal" on page F-4)

Install a new spring by first attaching the front of the spring to the axle with hardware (12) and then installing the rear hardware (13). Tighten the spring hardware to 35 - 50 ft. lbs. torque. (Ref. Fig. F-1)

Remove the cotter pin (1) from the ball joint (2) and remove the castellated nut (3). Insert a ball joint separator between the ball joint and the linkage and separate the ball joint from the linkage at both ends.

O\D@lf�

If a spring is to be replaced, the axle will need to be aligned to the frame. This is NOT a wheel alignment.

If a spring is to be replaced, the front axle must be aligned to the frame. The distance from the rear inner left spring bolt to the front inner right spring bolt must be the same as the distance from the rear inner right spring bolt to the front inner spring bolt of the left spring. (Ref. Fig. F-2)

LJ\D@lf�

'r

Be sure that the new tie rod is adjusted to the same length as the one that has been removed.

If any doubt exist regarding the adjustment of the new tie rod, the vehicle will require a wheel alignment before being returned to service.

Tie Rod Installation

Tie Rod and Spindle Pin Inspection

(See Fig. F-3 "Tie Rod Removal" on page F-4)

Lift the front of the vehicle and support on jack stands as per Section 'B' (Safety).Grasp the tie rod and check for any vertical motion which would indicate a worn condition and require replacement. Grasp the top and bottom of the wheel and use a rocking motion to check for spindle pin movement which indicates a worn condition.

A correctly adjusted tie rod should be installed in the reverse order of disassembly. The castellated nut (3) should be tightened to a minimum of 35 ft. lbs. torque and tightened as required in order to insert a new cotter pin.

Maximum torque is 50 ft. lbs.

E2GDii:f:ii1M:t

Repair and Service Manual

Page F-3

FRONT SUSPENSION & STEERING

�

3/I

�-1

Fig. F-3 Tie Rod Removal

STEERING Steering Wheel Removal (See Fig. F-4 "Steering Wheel Removal" on page F-4)

Remove the two screws (1) that attach the clipboard assembly (2) to the steering wheel (3) and remove the score card holder. Remove the steering wheel nut (4) and remove steering wheel.

Steering Wheel Installation (See Fig. F-4 "Steering Wheel Removal" on page F-4)

With the wheels straight ahead, align the steering wheel (3) on the steering shaft. Tighten the steering wheel nut (4) to 1o - 15 ft. lbs. torque. Tighten the scorecard screws to 6 in. lbs. torque maximum.

Steering Removal (See Fig. F-5 "Steering Components" on page F-5)

Except for major damage to the steering assembly hous­ ing, there is no need to remove the housing from the vehicle to perform repair or component replacement. The only component replacement that would require remov­ ing the housing from the vehicle would be the replace­ ment of the bearing (1) and bushing (22). The bearing and bushing must be pressed out and will require the housing to be removed from the vehicle by removing the steering wheel, four mounting bolts (2) and washers (26) and removing the unit from the underside of the vehicle.

Page F-4

Fig. F-4 Steering Wheel Removal

Steering Installation (See Fig. F-5 "Steering Components" on page F-5)

Tighten mounting bolts (2) to 34 - 42 ft.lbs. torque.

Tighten nut (23) to 70 - 80 ft.lbs. torque. Insert new cotter pin {24).

Repair and Service Manual

FRONT SUSPENSION & STEERING

Front Of Vehicle

20

Fig. F-5 Steering Components

Repair and Service Manual

Page F-5

'" FRONT SUSPENSION & STEERING Rack Tensioner (See Fig. F-5 "Steering Components" on page F-5)

In general, there is no need to remove the rack tensioner unless the rack bellows (3) and or the rack cover (4) have been torn or damaged and there is reason to believe that water or dirt has entered the housing (5). The tensioner can be greased through a right angle grease fitting (6) located on the steering housing directly behind the front shield. The tensioner (8) does need to be removed in order to replace the rack. The rack can be 'pulled' into place by inserting the rack against the steering pinion, loosening the tensioner bolts (7) and rotating the steering wheel. To remove the tensioner, remove the hardware (7), gasket (9) and the cover plate (10) that secures the rack tensioner.

Remove the spring (11) and tensioner.

(See Fig. F-5 "Steering Components" on page F-5)

WARNING

Rack Removal (See Fig. F-5 "Steering Components" on page F-5)

The rack (20) can be removed by removing rack ball joint from the idler and loosening the tensioner bolts (7).

Remove the large clamp (21) that secures the rack bel­ lows (3) to the steering housing (5). The rack and the bel­ lows may be pulled from the steering housing.

Rack Ball Joint Removal (See Fig. F-6 "Rack Ball Joint Installation" on page F-6)

The rack end ball joint (1) can be removed by loosening the jam nut (2) and unthreading the ball joint.

Steering Shaft Removal

A

vehicle. If in the unlikely event that it should require replacement, a competent machine shop must remove the bushing without damage to the bore. A new pinion bearing can then be inserted.

Rack Ball Joint Installation

A

TO PREVENT LOSS OF STEERING CONTROL, ALWAYS USE NEW RETAINING RINGS WHEN ASSEMBLING. DO NOT OVERSTRESS RETAINING RINGS DURING INSTALLATION. TEST BY CHECKING FOR ZERO CLEARANCE BETWEEN RETAINING RING AND GROOVE.

(See Fig. F-6 "Rack Ball Joint Installation" on page F-6)

Apply thread locking adhesive to rack ball end before attachment to steering rack. The ball joint (1) and jam nut (2) should be threaded into the rack until the dimension between the end of the rack and the center of the ball joint stud is 14-27/32". Tighten the jam nut to 25 - 30 ft.lbs. torque.

14-27/32"

Remove the steering wheel. Remove the steering col­ umn (12) by removing the three bolts (13) that secure the steering column to the steering housing (5) and remove the column and gasket (14) from the steering shaft (15).

Remove the bolts (25) from the coupling and remove shaft.

Steering Shaft Pinion Ball Bearing Removal (See Fig. F-5 "Steering Components" on page F-5)

Remove the internal snap ring (16) from the steering housing and pull the bearing and pinion as an assembly from the housing.

Steering Shaft Bearing Replacement (See Fig. F-5 "Steering Components" on page F-5)

The steering pinion bearing (17) can be removed from the pinion gear by removing the external snap ring (18) and pressing the bearing from the shaft. The steering pinion gear bushing (19) is designed to last the life of the Page F-6

•I

Fig. F-6 Rack Ball Joint Installation

MAINTENANCE Good routine maintenance of the front suspension and steering consists of routine lubrication (See Lubrication Chart and the Periodic Service Schedule in Section 'A').

Be sure to use only the recommended lubricants. Main­ tain the correct adjustment of the front bearings and repack them in accordance with the periodic mainte­ nance schedule or if a bearing replacement is required.

Routine examination of the tires will provide indications that an alignment is required.

Repair and Service Manual

FRONT SUSPENSION & STEERING Lubrication

Routinely grease the rack tensioner (8), the idler bushing (22} all ball joints (Ref. Fig. F-5), and spindle pin bush­ ings (20) (Ref. Fig. F-1).

it. If any movement is detected the wheel bearing may require replacement/adjustment. Remove the dust cap (14), cotter pin (15) and castellated nut (16) and remove the hub assembly (17). Remove the inner bearing (18) and seal (19) by tapping out the bearing using a soft non ferrous punch and tapping lightly around the bearing.

Clean all bearings, seal, hub and dust cap in solvent and dry thoroughly. Inspect for signs of damage. Pitting or a blue coloration of the rollers will require replacement of the bearing. If the roller portion of the bearing is to be replaced, the race must also be replaced. T he old race may be tapped out of the hub using a punch inserted through the bore. Tap the punch in a circular pattern to avoid damaging the bore of the hub. Install a new bearing after packing the bearing.

Packing and Adjusting Wheel Bearings

Seal Installation

(See Fig. F-8 "Front Spindle and Bearing" on page F-8)

(See Fig. F-7 "Seal Installation" on page F-8)

T he front wheel bearings are tapered roller type and must be packed with grease at installation, or any time that the bearing is removed for inspection. It is recom­ mended that a bearing packer attached to a grease gun be used; however, manual packing is acceptable if done correctly. To pack a bearing manually requires that a dab of grease be placed in the palm of the hand and the bear­ ing be dipped in the grease. Force the grease up through and around all of the rollers until the entire bearing is coated in grease. Fill the area between the rollers with grease and apply a light coating to the bearing race.

Install and adjust the bearing.

Clean the hub seal surface to remove grease and press the seal into place with the flange side of the seal facing into the bore. Tap gently into place with a seal installation tool until it is flush with the outside of the hub assembly.

Lubricate the seal surface with a light oil.

(See Fig. F-1 "Suspension Components" on page F-2) (See Fig. F-5 "Steering Components" on page F-5)

Tool List

Qty. Required

Floor jack..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Grease gun ................................................................. 1 Bearing packer ............................................................ 1

Bearing Inspection (See Fig. F-1 "Suspension Components" on page F-2)

Tool List

Qty. Required

Floor jack..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Bearing packer ............................................................ 1 Grease gun ................................................................ 1 Wrench, 1 1/2" ............................................................ 1 Needle nose pliers ...................................................... 1 Non ferrous punch ....................................................... 1 Ball peen hammer ....................................................... 1 Socket, 3/4", 1/2" drive ................................................ 1 Extension, 6", 1/2" drive .............................................. 1 Lift the front of the vehicle and support on jack stands as per Section 'B' (Safety). Rotate the front wheel and feel for any roughness. Grasp the outside of the tire and rock

E�GiEliu;; i1M:I

Bearing Adjustment (See Fig. F-8 "Front Spindle and Bearing" on page F-8)

Rotate the wheel while tightening the castellated nut (1).

T ighten until the wheel becomes noticeably resistant to being rotated.

Rotate the wheel 2 - 3 more turns to displace excess grease. If the cotter pin hole in the spindle (2) aligns with a slot in the castellated nut (1), insert a new cotter pin (3).

If the hole does not align, the castellated nut must be loosened to align with the closest available slot in the nut.

Check for smooth rotation of the wheel and an absence of play when the wheel is grasped by the outside of the tire. Bend the cotter pin (3) against the flats of the castel­ lated nut (1) and cut off any excess.

Replace the dust cap (4).

Wheel Alignment (See Fig. F-2 "Front Axle Alignment" on page F-3) (See Fig. F-9 "Front End Alignment" on page F-8)

Tool List

Qty. Required

Floor jack ..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Wrench, 1 1/2" ............................................................. 1

Repair and Service Manual

Page F-7

FRONT SUSPENSION & STEERING

Rear 4

\

3

1

I

I

I

I

A

�I

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A - Install This Side of Seal into Housing B - Lubricate Seal Surface

Fig. F-9 Front End Alignment

Fig. F-7 Seal Installation

Rotate each wheel and scribe or chalk a line around the circumference of the tire at the center of the tread pat­ tern. Lower the vehicle and roll it forward approximately five feet in order to allow the tires to take their normal running position.

Measure the distance between the chalk lines at both the front and rear of the tires. The measurement taken at the front of the tire should be 1/4" ± 1/8" less than the rear.

Manufacturing tolerances may cause some variance, however typical dimensions would be 33 1/2" front and 33-3/4" rear.

2

cSJ?i Chalk ........................................................................... 1

To adjust the wheel alignment first turn the steering wheel to the left until it stops. Look at the drivers side spindle arm (1) and see if it is touching the 'U' shaped bracket at the front axle. If not. adjust the driver's side tie rod (2). Loosen the tie rod jam nuts (3) and adjust the driver's side tie rod (2) until the spindle arm contacts the 'U' bracket with the steering wheel turned fully to the left.

Lock the tie rod jam nuts (25 - 30 ft. lbs. torque). Turn the wheel all the way to the right and confirm that the pas­ senger side spindle arm is touching the 'U' shaped bracket at the front axle.

Lift the front of the vehicle and support on jack stands as per Section 'B' (Safety). Confirm the alignment of the springs as shown in "Front Spring Installation".

Center the steering wheel and adjust the passenger side tie rod (4) until the correct alignment is achieved. Lock the tie rod jam nuts (25 - 30 ft. lbs. torque).

Fig. F-8 Front Spindle and Bearing

Tape measure .............................................................. 1

Test drive the vehicle and confirm that the steering wheel is correctly centered. If not remove steering wheel and rotate it to the correct position.

Page F-8

Repair and Service Manual

E�GDU:f:fot•m

FRONT SUSPENSION & STEERING Spindle Pin Bearing Inspection/Replacement (See Fig. F-1 "Suspension Components" on page F-2)

Qty. Required

Tool List

Floor jack..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks.............................................................. 4 Pliers ........................................................................... 1 Wrench, 15/16" ........................................................... 1 Sizing reamer, 7/8" ...................................................... 1 Socket, 15/16", 1 /2" drive ............................................ 1 Torque wrench, ft. lbs., 1 /2" drive ................................ 1 Inside micrometer, 1" .................................................. 1 Remove the spindle assembly and clean the spindle pin bushings with solvent. If the inside diameter of the bush­ ings are worn to .880" or greater, the bushings should be replaced. Press out the old bushings and press new ones into the spindle until flush with the spindle housing.

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As a result of the press operation, the bushing inside diame­ ter may close slightly. If a reaming operation is required, use an 7/8" diameter sizing reamer to correctly size the new bushings.

Reinstall the spindle and tighten the spindle pin nut to 40 ft. lbs. torque. If a cotter pin cannot be aligned with the nut and the king pin, continue tightening the nut until a cotter pin can be inserted.

Repair and Service Manual

Page F-9

FRONT SUSPENSION & STEERING

Notes: ___________________________

Page F-10

Repair and Service Manual

ELECTRONIC SPEED CONTROL

Section

TABLE OF CONTENTS FOR SECTION 'G' SECTION TITLE

PAGE NO.

GENERAL G-1 Pedal Box ............................................................................................................................. G - 1 Controller .............................................................................................................................. G - 1 TROUBLESHOOTING G-1 Symptoms ............................................................................................................................ G - 2 Testing .................................................................................................................................. G - 2 Continuity Checks ................................................................................................................ G - 2 Testing a Switch for Continuity ............................................................................................. G - 2 Testing a Solenoid for Continuity ......................................................................................... G - 2 Testing the Inductive Throttle Sensor (ITS) and Controller .................................................. G - 4 Battery Reference Voltage ................................................................................................... G - 4 Power to the Controller ......................................................................................................... G - 5 Inductive Throttle Sensor (ITS) Circuit ................................................................................. G - 6 Checking Controller Output .................................................................................................. G - 8 SIMPLIFIED TESTING SEQUENCE

G-9

INDUCTIVE THROTTLE SENSOR REPLACEMENT

G-9

REPLACING THE CONTROLLER

G - 13

LIST OF ILLUSTRATIONS Fig. G-1 Pedal Box Assembly ........................................................................................................ G - 1 Fig. G-2 Controller and Four Pin Connector................................................................................... G - 1 Fig. G-3 Continuity Check of Switch............................................................................................... G - 3 Fig. G-4 Continuity Check of Solenoid ........................................................................................... G - 3 Fig. G-5 Insulated Wrench ............................................................................................................. G - 3 Fig. G-6 Negative Probe to Battery BL- ......................................................................................... G - 4 Fig. G-7 Positive Probe to Battery B+ ............................................................................................ G - 5 Fig. G-8 Positive Probe to Battery Side of Solenoid ...................................................................... G - 5 Fig. G-9 Positive Probe to Controller Side of Solenoid .................................................................. G - 6 Fig. G-10 Installing Jumper Wire .................................................................................................... G - 6 Fig. G-11 Positive Probe to Red Wire at Six Pin Connector .......................................................... G - 6 Fig. G-12 Positive Probe to Black Wire at Six Pin Connector ........................................................ G - 7 Fig. G-13 Checking Black Wire with Four Pin Connector Separated ............................................. G - 7 Fig. G-14 Positive Probe to White Wire at Six Pin Connector........................................................ G - 8 Fig. G-15 Positive Probe to Controller M- & B+ ............................................................................. G - 8 Fig. G-16 ITS and Plunger ............................................................................................................. G - 9 Fig. G-17 ITS Adjustment............................................................................................................. G - 11 Fig. G-18 ITS Adjustment (Continued) ......................................:.................................................. G - 12 Fig. G-19 Simplified Testing Procedure Page 1 ........................................................................... G - 14 Fig. G-20 Simplified Testing Procedure Page 2 ........................................................................... G - 15 Fig. G-21 Wiring Diagram............................................................................................................. G - 16

Repair and Service Manual

Page G-i

ELECTRONIC SPEED CONTROL Notes: ___________________________

Page G-ii

Repair and Service Manual

E�laDii:f:Jid•l:I

Section

ELECTRONIC SPEED CONTROL GENERAL The Electronic Speed Control system consists of two separate units.

Pedal Box (See Fig. G-1 "Pedal Box Assembly" on page G-1)

The Pedal Box assembly is a modularized unit that con­ tains the accelerator pedal, return spring and an enclosed box that contains the pedal position micro switch and a solid state Inductive Throttle Sensor (ITS) that is activated by a moving plunger attached to the accelerator pedal. The ITS and plunger are accessed by removing a panel located under the floor mat directly behind the accelerator pedal.

Controller Enclosure Fig. G-2 Controller and Four Pin Connector

The ITS unit and the Controller are both solid state units that contain no user serviceable parts. The testing proce­ dures are designed to test the basic functionality of the Power and Control wiring systems. Once the functionality of the wiring has been confirmed, the remaining tests are used to identify which of the components (Controller or ITS) must be replaced.

TROUBLESHOOTING Tool List

Fig. G-1 Pedal Box Assembly

Controller (See Fig. G-2 "Controller and Four Pin Connector" on page G-1)

The Controller Enclosure contains a solid state speed controller and solenoid to activate the unit. The controller unit is located under the seat and is contained in a pro­ tective environmental enclosure.

The pedal box and controller are connected by a four pin connector that is located within the battery compartment.

The controller is wired to the batteries and develops a regulated power supply for the ITS. The plunger position relative to the ITS varies the voltage which is fed back to the controller which interprets the change in voltage and supplies the appropriate power to the motor.

E�GDii:f:Ust•W

Qty. Required

Floor jack ..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Jumper wire (with alligator clips) ................................. 1 Digital VOM ....................: ............................................ 1 3/8" Socket, 3/8" drive ................................................. 1 Ratchet, 3/8" drive ....................................................... 1 Torque wrench, in. lbs., 3/8" drive ................................ 1 Torque wrench, ft. lbs., 3/8" drive ................................ 1 Extension, 6", 3/8" drive .............................................. 1 Insulated wrench, 9/16" ............................................... 1 Wrench, 1/211 1 Wrench, 7/16" .............................................................. 1 Phillips screwdriver (large) .......................................... 1 Phillips screwdriver (small) .......................................... 1 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

Shop towel ................................................................... 1 Allen wrench, .050" ..................................................... 1

Repair and Service Manual

Page G-1

ELECTRONIC SPEED CONTROL Symptoms If the vehicle does not operate or operates poorly or intermittently, proceed to the following procedure:

pedal micro switch, neutral micro switch (direction selec­ tor switch), solenoid, key switch and four pin connector should be checked for continuity.

Testing

Continuity Checks

It is unlikely that the mechanical adjustment of the throttle box has changed, therefore the initial tests will be con­ ducted with a digital VOM to identify the failed compo­ nent.

The VOM shown is available through the E-Z-GO Service Parts Department as P/N 27481-G01. Any digital VOM may be used; however, the accuracy, controls, displays and features may vary depending on the make and model. Always follow the meter manufacturer's recom­ mendations and instructions for the use and care of the meter.

To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage.

A_ WARNING A_ TO PREVENT UNEXPECTED MOVEMENT OF THE VEHICLE, ALWAYS RAISE THE REAR WHEELS BEFORE CONDUCTING ANY TESTS. NEVER OPERATE VEHICLE AT FULL THROTTLE FOR MORE THE 4 TO 5 SECONDS WHILE VEHICLE IS IN A "NO-LOAD" CONDITION.

Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to The Operation and Ser­ vice Manual, Lifting Procedure in Section 'B' Safety). Test the vehicle stability before proceeding.

Remove the seat.

Place the direction selector in 'F' and turn the key switch to 'ON'. Depress the accelerator pedal until the micro switch in the pedal box activates which should cause the solenoid contained in the environmental enclosure on the passenger side of the vehicle to make an audible click.

It is important to determine the condition of the battery set before proceeding with any electrical troubleshooting.

An open voltage test is of little use since a battery that has deteriorated to the point of requiring replacement can still show six volts or higher in an open voltage test. If there is any doubt as to the adequacy of the battery set, charge the batteries and perform a load test using a dis­ charge machine. If the solenoid does not function, the Page G-2

A_ WARNING A_ BEFORE ATTEMPTING TO PERFORM A CONTINUITY CHECK TURN THE KEY SWITCH TO 'OFF' AND PLACE THE DIRECTION SELECTOR IN NEUTRAL. USING AN INSULATED WRENCH, REMOVE THE BL+ WIRE FROM THE BATTERY. CONTINUITY CHECKS MUST BE PERFORMED WITH THE POWER OFF.

Turn the key switch to 'OFF' and place the direction selector in neutral before disconnecting power by remov­ ing the BL+ connection to the battery. Always use insu­ lated wrenches when working on batteries. To check for continuity, set the VOM to the Kn setting and select 'Con­ tinuity' (See Fig. G-3). The meter will give an audible sig­ nal when it detects continuity. If the meter does not have a continuity setting, set it to Kn, the meter will indicate 0.00 when it detects continuity.

Testing a Switch for Continuity (See Fig. G-3 "Continuity Check of Switch" on page G-3)

Place one probe on one contact of the switch, place the second probe on the second terminal of the switch. Actu­ ating a normally open (NO) switch will cause the recom­ mended meter to show 0.00 or give an audible indication when the switch is operated. A normally closed (NC) switch will cause the meter to show o.oo or give an audi­ ble indication when the probes are attached. The audible indicator will stop and the meter display will indicate a value greater than O when the ·switch is activated.

The change in display or audible indicator demonstrates that the switch is functioning.

Testing a Solenoid for Continuity (See Fig. G-4 "Continuity Check of Solenoid" on page G-3)

Place one probe on one of the large terminals and the other probe on the second large terminal. If the meter shows 0.00 or gives an audible indication, the solenoid terminals are "welded" closed and the solenoid must be replaced.

If the continuity test indicates that the contacts are · not ''welded" and the wiring to the solenoid coil is good, the coil has failed and the solenoid must be replaced.

Repair and Service Manual

E.ZlaDiit:tid•]:I

ELECTRONIC SPEED CONTROL

Oillllii'NUnY

DD

(+) Probe

Press to Activate Switch

Fig. G-4 Continuity Check of Solenoid

Fig. G-3 Continuity Check of Switch

EiZISCJii:f:tid•l:I

Repair and Service Manual

Fig. G-5 Insulated Wrench

Page G-3

ELECTRONIC SPEED CONTROL Testing the Inductive Throttle Sensor (ITS) and Controller (See Fig. G-5 ulnsulated Wrench" on page G-3)

_A WARNING _A TO PREVENT THE POSSIBILITY OF BATTERY REMOVING/INSTALLING WHEN EXPLOSION HARDWARE FROM THE ENVIRONMENTAL COVER, DISCONNECT THE BATTERY BL+ TERMINAL USING AN INSULATED WRENCH.

Oiliilii'NUITY

Ill

COVER THE DIRECTION SELECTOR SWITCH WITH A SHOP TOWEL Using an insulated wrench, remove the BL+ wire from the battery and cover the direction selector switch with a shop towel.

Remove the four bolts that secure the environmental cover to the controller heatsink and remove the cover.

Inspect all connections to the controller to determine if the connections are clean and tight.

Battery Reference Voltage (See Fig. G-6 uNegative Probe to Battery BL-" on page G-4) (See Fig. G-7 uPositive Probe to Battery B+" on page G-5)

TURN THE KEY SWITCH TO 'OFF' for this test.

1. Using the insulated wrench, attach the BL+ wire to the battery. Using a digital VOM, select an appropri­ ate DC voltage range greater than 37 volts. Attach the negative probe to the BL- battery post. (Ref. Fig. G-6)

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The negative probe will remain attached to the battery BL­ post throughout the following tests.

2. Place the positive probe to the BL+ battery post and note the reading. This reading is considered as 'Bat­ tery Voltage'. (Ref. Fig. G-7) Page G-4

Fig. G-6 Negative Probe to Battery BL-

Repair and Service Manual

E.ZlaDii=F:;it{•l:I

ELECTRONIC SPEED CONTROL Power to the Controller (See Fig. G-8 "Positive Probe to Battery Side of Solenoid" on page G-5) (See Fig. G-9 "Positive Probe to Controller Side of Solenoid" on page G-6)

TURN THE KEY SWITCH TO 'ON' AND PLACE DIREC­ TION SELECTOR IN 'F' for this test.

Reference Battery Voltage

O

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NUITY

1. Place the positive probe on the battery side of the solenoid (Ref. Fig. G-8). If the reading is below refer­ ence battery voltage, disconnect the battery at BL+ and check the wiring and terminals.

Ill

Positive Probe To BL+ Negative Probe To BL-

Reference Battery Voltage Replace Solenoid

Fig. G-8 Positive Probe to Battery Side of Solenoid

2. Place the positive probe to the controller side of the solenoid (Ref. Fig. G-9). The reading should be 0.1 3.0 volts less than battery voltage. If the reading is more than 3.0 volts less than battery voltage, the 2500 resistor is faulty. Replace the resistor.

Fig. G-7 Positive Probe to Battery B+

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If the voltage is the same as battery voltage (Ref. Fig. G-9), replace the solenoid.

Repair and Service Manual

Page G-5

ELECTRONIC SPEED CONTROL

Jumper Wire

Fig. G-10 Installing Jumper Wire Fig. G-9 Positive Probe to Controller Side of Solenoid

Inductive Throttle Sensor (ITS) Circuit (See Fig. G-10 "Installing Jumper Wire" on page G-6)

At the six pin connector on the controller: 1. Place the positive probe on the red wire terminal of the six pin connector. T he reading should be battery voltage (Ref. Fig. G-11). If battery voltage is not present, the red wire between the solenoid and the six pin connector at the controller is faulty.

(See Fig. G-11 "Positive Probe to Red Wire at Six Pin Connector' on page G-6) (See Fig. G-12 "Positive Probe to Black Wire at Six Pin Connector" on page G-7) (See Fig. G-13 "Checking Black Wire with Four Pin Connector Sepa­ rated" on page G-7) (See Fig. G-14 "Positive Probe to White Wire at Six Pin Connector" on page G-8)

Reference Battery Voltage

(+) Positive Probe

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As previously stated the rear wheels of the vehicle must be raised during these tests.

In the following ITS tests measurements are taken with the accelerator pedal depressed JUST enough to cause the solenoid to click.

WITH THE KEY SWITCH TO 'ON' AND THE DIREC­ TION SELECTOR IN 'F' continue test.

To energize the controller, install a jumper between the battery BL+ terminal and the solenoid terminal with the red wires attached (Ref. Fig. G-10).

Page G-6

Fig. G-11 Positive Probe to Red Wire at Six Pin Connector

Repair and Service Manual

EeGDii:f:iit{•J:I

ELECTRONIC SPEED CONTROL 2. Place the positive probe on the black wire terminal of the six pin connector. The reading should be slightly above 14 but less than 15 volts (Ref. Fig. G-12). If the voltage is below 14 or above 15 volts the ITS may be faulty.

Four Pin Connector

(+) Positive Probe

(+) Positive Probe Replace ITS

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Less than 14.0 volts Replace Controller

Fig. G-13 Checking Black Wire with Four Pin Connector Separated Fig. G-12 Positive Probe to Black Wire at Six Pin Connector

3. Separate the four pin connector between the pedal box and the controller that is located in passenger side of the battery compartment. If the voltage goes to 14 volts, the ITS is faulty and must be replaced.

If the voltage remains below 14 volts, the controller is faulty and must be replaced.

E�GDli:f:ii1M:i

4. Reconnect the four pin connector.

5. Place the positive probe on the white terminal of the controller side connector. Depress the pedal slowly.

The reading should be 0.45 - 0.53 volts just as the micro switch is energized (clicks). Depress the accel­ erator slowly to full pedal. The reading should move smoothly to above 1.5 volts (Ref. Fig. G-14). If the reading is incorrect the ITS is faulty and must be replaced.

Repair and Service Manual

Page G-7

ELECTRONIC SPEED CONTROL Checking Controller Output

U\D@u�

When depressing the accelerator, do so for only as long as required to take the reading.

As previously stated the rear wheels of the vehicle must be raised during these tests.

(See Fig. G-15 "Positive Probe to Controller M- & B+" on page G-8)

1. Move the negative probe to the M- terminal.

2. Place the positive probe on the B+ terminal of the controller (Ref. Fig. G-15), the meter reading should indicate approximately o volts.

(-) Negative Probe (+) Positive Probe

I

v [1_[1[1 l

/) a.a1v / �

J..)

I

D.DDv

to

Greater Than

Accelerator Pedal

Pedal fully depressed Accelerator Pedal

D. 01

V

to Pedal fully depressed

Fig. G-14 Positive Probe to White Wire at Six Pin Connector 6. Remove the jumper wire.

Page G-8

Fig. G-15 Positive Probe to Controller M- & B+

Repair and Service Manual

ELECTRONIC SPEED CONTROL 3. Move the direction selector to forward. The reading should be O volts. Slowly depress the accelerator pedal. The reading should show the voltage increas­ ing to battery voltage when the pedal is fully depressed.

4. If the voltage is at or near battery voltage and the motor is not turning, the problem is in the direction selector switch, the wiring or the motor. If the volt­ age increases by a few volts and then stops changing while the pedal is still being depressed, remove the orange wire at the reverse micro switch. If the voltage is not at or near battery voltage, replace the control­ ler.

Manual, Lifting Procedure in Section 'B' Safety). Test the vehicle stability before proceeding.

Remove the driver's side rocker panel insert and pull the floormat forward to expose the metal cover to the pedal box. Remove the cover and remove the four screws securing the plastic cover to the pedal box (Ref. Fig. G1). Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the plastic pedal box studs.

5. If battery voltage is indicated, the problem is with the reverse circuit.

6. Replace the orange wire to the reverse micro switch.

�

Remove test leads, install connectors and replace the environmental cover, tightening the bolts to 108 - 132 in. lbs.

,,-,

(See Fig. G-1 "Pedal Box Assembly" on page G-1) (See Fig. G-16 "ITS and Plunger" on page G-9) (See Fig. G-17 "ITS Adjustmenf' on page G-11) (See Fig. G-18 "ITS Adjustment (Continued)" on page G-12)

Tool List

Qty. Required

Phillips screwdriver ..................................................... 1 Wrench, 7/16" ............................................................. 1 Nut driver, 7/16" .......................................................... 1 Drill bit, 17/64" ............................................................. 1 Digital VOM ................................................................. 1 Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to The Repair and Service

EazlaDii=F:tid•l�I

Lock Nut

Micro Switch

,��

At the end of this section is a 'Simplified Testing Sequence'. It is important to realize that this should only be used as a check list and not a substitute for the procedures listed elsewhere in this section.

INDUCTIVE THROTTLE SENSOR REPLACEMENT

I

Micro Switch '------.."'

Adjusting Cam � Plunger 'ITS'

SIMPLIFIED TESTING SEQUENCE

It is vital to the safety of the technician and any other per­ sons that all warnings and safety procedures be followed by the technician using the simplified test sequence.

I,

4 Pin Connector

Fig. G-16 ITS and Plunger

Install a new ITS being careful to align the ITS and not to over tighten the retaining nuts. Attach the wiring.

CAUTION THE 'ITS' ATTACHES TO THE PLASTIC PEDAL BOX WITH TWO PLASTIC STUDS AND TWO SPEED NUTS. BE CAREFUL NOT TO OVERTIGHTEN THE NUTS WHICH COULD STRIP THE PLASTIC STUDS. BE SURE TO TIGHTEN THE NUTS ENOUGH TO PREVENT MOVEMENT OF THE 'ITS'.

With the accelerator pedal in the full up position, insert a 17/64" drill bit between the plunger and the face of the ITS. The drill bit should be used to verify and adjust the distance between the face of the ITS and the face of the plunger (Ref. Fig. G-17). If the plunger needs adjust­ ment, loosen the lock nut and rotate the plunger until the desired dimension is achieved. Firmly tighten the jam nut.

Repair and Service Manual

Page G-9

ELECTRONIC SPEED CONTROL Set the parking 'PARK' brake. With the VOM set to volts, probe the white wire at the ITS with the positive probe and attach the negative probe to the battery BL-. Place the direction selector in 'F' and turn the key switch to 'ON'. Depress the accelerator pedal until the parking brake releases. The micro switch in the pedal box should activate after the parking brake releases. The meter should read 0.00 until the brake releases and the micro switch is activated. The meter should read 0.45 - 0.53 through 1.5 volts at full pedal (Ref. Fig. G-18). If the read­ ing is out of specification, the ITS sensor must be replaced.

Page G-10

If the parking (PARK) brake does not release before the micro switch activates, the brake/cam adjustment should be verified per the instructions in the Brake section of the Repair & Service Manual. If the brake adjustment is cor­ rect, the micro switch cam must be adjusted by loosening the set screw and rotating the cam until the correct adjustment is achieved. Do not allow the set screw holes to align with the micro switch actuator. Tighten the set screw.

Replace the plastic cover and press it firmly into place before tightening the cover screws.

Replace the metal cover, floormat and rocker panel insert.

Repair and Service Manual

EaEiDii=F:tid•l:I

ELECTRONIC SPEED CONTROL

0

PEDAL UP

PEDAL PRE-TRAVEL Parking brake 'kick off' linkage releases

�

\..::..J

Pedal bracket rest against front of pedal frame opening

Lock Nut Micro Switch disengaged Plunger has not entered 'ITS'

To adjust plunger: - Loosen lock nut - Rotate plunger until desired dimension is achieved - Tighten lock nut

Parking brake must disengage before micro switch is activated See Brake Section of this manual

Use 17 /64" drill to measure gap between plunger and 'ITS'

Fig. G-17 ITS Adjustment

E.ZGDiiUi;M�i

Repair and Service Manual

Page G-11

ELECTRONIC SPEED CONTROL

PEDAL ALL THE WAY DOWN

SOLENOID ACTIVATED

0

0

Pedal bracket rests on rear of pedal frame opening Micro Switch activated Plunger enters 'ITS'

Plunger fully activated To adjust micro switch: - Loosen setscrew - Rotate cam until correct adjustment is achieved - Do not allow setscrew hole to contact micro switch actuator - Tighten setscrew

I'I" .

JW

Fig. G-18 ITS Adjustment (Continued)

Page G-12

Repair and Service Manual

With pedal 1311 the way down: Plunger should be flush with or extend beyond rear of 'ITS'

ELECTRONIC SPEED CONTROL REPLACING THE CONTROLLER Tool List

Qty. Required Floor jack ..................................................................... 1 Jack stands ................................................................. 2 Chocks ........................................................................ 4

3/8" Socket, 3/8" drive ................................................. 1 Ratchet, 3/8" drive ....................................................... 1 Extension, 611 3/8" drive .............................................. 1 Insulated wrench, 9/16" ............................................... 1 Shop towel .................................................................. 1 Wrench, 1/2" ............................................................... 1 Straight blade screwdriver ........................................... 1 Torque wrench, 3/8" drive, in. lbs. ............................... 1 Torque wrench, 3/8" drive, ft. lbs. ................................ 1 ,

Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to the Repair and Service Manual, Lifting Procedure in Section 'B' Safety). Test the vehicle stability before proceeding.

Using an insulated wrench, remove the BL+ wire from the battery and cover the direction selector switch with a shop towel.

Remove the environmental cover.

Note the location of the wiring to the controller before unbolting and removing all wiring. Remove the mounting bolts from the controller, loosen the solenoid mounting bracket and slide the controller out.

E.Z13Dii:f:tid•J�I

A_ WARNING A_ TO PREVENT THE POSSIBILITY OF BATTERY EXPLOSION WHEN REMOVING HARDWARE ENVIRONMENTAL COVER, THE FROM DISCONNECT THE BATTERY BL+ TERMINAL USING AN INSULATED WRENCH. COVER THE DIRECTION SELECTOR SWITCH WITH A SHOP TOWEL.

A_ WARNING A_ THE BL+ WIRE MUST BE REMOVED BEFORE DISCHARGING THE CONTROLLER. DISCHARGE THE CONTROLLER BY SHORTING THE BL+ AND BL- TERMINALS OF THE CONTROLLER WITH A LARGE SCREWDRIVER. BE SURE TO HOLD THE INSULATED PORTION OF THE SCREWDRIVER.

Install a new controller in the reverse order of disassem­ bly and tighten the controller mounting bolts and solenoid mount to 108 - 132 in. lbs. torque and the terminal bolts to 11 - 14 ft. lbs. Replace the environmental cover and tighten the mounting bolts to 108 - 132 in. lbs. torque.

Repair and Service Manual

Page G-13

ELECTRONIC SPEED CONTROL

SIMPLIFIED TESTING SEQUENCE Page 1 WARNING: ALWAYS RAISE THE REAR WHEELS BEFORE CONDUCTING TESTS This is a simplified check list. be sure to read, understand and follow all safety procedures described in Section 'G' of the O ration and Service Manual

1

d ..

I�-

FWD

O

•

�-

_ 'Yl 0

-

CLICK!

I:)

- I -

i

(1) 0.0 or more than 3.0 volts below battery voltage= Replace resistor (2) Same as battery voltage = Replace solenoid

v 37.�'1 l

Battery Voltage is the actual reading measured between BL- & BL+

Battery Voltage Less 0.1 to 3.0 volts

� � �

(3) Solenoid good but voltage wrong = Replace controller Activate solenoid with jumper wire

Six pin connector

If less than 14 or more than 15 volts separate 4 pin connector & probe BLK again

I

.

Battery Voltage if less than battery voltage check solenoid to controller B+

=I f BLK

n connector

If the voltage changes to 14 15 volts f L/•'1'1 v .

I_

OR

� , �

s � L/.'1'1 v h:� :�1: or � above 15.0 volts go to next step

=

If voltage does not change but remains ___,,ss than 14.0 volts � ...,. �r -,,.., -,-._, , v •'1 , more than 15.0 volts .

Fig. G-19 Simplified Testing Procedure Page 1 Page G-14

Repair and Service Manual

E:ZGDii:f:ii1M:1

ELECTRONIC SPEED CONTROL

Page2

SIMPLIFIED TESTING SEQUENCE

6 �WHT

connector

IJ. LfQv l ro

��CLICK!=

If out of specification

7

POS(+)

IJ.IJ Ovl

8+

Remove jumper

•=r D .DDvl,�- =I

FW�

D.0Dvl�l 311�vl

Not turning Battery Voltage

-

fi�i

��

BatteryVoltage (under load may be less)

��

12 S.1'1'v,.

:::::-- Remove orange wire from reverse micro switch

I 37.��vl=

25.1'1'v Fig. G-20 Simplified Testing Procedure Page 2

E�EiClii:f:tid•l:I

Repair and Service Manual

Page G-15

�

(0 CD

Ignition Interlock

....

,-----, I[:�

I

G)

RED I i +;JI I

CJ)

i

l

'.

WHT

RED

I +\I +\I

I •�I

250.0 5W

J,

BL+

I

\ BLU

I L Ch arger' Receptacle

:��

al

II

I

�:;::i

:;::i

;:s

� � �

CJ')

..... @

�

;:s :::: :;::i .......

m I Iii

I D

Key Switch

BLU

I

BLU

r:::;:,---------1 '.'.'' , '.: � , ,: ; �:�� :� :, , , , , � __-, ,i

<

/;;". ',

WHT

A " ,,

- ' _,' ': ,;,

BLK

,

3

,��,

, I ,� ',, '-� ,,,

·-- �--�-GRN

'

I

RED

'Tl

cp"

C)

�s·- I ....

:e cc

C

Direction Selector Switch

WHT

BLK

RED

ii' cc

; 3

Wires Indicated ---- are Contained in Power Harness All Other Wires are Control Wiring Ms2 is Closed When Direction Selector Switch is in Fwd or Reverse Ms3 is Activated by Accelerator Pedal Ms4 is Closed by Direction Selector Switch in Reverse Only

GRN

m r­ m �

:a 0 2

-n ,,

en m m

Cl

n 0

...

2 :a 0 r-

MOTOR

Section TABLE OF CONTENTS FOR SECTION 'J' SECTION TITLE

PAGE NO.

GENERAL J-1 Motor Removal ...................................................................................................................... J - 1 Motor Disassembly ................................................................................................................ J - 3 Field Coil Replacement ......................................................................................................... J - 3 Brush Replacement............................................................................................................... J - 4 Motor Assembly..................................................................................................................... J - 4 Motor Tests ........................................................................................................................... J - 4 Motor Installation ................................................................................................................... J - 4

LIST OF ILLUSTRATIONS Fig. J-1 Fig. J-2 Fig. J-3 Fig. J-4 Fig. J-5

Removing the Motor ........................................................................................................... J - 2 Motor Components............................................................................................................. J - 3 Removing Armature with Puller.......................................................................................... J - 4 Motor Wiring (DCS Models) ............................................................................................... J - 4 Motor Wiring ....................................................................................................................... J - 4

Repair and Service Manual

Page J-i

Notes: _________________________________

Page J-ii

Repair and Service Manual

Section

MOTOR GENERAL

Tool List

The brush life in the electric motor used in this vehicle is rated at 5,000 hours of continuous use. A conservative estimate of brush life in an average golf course operation would indicate that the motor will not require brush replacement for at least ten years. The brushes are a ser­ rated design which promotes rapid seating and long life.

Disassembly of the motor is not recommended unless the vehicle has reached the 5,000 hour running time or replacement of a worn or noisy bearing is required.

Insulated wrench, 9/16" ............................................... 1

CAUTION

Neither the motor housing or armature are available as service items, therefore in the unlikely event of a failure in either of these components, the entire motor must be replaced.

Motor Removal

A

REMOVE A BATTERY WIRE BEFORE ATTEMPTING TO REMOVE WIRES FROM THE MOTOR (SEE SAFETY PROCEDURES IN SECTION 'B' OF THIS MANUAL). THE SHORTING OF MOTOR WIRES COULD RESULT IN AN EXPLOSION.

Eel!iCI ii:f:;id•l:I

1

Wrench, 7/16".............................................................. 1 Ratchet, 1/4" drive ....................................................... 1 Socket, 1/4", 1/4" drive ................................................ 1 Socket 5/16", 1/4" drive ............................................... 1

Torque wrench, in. lbs. 1/4" drive ................................. 1 Straight blade screwdriver ........................................... 1 Bearing puller .............................................................. 1 Snap ring pliers ........................................................... 1 Plastic faced hammer .................................................. 1 Using an insulated wrench, remove the positive (+) bat­ tery wire from controller at the battery. Remove all wires from the motor.

Mark both the axle and motor housings to permit realign­ ment during assembly of the motor to the rear axle.

(See Fig. J-1 "Removing the Motor" on page J-2)

WARNING

••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

Extension, 3", 1/4" drive .............................................. 1

DO NOT HOLD THE VEHICLE ON AN INCLINE WITH THE ACCELERATOR. THIS WILL RAISE THE BARS COMMUTATOR RESULTING IN UNACCEPTABLE NOISE AND ACCELERATED BRUSH WEAR.

A

Wrench, 1/2 11

Qty. Required

CAUTION

TAKE CARE NOT TO DAMAGE THE SPLINES WHEN REMOVING AND ASSEMBLING THE MOTOR TO THE REAR AXLE HOUSING. Remove the three bolts tbat secure the motor to the axle housing and carefully slide the motor straight out from the axle splines.

Repair and Service Manual

Page J-1

MOTOR

1

;'.rati<-i

Wait 30 Seconds

ICID.:IDI

Cable

3

Remove All Wires

4

Remove Bolts and Washers

Fig. J-1 Removing the Motor

Page J-2

Repair and Service Manual

E�laDii:f:iid•J:I

MOTOR Motor Disassembly (See Fig. J-2 "Motor Components" on page J-3) (See Fig. J-3 "Removing Armature with Puller" on page J-4)

Remove bearing cap (1).

Remove bolts (2) that hold the commutator end cover (3) to the motor housing (4).

Pull on commutator end cover to remove armature (5) and cover (as an assembly) from the housing. A light tap may be necessary to loosen.

To remove armature from commutator end cover and bearing:

Place puller (Ref Fig. J-3) around the commutator end cover using the center in the armature shaft to locate puller.

Pull commutator end cover assembly from armature being careful to maintain equal pressure on all sides of end cover.

To remove bearing:

Remove internal snap ring (8) and press bearing (7) to remove from commutator end cover (3).

Field Coil Replacement To replace field coil (8), remove field coil terminal hard­ ware (9) at S1 and S2.

Remove bolts (10) that secure field coil retainers (11) to motor housing (4). Remove the field coils.

Replacement field coils are installed in reverse order of disassembly.

11

Fig. J-2 Motor Components

EeGCii:f:ji;M:I

Repair and Service Manual

Page J-3

MOTOR Motor Installation (See Fig. J-1 "Removing the Motor" on page J-2) (See Fig. J-4 "Motor Wiring (DCS Models)" on page J-4) (See Fig. J-5 "Motor Wiring" on page J-4)

Be sure that a bumper spline is installed between the motor input pinion shaft and splines. Apply a small quan­ tity of molybdenum grease to the male portion of the spline. Carefully mate the motor spline with the input shaft of the rear axle. Align the orientation marks and install the mounting hardware. Tighten to 168 in. lbs. torque.

Attach the motor wiring per tables below and tighten the terminals to 66 in. lbs. torque.

MOTOR WIRE TERMINALS MARKER

FROM

S1

S1

Direction Selector "B"

Brush Replacement

S2

S2

Direction Selector "D"

Remove brush terminal hardware (12) at A1 and A2.

A1

A1

B+ at Controller

Remove screws (13) securing brush plate (14). Remove brushes, rigging and brush plate.

A2

A2

A2 at Controller

Fig. J-3 Removing Armature with Puller

Pull back each brush until each of the springs (15) rest against the side of its brush. Remove brushes and replace with new brush replacement kit. Locate springs against the side of each brush.

Install terminals and brush plate using reverse order of disassembly. Insert armature (commutator end) through brush plate and press into bearing. Position brushes against commutator and ensure that springs are seated against rear of brush and able to move freely.

Motor Assembly (See Fig. J-2 "Motor Components" on page J-3)

Align the commutator end cover with the holes in the motor housing. Assemble the commutator end cover and motor housing by installing the four long mounting bolts (2) and tighten to 90 in. lbs. torque.

Fig. J-4 Motor Wiring (DCS Models)

MOTOR TERMINAL

WIRE MARKER

S1

S1

Direction Selector "D"

S2

S2

Direction Selector "B"

A1

A1

M - at ESC Controller

A2

A2

Direction Selector "C"

Motor Tests The armature and motor housing are not available as individual parts therefore no testing is recommended to determine the specific area of failure. When a test of the power wiring system indicates that the system is operat­ ing correctly and the vehicle either does not run or runs poorly, the motor is the only remaining component, there­ fore the motor must be replaced.

Page J-4

Repair and Service Manual

FROM

Fig. J-5 Motor Wiring

BATTERIES AND CHARGING

Section

TABLE OF CONTENTS FOR SECTION 'K' SECTION TITLE

PAGE NO.

SAFETY

K- 1

GENERAL

K- 2

MAINTENANCE K- 2 At Each Charging Cycle ........................................................................................................ K - 2 Monthly .................................................................................................................................. K - 2 Electrolyte Level and Water .................................................................................................. K - 2 Cleaning Batteries ................................................................................................................. K -3 Prolonged Storage ................................................................................................................ K - 4 Battery Installation ................................................................................................................. K - 4 Battery Charging ................................................................................................................... K -5 AC Voltage ............................................................................................................................ K - 5 Rotating Vehicles .................................................................................................................. K -5 TROUBLESHOOTING K -5 Hydrometer ............................................................................................................................ K - 6 Using a Hydrometer............................................•.................................................................. K - 6 Charger Installation ............................................................................................................... K - 7

LIST OF ILLUSTRATIONS Fig. K-1 Fig. K-2 Fig. K-3 Fig. K-4 Fig. K-5 Fig. K-6 Fig. K-7 Fig. K-8

E�l3Diif:iit{•l:I

Correct Electrolyte Level.................................................................................................... K - 2 Water Purity Table ............................................................................................................. K - 3 Automatic Watering Gun ................ ,.................................................................................. K - 3 Freezing Point of Electrolyte .............................................................................................. K - 4 Battery Connections .......................................................................................................... K - 5 Hydrometer ........................................................................................................................ K - 6 Battery Maintenance Kit .................................................................................................... K -8 Hydrometer Temperature Correction ................................................................................. K - 9

Repair and Service Manual

Page K-i

BATTERIES AND CHARGING Notes: ____________________________

Page K-ii

Repair and Service Manual

E�l3Dii:f:tid•J�I

Section

BATTERIES AND CHARGING SAFETY •

Batteries contain dilute sulfuric acid which can result in severe burns.

•

Hydrogen gas is formed within a battery during the charging cycle.

•

4% concentrations of hydrogen are explosive and can be ignited by open flame or an electrical spark. A battery explosion will cause sulfuric acid and battery components to be thrown over a large area with considerable force.

Always observe the following warnings when working on or near batteries:

A

WARNING

A

THE ELECTROLYTE IN A STORAGE BATTERY IS A DILUTE ACID WHICH CAN CAUSE SEVERE BURNS TO THE SKIN AND EYES. ALWAYS WEAR A SAFETY SHIELD OR APPROVED SAFETY GOGGLES WHEN ADDING WATER OR CHARGING BATTERIES.

A

WARNING

A

BE SURE THE KEY SWITCH IS OFF AND ALL ELECTRICAL ACCESSORIES ARE TURNED OFF BEFORE STARTING WORK ON VEHICLE. NEVER DISCONNECT A CIRCUIT UNDER LOAD AT A BATTERY TERMINAL. REMOVE ALL JEWELRY (WATCHES, RINGS, ETC.).

WRAP WRENCHES WITH VINYL TAPE TO

PREVENT THE POSSIBILITY OF A DROPPED WRENCH FROM 'SHORTING OUT' A BATTERY WHICH COULD RESULT IN AN EXPLOSION AND SEVERE PERSONAL INJURY.

WEAR APPROPRIATE O.S.H.A. PROTECTIVE CLOTHING WHEN WORKING WITH BATTERIES. ELECTROLYTE CAN CAUSE SEVERE BURNS TO THE EYES, SKIN AND CLOTHING. BATTERIES ARE HEAVY. USE PROPER LIFTING TECHNIQUES WHEN MOVING THEM. ALWAYS LIFT THE BATTERY WITH A COMMERCIALLY AVAILABLE BATTERY LIFTING DEVICE.

TREAT ALL ELECTROLYTE SPILLS TO THE BODY AND EYES WITH EXTENDED FLUSHING WITH CLEAR WATER. CONTACT A PHYSICIAN IMMEDIATELY. HYDROGEN GAS IS FORMED WHEN CHARGING BATTERIES. DO NOT CHARGE BATTERIES WITHOUT ADEQUATE VENTILATION. 4% CONCENTRATIONS OF HYDROGEN ARE EXPLOSIVE. NEVER SMOKE AROUND BATTERIES. NEVER CHARGE BATTERIES IN AN AREA THAT HAS OPEN FLAME OR ELECTRICAL EQUIPMENT THAT COULD CAUSE AN ELECTRICAL ARC.

Eml!iCJii:f:tid•l:I

USE CARE NOT TO TIP BATTERIES WHEN REMOVING OR INSTALLING THEM. SPILLED ELECTROLYTE CAN CAUSE BURNS AND DAMAGE. ELECTROLYTE SPILLS SHOULD BE NEUTRALIZED WITH A SOLUTION OF 1/4 CUP OF SODIUM BICARBONATE {BAKING SODA) DISSOLVED IN 1 1/2 GALLONS OF WATER AND FLUSHED WITH WATER. OVERFILLING A BATTERY COULD RESULT IN ELECTROLYTE BEING EXPELLED FROM THE BATTERY DURING THE CHARGING CYCLE. THE ELECTROLYTE MAY CAUSE PERSONAL INJURY, DAMAGE TO THE VEHICLE OR DAMAGE TO THE STORAGE FACILITY. OVERFILLING THE BATTERIES WILL VOID THE VEHICLE AND BATTERY WARRANTIES.

Repair and Service Manual

Page K-1

BATTERIES AND CHARGING GENERAL

Monthly

A battery does not store electricity, but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy. The chemical reaction takes place faster in warm conditions and slower in cold conditions. Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences.

•

Perform a more detailed inspection of the plug and receptacle using a flashlight to permit close inspection.

[Ri]@u�

It is important to identify damaged connector components since the damage may be transferred to any other vehicle or charger that is connected to a damaged connector.

As a battery ages, it still performs adequately except that its capacity is diminished. Capacity describes the time a battery can continue to provide its design amperes from a full charge.

•

Inspect all wiring for frayed wire, loose termina­ tions, corrosion or deterioration of insulation.

•

A battery is defined as two dissimilar metals immersed in an acid. If the acid is removed or if the metals are not dis­ similar, the battery ceases to exist. The batteries most commonly used in golf and utility vehicles are lead acid.

Check that the electrolyte level is correct and add suitable water as required.

•

Clean the batteries and terminations.

A battery has a maximum life, therefore good mainte­ nance is designed to maximize the available life and reduce the factors that can reduce the life of the battery.

MAINTENANCE Tool List

Electrolyte Level and Water (See Fig. K-1 "Correct Electrolyte Lever on page K-2) (See Fig. K-2 'Water Purity Table" on page K-3) (See Fig. K-3 "Automatic Watering Gun" on page K-3)

The correct level of the electrolyte is at least 1/2" above the plates in each cell.

Qty. Required

Insulated wrench, 9/16" ............................................... 1 Insulated wrench, 1/2" ................................................. 1 Battery carrier .............................................................. 1 Hydrometer .................................................................. 1 Battery maintenance kit P/N 25587-G01 ..................... 1

��1-;;::..L;::::_=_=:_=:._�i��

Expansion Space 1/4" to 3/8"

--r1/2"

Wire brush ................................................................... 1 Lubricant, Stoner K313 P/N 27934-G02 ..................... 1

At Each Charging Cycle

Plates

Charge the batteries daily providing the vehicle has been used for the equivalent of 18 holes of golf. {There is no need to charge a vehicle until it has run for at least 18 holes.)

Page K-2

Vent

___j_

Flashlight ..................................................................... 1

Before charging the batteries, inspect the connector housing of the battery charger and vehicle connector housing for dirt, debris, signs of misalignment, discolora­ tion or pitting. A deformed housing or one that is broken is an indication of a connector that requires replacement.

A deficient connector system may adversely effect the ability of the charger to fully charge the batteries.

Gas Vent

El�ctrolyte level should be at least 1/2" above the plates and 1/4" to 3/8" below the vent

Fig. K-1 Correct Electrolyte Level

A battery being charged will 'gas' with the majority of the gassing taking place at the end of the charging cycle.

This gas is hydrogen which is lighter than air. Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas, however this loss is minimal.

If the battery electrolyte level is too high, the electrolyte will block the vent tube where the gas will force it out of the vent tube and battery cap. The water will evaporate

Repair and Service Manual

BAT TERIES AND CHARGING but the sulfuric acid will remain where it can damage vehicle components. Sulfuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery.

Watering Gun similar to the type included in the E-Z-GO Battery Maintenance Kit

This level will leave approximately 1/4" to 3/8" of space between the electrolyte and the vent tube. The electrolyte level is important since any portion of the plates exposed to the air will be ruined beyond repair. Of equal importance is too much water, which will result in electro­ lyte being forced out of the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle.

Over the life of the battery a considerable amount of water is consumed. It is important the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction. The water must be distilled or purified by an efficient filtration sys­ tem. Water that is not distilled should be analyzed and if required, filtration installed to permit the water to meet the requirements of the following table:

Pure Water

Parts Per Million Clear

Impurity Color Suspended

Trace

Total Solids

100

Calcium & Magnesium Oxides

40

Iron

5

Ammonia

8

Organic & Volatile Matter

50

Nitrites

5

Nitrates

10

Chloride

5 Fig. K-2 Water PurityTable

Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it does not exceed the impurity levels specified in the table.

Automatic watering devices (such as the one included in the E-2-GO Battery Maintenance Kit) can be used with an approved water source. These watering devices are fast and accurate to use and maintain the correct elec­ trolyte level within the battery cells.

Cleaning Batteries (See Fig. K-7 "Battery Maintenance Kif' on page K-8)

E�GDii+:;id•J:I

Valve consistently fills to a predeter mined level

Single Battery Cell

Fig. K-3 Automatic Watering Gun

When cleaning the batteries, do not use a water hose without first spraying with a solution of sodium bicarbon­ ate (baking soda) and water to neutralize any acid deposits.

Use of a water hose, without first neutralizing any acid, will move acid from the top of the batteries to another area of the vehicle or storage facility where it will attack the metal structure or ttie concrete/asphalt floor. After hosing down the batteries, a residue will be left on the batteries which is conductive and will contribute to the discharge of the batteries.

The correct cleaning technique is to spray the top and sides of the batteries with a solution of sodium bicarbon­ ate {baking soda) and water. This solution is best applied with a garden type sprayer equipped with a non metallic spray wand. The solution should consist of 1/4 cup of sodium bicarbonate {baking soda) mixed with 1 1/2 gal­ lons of clear water. In addition to the batteries, special attention should be paid to metallic components adjacent to the batteries, which should also be sprayed with the sodium bicarbonate (baking soda} solution.

Repair and Service Manual

Page K-3

BATTERIES AND CHARGING Allow the solution to sit for at least three minutes. Use a soft bristle brush or rag to wipe the tops of the batteries in order to remove any residue that could cause the self discharge of the battery. Rinse the entire area with low pressure clear water. All of the items required for com­ plete battery cleaning and watering are contained in the E-Z-GO Battery Maintenance Kit. Cleaning should take place once a month or more often under extreme conditions.

Prolonged Storage (See Fig. K-4 "Freezing Point of Electrolyte" on page K-4)

A_ WARNING A_ NEVER ATTACH A BATTERY CHARGER TO A VEHICLE THAT IS TO BE UNATTENDED. A CHARGER FAILURE COULD CAUSE DAMAGE TO THE VEHICLE BATTERIES AND RESULT IN EXTREME OVERHEATING. During periods of storage, the batteries will need atten­ tion to keep them maintained and prevent discharge.

In high temperatures the chemical reaction is faster, while low temperatures cause the chemical reaction to slow down. A vehicle that is stored at 90° F will lose .002 of specific gravity each day. If a fully charged battery has a specific gravity of 1.275, and the battery is allowed to sit unused, it will become partially discharged. When it reaches 1.240 which it will do in less than twenty days, it should be recharged. If a battery is left in a discharged state, sulfation takes place on and within the plates. This condition is not reversible and will cause permanent damage to the battery. In order to prevent damage, the battery should be recharged. A hydrometer can be used to determine the specific gravity and therefore the state of charge of a battery.

In winter conditions, the battery must be fully charged to prevent the possibility of freezing. A fully charged battery will not freeze in the most severe of winter climates.

Although the chemical reaction is slowed in cold temper­ atures, the battery must be stored fully charged, and dis­ connected from any circuit that could discharge the battery. Disconnect the charging plug from the vehicle receptacle. In DCS vehicles, the Run-Tow/Maintenance switch must be left in the "TOW/MAINTENANCE" posi­ tion in order to eliminate any electrical drain from the bat­ teries caused by the controller. The battery must be Page K-4

cleaned and all deposits neutralized and removed from the battery case to prevent self discharge. The battery should be tested or recharged at thirty day intervals.

0 0 E F C L +15 -9.4

E

C +5 -15

... �..

T

...

-..

""I

R -5 -20.6 0 -15 -26.1

...

"'I

"'

...

L y -25-31.7

·�

I�

� -35 -37.2 T

-45 -42.8

....

L

�

E -55 -48.3 M -65 -54 p E -75 -59.5

• ..�

R -85-65 A

T -95 -70.6

u

R

.100

E

1.140 1.120

1.180

1.160

1.220

1.200

"-

1.260

1.240

1.300

1.280

SPECIFIC GRAVITY

Fig. K-4 Freezing Point of Electrolyte

Battery Installation (See Fig. K-5 "Battery Connections" on page K-5)

If the batteries have been cleaned and any acid in the battery rack area neutralized, no corrosion to the battery racks or surrounding area should be present. Any corro­ sion found should be immediately removed with a putty knife and a wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint.

The batteries should be placed into the battery racks and the battery hold downs tightened snugly (25 - 30 in. lbs torque), to prevent movement but not tight enough to cause distortion of the battery cases.

Inspect all wires and terminals. Clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate (baking soda) and brush, clean if required.

Repair and Service Manual

EZGtiiiUi1!•):1

BATTERIES AND CHARGING

_A WARNING _A

AEROSOL CONTAINERS OF BATTERY TERMINAL PROTECTANT MUST BE USED WITH EXTREME CARE. INSULATE THE METAL CONTAINER TO PREVENT THE METAL CAN FROM CONTACTING BATTERY TERMINALS WHICH COULD RESULT IN AN EXPLOSION. Use care to connect the battery wires as shown in the fol­ lowing illustration and tighten the battery post hardware securely. Protect the battery terminals and battery wire terminals with a commercially available protective coat­ ing.

Front of Vehicle

"t

BL+

BL-

• The charging connector components are in good condition and free from dirt, debris, pitting or evi­ dence of other physical damage.

• The charger connector is fully inserted into the vehicle receptacle.

• The charger connector/cord set is protected from damage and is located in an area to prevent injury that may result from personnel running over or tripping over the cord set. , • The charger is automatically turned off during the connect/disconnect cycle and therefore no electri­ cal arc is generated at the DC plug/receptacle contacts.

AC Voltage Battery charger output is directly related to the input volt­ age. If multiple vehicles are receiving an incomplete charge in a normally adequate time period, low AC volt­ age could be the cause and the power company should be consulted.

ffiiJ@v�

There will be a rattle present in the body of the charger DC plug. This rattle is caused by an internal magnet contained within the charger plug. The magnet is part of the interlock system that prevents the vehicle from being driven when the v, ·�· ::,v,- plug is inserted in the vehicle charging receptacle.

Rotating Vehicles Fig. K-5 Battery Connections

Battery Charging The E-Z-GO Powerwise™ and Powerwise™ + battery charger is designed to fully charge the battery set. If the batteries are severely deep cycled to a point that the bat­ tery voltage level is too low to activate the charger mod­ ule, the battery charger will not function. The charger will determine the correct duration of charge to the battery set and will shut off when the battery set is fully charged.

In order to maximize the time available for the charge cycle, it is recommended that vehicles be rotated. The first vehicles that return from play should be put on charge immediately. These vehicles should be the first used on the following day of play (providing all vehicles were used).

TROUBLESHOOTING

• The electrolyte level in all cells must be at the rec­ ommended level and cover the plates.

In general, troubleshooting will be done for two distinct reasons. First, a battery that performs poorly and outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturers warranty. Different manufacturers have different require­ ments. Consult with the battery manufacturer or an E-Z­ GO representative for specific requirements.

• The charging must take place in an area that is well ventilated and capable of removing the hydro­ gen gas that is generated by the charging pro­ cess. A minimum of five air exchanges per hour is recommended.

The second reason is to determine why a particular vehi­ cle does not perform adequately. Performance problems may result in a vehicle that runs slowly or in a vehicle that is unable to operate for the number of rounds that are required.

Before charging, the following should be observed:

E-21SiClii=F:ii;{•l:I

Repair and Service Manual

Page K-5

BATTERIES AND CHARGING A new battery must mature before it will develop its max­ imum capacity. Maturing may take up to 100 charge/dis­ charge cycles. The older a battery gets, the lower the capacity. The only way to determine the capacity of a bat­ tery is to perform a load test using a discharge machine.

A cost effective way to identify a poorly performing bat­ tery is to use a hydrometer to identify a battery in a set with a lower than normal specific gravity. Once the partic­ ular cell or cells that are the problem are identified, the suspect battery can be removed and replaced. At this point there is nothing that can be done to salvage the battery; however, the individual battery should be replaced with one of the same brand, type and approxi­ mate age that is known to be good.

Hydrometer (See Fig. K-6 "Hydrometer" on page K-6) (See Fig. K-8 "Hydrometer Temperature Correction" on page K-9)

Hydrometers are used to test the state of charge of a bat­ tery cell. This is performed by measuring the density of the electrolyte, which is accomplished by measuring the specific gravity of the electrolyte. The greater the concen­ tration of sulfuric acid, the more dense the electrolyte becomes. The higher the density, the higher the state of charge.

Specific gravity is the measurement of a liquid that is compared to a baseline. The baseline is water which is assigned a base number of 1.000. The concentration of sulfuric acid to water in a new golf car battery is 1.280 which means that the electrolyte weighs 1.280 times the weight of the same volume of water. A fully charged bat­ tery will test at 1.275 - 1.280 while a discharged battery will read in the 1.140 range.

[Ki]@1f�

Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte.

Bulb

1150

1175 1200

t

1225 1250

Add to Float Reading

1275

1300

+-

Subtract from Float Reading

Weight

A_ WARNING A_

Thermometer

NEVER INSERT A METAL THERMOMETER INTO A BATTERY. USE A HYDROMETER WITH A BUILT IN THERMOMETER THAT IS DESIGNED FOR TESTING BATTERIES.

Fig. K-6 Hydrometer

The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80° F. High quality hydrometers are equipped with an internal ther­ mometer that will measure the temperature of the elec­ trolyte and will include a conversion scale to correct the float reading. It is important to recognize that the electro­ lyte temperature is significantly different from the ambient temperature if the vehicle has been operated.

Page K-6

Float

Using a Hydrometer 1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading. Examine the color of the electrolyte. A brown or gray coloration indicates a problem with the battery and is a sign that the bat­ tery is nearing the end of its life.

2. Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder.

Repair and Service Manual

BATTERIES AND CHARGING 3. Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float.

4. Add or subtract four points to the reading for every ten degrees F above or below 80°. Adjust the reading to conform with the electrolyte temperature. E.g. If the reading indicates a specific gravity of 1.250 and the electrolyte temperature is 90° F, add four points to the 1.250 which gives a corrected reading of 1.254. Simi­ larly if the temperature was 70° F, subtract four points from the 1.250 to give a corrected reading of 1.246.

5. Test each cell and note the readings (corrected to 80° F). A variation of fifty points between any two cell readings (example 1.250 - 1.200) indicates a problem with the low reading cell(s).

As a battery ages the specific gravity of the electrolyte will decrease at full charge. This is not a reason to replace the battery, providing that all cells are within fifty points of each other.

Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should be recharged and the test repeated. If the results indicate a weak cell, the battery or batteries should be removed and replaced with one of the same brand, type and approximate age that is known to be good.

_A WARNING _A PORTABLE CHARGERS SHOULD BE MOUNTED ON A PLATFORM ABOVE THE GROUND, OR IN SUCH A MANNER AS TO PERMIT THE MAXIMUM AIR FLOW UNDERNEATH AND AROUND THE CHARGER. IF THE CHARGER IS MOUNTED SUCH THAT SUFFICIENT AIR FLOW IS PREVENTED FROM ENTERING THE LOUVERS, OVERHEATING MAY RESULT WHICH COULD CAUSE SERIOUS DAMAGE TO THE CHARGER AND POTENTIAL FOR FIRE.

The power (AC) cord is equipped with an appropriate plug. If the charger is equipped with a grounding plug, do not attempt to defeat its functionality.

_A WARNING _A AN UNGROUNDED ELECTRICAL DEVICE MAY BECOME A PHYSICAL HAZARD THAT COULD RESULT IN AN ELECTRICAL SHOCK OR ELECTROCUTION.

Charger Installation Install all chargers in accordance with the manufacturers instructions.

If the charger is operated in an outdoor location, rain and sun protection must be provided.

[RI]@u�

If your vehicle is to be charged with a non-standard charger, refer to the instructions supplied with the charger.

In portable applications, the charging (DC) cord is equipped with a polarized connector which fits into a matching receptacle on the vehicle.

EmlaDii=F:;i;{•J�I

Repair and Service Manual

Page K-7

BATTERIES AND CHARGING

1 1/2 Gallons Clear Water

+ 1/4 Cup Sodium Bicarbonate (Baking Soda)

Non Metal Wand ____,

2 Gallon Garden Sprayer (1 1/2 Gallons of Water)

Fig. K-7 Battery Maintenance Kit

Page K-8

Repair and Service Manual

E�GiD ii:f:;it{•l:I

BAT TERIES AND CHARGING

OF

oc

160 71.1 150

65.6

140 60.0 130 54.4 120 48,9 110 43.3 100 37.8 90

32.2

80

26.7

70

21.1

60

15.6

50

10

40

4.4

30

-1.1

20

-6.7

10

+32 +30 +28 +26 +24 +22 +20 +18 +16 +14 +12 +10 +8 +6 +4 +2 0 -2 -4 -6 -8

-10 -12 -14 -16 -18 -20 -22 -24 -26 -28

EXAMPLE#1 Temperature above 80 ° F (26.7° C) Hydrometer reading 1.240 Electrolyte temperature 110 ° F (43.3° C) 1.240 + .012 = 1.252 corrected specific gravity reading

EXAMPLE#2 Temperature below 80° F (26.7 ° C) Hydrometer reading 1.270 Electrolyte temperature 30 ° F (-1.1° C) 1.270 + .020 = 1.250 corrected specific gravity reading

Fig. K-8 HydrometerTemperature Correction

Eml!iCJiif:tid•l:I

Repair and Service Manual

Page K-9

BATTERIES AND CHARGING Notes: ______________________________

Page K-10

Repair and Service Manual

E�laCJii=f:tid•l:I

TABLE OF CONTENTS FOR SECTION 'L' SECTION TITLE

PAGE NO.

DESCRIPTION

L-1

UNDERSTANDING THE CHARGER

L- 1

POWERWISE™ +

L-1

OPENING THE CHARGER

L- 1

TROUBLESHOOTING L- 2 Continuity Checks ................................................................................................................... L- 2

LIST OF ILLUSTRATIONS Fig. L-1 Fig. L-2 Fig. L-3 Fig. L-4

Continuity Check .................................................................................................................. L - 2 Troubleshooting Sequence .......................................................•.......................................... L - 3 Powerwise™ Wiring Diagram .............................................................................................. L- 4 Powerwise™ + Wiring Diagram ........................................................................................... L- 5

Repair and Service Manual

Page L-i

BATTERY CHARGER Notes: _________________________________

Page L-ii

Repair and Service Manual

Section

BATTERY CHARGER DESCRIPTION The PowerwiseTM battery chargers are automatic and are designed specifically for charging electric vehicle batter­ ies.

The charger type is known as ferroresonant. The term is applied to a charger that starts the charge at a relatively high rate of charge and continuously reduces the rate as the batteries become nearer to the full charge condition.

The battery charger can be connected to a vehicle that has been driven any distance and will charge the batter­ ies fully before shutting itself off. The charger has a 3 second delay before turn on after plugging receptacle into vehicle.

The electronic module within the charger samples the battery voltage during the charging period. If the module senses that the battery voltage has risen, it continues the charge. If the module senses no charge, it determines that the batteries are fully charged and shuts the charger off.

UNDERSTANDING THE CHARGER

• Two yellow lamps illuminated in addition to the green, indicates that the charger has operated for more than 4 hours but less than 6 hours.

• Three yellow lamps illuminated in addition to the green, indicates that the charger has operated for more than 6 hours but less than 8 hours.

• Four yellow lamps illuminated in addition to the green, indicates that the charger has operated for more than 8 hours.

• After completing charge cycle, if the DC cord is left connected for at least 24 hours, all four yellow lamps will go into the "flashing mode" representing maximum time on, to conserve battery drain.

A lamp failure is extremely unlikely. Should it fail, the entire printed circuit board must be replaced.

All of the Powerwise™ + functions are identical to the PowerwiseTM charger.

OPENING THE CHARGER 1. Remove the screws securing the front and rear of the handle. This handle acts as a "key'' and must be removed to permit the charger cover to be removed.

The battery charger reacts to unusual situations in vari­ ous ways.

2. Remove remaining screws from sides and cover.

1. If the charger is disconnected from the vehicle dur­ ing the charge cycle, it will shut off immediately.

3. Tilt rear of the cover up and forward to release it from the front face of the charger.

2. If the AC power is interrupted, the charge cycle will continue normally for the remainder of the cycle when the power is restored.

4. Assembly is in the reverse order of disassembly.

3. If the batteries become fully charged in a short peri­ od of time (under 2 hours), the charger will shut off.

If the open circuit battery voltage drops to the point that charge is required the charger will turn itself on until the batteries are fully charged.

4. The charger features an internal timer that will per­ mit no more than 16 hours of continuous charge.

POWERWISE ™ + Four yellow LED's (lamps) located on the left side of the charger indicate elapsed charge time. The single green lamp is on only when the charger is in the charging mode.

• When the charger is plugged in, the green lamp will illuminate and continue until the charger fin­ ishes the charge cycle, at which time the lamp will go off.

• One yellow lamp illuminated in addition to the green, indicates that the charger has operated for more than 2 hours but less than 4 hours.

E�GCHi:f:fot•m

Repair and Service Manual

Page L-1

TROUBLESHOOTING Qty. Required

Tool List

Digital VOM ................................................................. 1

Continuity

Phillips screwdriver ...................................................... 1

Continuity Checks (See Fig. L-1 "Continuity Check" on page L-2)

To check for continuity, set the VOM to KQ setting and select 'Continuity'. T he meter will give an audible signal when it detects continuity. If the meter does not have a continuity setting, set the meter then to KQ, the meter will indicate 0.00 when continuity is detected.

A

WARNING

A

BEFORE ATTEMPTING TO PERFORM A CONTINUITY CHECK, DISCONNECT THE BATTERY CHARGER FROM BOTH AC AND DC POWER SOURCES.

(Fuse shown as typical example of performing continuity check) No Continuity

A simple but effective method of troubleshooting a bat­ tery charger that does not operate is to follow the sequenced procedures. (Ref Fig. L-2)

Page L-2

Repair and Service Manual

Fig. L-1 Continuity Check

EZGtni:£fot•m

START

Plug AC Cord >';.:;__., into Known ___._.

Good Socket

Unplug C & DC Cord

Finish Check Vehicle Batteries

Replace PC Board(s) Go to START

Check Ammeter Connections

Finish Goto START

&wARNING_&

Repair or Replace Goto START

LETHAL VOLTAGES ARE PRESENT WHEN CHARGER IS PLUGGED IN AND THE COVER REMOVED. IF YOU HAVE ANY DOUBTS REGARDING YOUR ABILITY TO SAFELY PERFORM THE FOLLOWING TEST BE SURE TO HAVE THE CHARGER REPAIRED BY A TRAINED ELECTRICIAN/TECHNICIAN.

Replace Fuse Go to START

USE EXTREME CARE NOT TO PERMIT THE UNINSULATED PORTION OF TEST LEADS TO CONTACT ANY OTHER COMPONENT OR THE CHASSIS OF THE CHARGER. BYPASS THE RELAY BY ATTACHING A TEST LEAD TO BOTH WIRES AT THE PRINTED CIRCUIT BOARD MOUNTED RELAY. THIS WILL PERMIT THE TRANSFORMER TO FUNCTION INDEPENDENTLY OF THE RELAY. PLUGGING THE CHARGER INTO AN AC RECEPTACLE MAY RESULT IN THE TRANSFORMER HUMMING WHICH INDICATES THAT THE PRIMARY WINDING IS FUNCTIONING. IF THE TRANSFORMER HUMS, THE PRINTED CIRCUIT BOARD HAS FAILED. IF THE TRANSFORMER DOES NOT HUM THE TRANSFORMER HAS FAILED.

Replace Diode(s) Goto START Good Finish

Replace Transformer

Fig. L-2 Troubleshooting Sequence

E�liCJiif:iid•l:I

Repair and Service Manual

Page L-3

Capacitor AC Input Line Cord

.J_ rf

BLK

GRN

�

Transformer

,------+---1---------+,.;�?

�

-----

WHT

XF

Ammeter

� Battery +

� Fuse

BLK

,._,.;._____,.__....!.,_______....=..:� Battery I I

·---- I

� ----I

JRED �o�t�ol Boa�d] RED 1 ORN �)>-----1 ORN r

' GAN

:____ ���>

!anN ----B��

Ground

))

RED

)

Battery Return

Fig. L-3 Powerwise™ Wiring Diagram Page L-4

Repair and Service Manual

EZGt:ni:f:Utt•m

BATTERY CHARGER

Ca�c�rt AC Input Line Cord

BLK WHT

Transformer

�

Power Input Board

�---------

I

I

I I

,_ Diod: _

I

XF"

1-

GRN

:

GRN

BRN

�o�trol B<:a!d___,

>--------,:.-ORG

).)>-------11

ORG J

L�L____ J

Ground

Heat Sink

I

BRN

RED BLK

y�---------tl ��L- - - - -

j

JRED

I I

>>

RED

) Battery Return

Fig. L-4 PowerwiseTM + Wiring Diagram

E�ISDii#:ii;{•l:I

Repair and Service Manual

Page L-5

BATTERY CHARGER Notes: _____________________________

Page L-6

Repair and Service Manual

TABLE OF CONTENTS FOR SECTION 'M' SECTION TITLE GENERAL

PAGE NO. M-1

DAILY BRAKE PERFORMANCE TEST M-1 General ................................................................................................................................. M - 1 Test Method ......................................................................................................................... M - 1 HOW THE BRAKE SYSTEM WORKS M-1 Wheel Brake Servo Action ................................................................................................... M - 1 Wheel Brake Adjuster ........................................................................................................... M - 3 Brake Pedal and Linkage ..................................................................................................... M - 3 BRAKE MAINTENANCE M-4 New Vehicles ........................................................................................................................ M - 4 Troubleshooting Brake Problems ......................................................................................... M - 4 Periodic Brake Maintenance ................................................................................................ M - 6 Brake Drum Removal ........................................................................................................... M - 6 Brake Shoe Removal/Inspection .......................................................................................... M - 7 Backing Plate Inspection/Lubrication ................................................................................... M - 7 Backing Plate Installation ..................................................................................................... M - 8 Brake Shoe Installation ........................................................................................................ M - 8 Brake Drum Replacement .................................................................................................... M - 8 Compensating Link Adjustment. ........................................................................................... M - 9 Adjusting the Compensating Spring ..................................................................................... M - 9 Adjusting Brake Pedal 'Free Travel' ................................................................................... M - 1 O Checking for 'Free Travel' Movement................................................................................. M - 1 O Brake Pedal Removal ......................................................................................................... M - 10 Parking Brake Pedal Removal ........................................................................................... M - 1 O Parking Brake Pedal Installation ........................................................................................ M - 1 O Brake Pedal lnstallation ...................................................................................................... M - 10 Adjusting the Pedal Bumper ............................................................................................... M - 1 O Adjusting and Seating Brake Components ......................................................................... M - 11 Parking Brake Adjustment .................................................................................................. M - 11 Latch Pedal and Latch Arm Inspection/Replacement ........................................................ M - 12 Parking Brake Release Linkage Removal .......................................................................... M - 12 Parking Brake Release Linkage Installation ....................................................................... M - 12 Final Test............................................................................................................................ M - 12 Burnishing Brake Shoes ..................................................................................................... M - 12

LIST OF ILLUSTRATIONS Fig. M-1 Brake System ............................................................... :................................................... M - 2 Fig. M-2 Compensator and Equalizer............................................................................................. M - 3 Fig. M-3 Wheel Brake Driver's and Passenger Side ...................................................................... M - 5 Fig. M-4 Brake Pedal 'Free Travel'................................................................................................. M - 5 Fig. M-5 Wheel Brake..................................................................................................................... M - 6 Fig. M-6 Removing Castellated Nut ............................................................................................... M - 6 Fig. M-7 Brake Shoe Wear ............................................................................................................. M - 7 Fig. M-8 Lubricating Backing Plate and Adjuster ........................................................................... M - 8 Fig. M-9 Backing Plate Installation ................................................................................................. M - 8 Fig. M-10 Brake Shoe Installation .................................................................................................. M - 8 Fig. M-11 Brake Drum Installation .................................................................................................. M - 9 Fig. M-12 Wheel Brake Lever Adjustment...................................................................................... M - 9 Fig. M-13 Equalizer Position .......................................................................................................... M - 9 Fig. M-14 Compensating Spring Adjustment ............................................................................... M - 10 Fig. M-15 Brake Pedal 'Free Travel' ............................................................................................. M - 10 Fig. M-16 Removing the Brake Pedal .......................................................................................... M - 11 Fig. M-17 Pedal Bumper Adjustment ........................................................................................... M - 11

Repair and Service Manual

Page M-i

BRAKES TABLE OF CONTENTS FOR SECTION 'M' (CONT.) LIST OF ILLUSTRATIONS

PAGE NO.

Fig. M-18 Checking Accelerator Rod Adjustment......................................................................... M - 11 Fig. M-19 Catch Bracket Adjustment.. .......................................................................................... M - 13 Fig. M-20 Parking Brake Release Linkage ................................................................................... M - 13

Page M-ii

Repair and Service Manual

E�ii!H:iitn i :f:foM11

Section

BRAKES

�@u�

To assure correct braking performance, all periodic mainte­ nance, inspections and procedures must be performed as indicated in the Periodic Service Schedule in Section 'A' of this manual. It is most important that a Daily Brake Per­ formance Test be performed and the entire brake system be serviced in accordance with the Periodic Service Schedule.

GENERAL (See Fig. M-1 "Brake System" on page M-2)

The brake system is mechanical and consists of actuat­ ing linkages and self adjusting wheel brake assemblies.

The actuating linkages require periodic adjustment to compensate for the normal wear of system components.

Replacement of any linkage components will also require a linkage adjustment.

The wheel brake units are self adjusting which automati­ cally adjust to compensate for brake shoe wear (see Periodic Service Schedule in Section 'A' of this manual).

The brake does require routine inspection to determine the rate of wear to the brake shoe linings. Normal wear applications require lubrication and complete inspection during brake shoe replacement only.

�@u�

If any brake system component is replaced, the entire brake system must be adjusted.

To determine the adequacy of the vehicles brake system, a brake performance test should be performed daily.

DAILY BRAKE PERFORMANCETEST

A_ WARNING A_ ALL BRAKE TESTS MUST BE DONE IN A SAFE LOCATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL.

General Since weather conditions and terrain frequently vary, no specific braking distance can be specified. The test is intended to compare similar vehicles by applying the parking brake (to eliminate different pedal pressures) at a common point to determine if any vehicle shows signifi­ cantly different braking characteristics from other vehi­ cles being tested.

E�GDii:f:titt•l:I

Since loss of braking performance can deteriorate over a prolonged period, brake performance characteristics should also be compared to the performance of a new vehicle.

Test Method On a dry paved surface that is free of gravel, sand, etc., approach a marker at governed speed. Engage and latch the parking (Park) brake at the marker and observe the stopping distance of the vehicle. Any vehicle that stops in a significantly greater distance than an acceptable vehi­ cle should be tested again. If it again fails to stop in an acceptable distance, it should be immediately removed from service and inspected by a qualified mechanic.

The brake pedal free travel should be inspected on a daily basis (1 - 1 1/2" free travel before any resistance is detected). Excessive pedal travel is an indication of one or both of the wheel brakes failing to adjust. Hard pedal is an indication that the linkage system has become too tight and may indicate a damaged cable or bracket.

The mechanic should sit in the center of the seat to equalize weight distribution and perform a 'panic stop' by applying maximum force and travel to the service brake pedal while moving at full governed speed. If both wheels lock as the result of the panic stop, it is reasonable to assume that the problem originates in the parking brake system and the parking brake should be adjusted. If one wheel fails to lock, it is reasonable to suspect the service brake system and a complete brake maintenance (described elsewhere in this section) must be performed.

Test the vehicle before returning it to service.

HOWTHE BRAKE SYSTEM WORKS Wheel Brake Servo Action

�@u�

The wheel brakes are 'servo acting' and should not require any adjustment for brake shoe wear. Periodic inspection and lubrication of the wheel brake is required as part of the rou­ tine brake maintenance procedure.

The actuating linkage may require periodic adjustment to compensate for normal component wear or the replacement of individual components.

With the vehicle moving forwards, depressing the brake pedal pulls the brake cables. The brake cable pulls the wheel brake actuating lever which pushes the rear brake shoe against the brake drum. Continuing pressure causes the actuating lever to move which pushes the front shoe against the brake drum. As both shoes contact

Repair and Service Manual

Page M-1

BRAKES

Pivot Arm (See Section A)

Fig. M-1 Brake System

Page M-2

Repair and Service Manual

E�liDii+:;id•l:I

BRAKES the drum, 'servo action' takes place which causes the rear brake shoe to move upwards and apply pressure to the upper rear portion of the brake drum. The front shoe moves downwards and applies pressure to the lower front portion of the brake drum. The action reverses when the vehicle is operating in reverse.

Wheel Brake Adjuster The wheel brakes are equipped with an automatic adjuster mechanism that is designed to compensate for brake shoe wear and eliminate the need for brake shoe adjustment.

In the initial break in period, the brake shoes wear at a more rapid rate than normal. This is the result of the shoes burnishing (seating) to the contour of the brake drum. Until the high spots have been worn away, auto­ matic brake adjustment will be more frequent than that of a seated brake shoe. As the brake shoe becomes seated to the brake drum, the shoe cures and becomes harder.

The adjusting mechanism is activated by movement of the brake lever that is attached to the brake cable. The movement of this lever activates the brake adjuster lever.

If adjustment is required, the brake adjuster lever engages and rotates the 'star wheel'. Rotation of the star wheel causes the threaded adjuster screw to move out­ wards against the brake shoes which moves the brake shoes into correct adjustment. Note that the adjustment occurs when the brake cable is released by releasing the brake pedal.

tube within the spring and becomes solid. The linkage between brake pedal and wheel brake transfers foot pressure to the wheel brake.

The left and right brake cables are joined to the compen­ sator linkage with an equalizer link. Due to variations in individual wheel brake adjustment and friction within the driver's and passenger side brake cables, the equalizer may be slightly misaligned. This misalignment is normal, however misalignment that exceeds 1/8" per side (1/4") total is an indication of a damaged brake cable or a wheel brake that is not adjusting correctly. The routine brake inspection will identify the suspect compo­ nent(s)

Adjust Passenger Side Brake Lever

Adjust Driver Side Brake Lever

t

Front Not to Exceed 1/8"

With the brake shoes in correct adjustment, the adjusting levers motion is limited to approximately 1/8" and cannot move enough to engage the next tooth on the star wheel.

The adjuster lever moves on top of the flat of the star wheel tooth and no rotation of the star wheel takes place.

As the brake shoes wear, the motion of the adjusting lever increases until it reaches the point that it engages the next tooth of the star wheel and rotates it to expand the adjuster screw and the brake shoes. The process is then repeated as the shoes continue to wear Brake Pedal and Linkage

View from Below

With Parking Brake Disengaged

Brake Pedal and Linkage

3 15/16"

(See Fig. M-2 "Compensator and Equalizer" on page M-3)

The brake pedal provides a mechanical advantage which is a relationship between the length of the brake pedal and the length of the arm that the brake cables and com­ pensator are attached to.

The brake compensator assembly applies a preload to the system that insures that the parking brake remains under tension whenever it is engaged. As the service brake pedal is engaged the spring within the compensa­ tor linkage is compressed until the linkage engages the

E�GClii:f:iitt•]:I

Fig. M-2 Compensator and Equalizer

Repair and Service Manual

Page M-3

BRAKES

[Rf]@u�

Brake Maintenance should include the inspection and adjust­ ment of all brake components. The following tool list includes the tools required to perform all maintenance.

than the wear of a seated brake shoe. As the brake shoe becomes seated to the brake drum, the shoe cures and becomes harder.

Socket, 1/4", 3/8" drive ................................................ 1

In this break in period it is not uncommon for the brake pedal free travel to be diminished and the effort required to latch the parking brake may rise to an unacceptable level. T he timing of this situation varies due to the terrain that the vehicle is used on and the driving habits of the operator(s). If this occurs, the brake linkage should be adjusted. The adjustment is made at the compensating rod (1) at the equalizer (2) end only. Adjust the spheri­ cal nut (3) until the brake pedal free play meets specifica­ tion. Tighten the jam nut (4) to 10 - 11 ft. lbs torque.

Inspect both wheel brake actuating levers to determine if the levers are returning fully with the brake pedal released. If the operation is satisfactory, return the vehi­ cle to service.

Torque wrench, 1/2" drive ft. lbs. ................................. 1

Troubleshooting Brake Problems

BRAKE MAINTENANCE Qty. Required

Tool List

Hydraulic floor jack ...................................................... 1 Jack stands ................................................................. 4 Chocks ........................................................................ 4 Socket, 1/2", 1/2" drive ................................................ 1 Socket, 3/4", 1/2" drive ................................................ 1 Socket, 11/16", 1/2" drive ............................................ 1

Torque wrench, 3/8" drive, in. lbs................................. 1 Extension, 6", 1/2" drive .............................................. 1 Ratchet, 1/2" drive ....................................................... 1 Wrench, 1/4" ................................................................ 1 Wrench, 1/2" ................................................................ 1 Straight blade screwdriver ........................................... 1 Straight blade screwdriver (narrow) ............................. 1 Pliers ........................................................................... 1 Ball peen hammer ....................................................... 1 Plastic tipped hammer ................................................. 1 Puller (E-Z-GO P/N 15947-G1) ................................... 1 Pry bar ......................................................................... 1

New Vehicles (See Fig. M-1 "Brake System" on page M-2)

[Rf]@u�

A brake problem that occurs before the routine maintenance should be carefully evaluated. A component change or repair may be in order, however if the routine maintenance time is imminent, it is recommended that the entire maintenance be performed.

A new vehicle will undergo an initial break in of compo­ nents that will include brake cables and the seating of the brake shoes. In this initial break in period, the brake shoes wear at a more rapid rate than normal. T his is the result of the shoes burnishing (seating) to the contour of the brake drum. Until the high spots have been worn away, automatic brake adjustment will be more frequent Page M-4

A_ .WARNING A_ EACH OF THE FOLLOWING PROBLEMS MAY BE INDIVIDUALLY CORRECTED, HOWEVER THE DAILY BRAKE PERFORMANCE TEST MUST BE PERFORMED TO DETERMINE THAT THE BRAK­ ING SYSTEM HAS BEEN RETURNED TO AN ACCEPTABLE CONDITION. SATISFACTORY BRAKE PERFORMANCE DOES NOT ELIMINATE THE NEED FOR ROUTINE BRAKE MAINTENANCE AS DESCRIBED IN THE PERIODIC MAINTENANCE SCHEDULE. 1. Hard pedal (No free play) • Linkage Adjustment or improper wheel brake actuator motion 2. Spongy pedal (Too much free play) • Linkage adjustment or wheel brake adjuster not functioning correctly 3. Dragging brake • Brake shoe not retracting or brake cable not returning 4. Inadequate braking (One wheel will not lock) • Wheel brake adjuster not functioning correctly or brake lever not returning 5. Inadequate braking (general) • Requires total periodic maintenance

Repair and Service Manual

BRAKES 6. Parking brake hard to latch • Adjust pedal free play and check that wheel brake actuators are returning fully.

Brake Pedal 'Free Travel' 1" to11/2"

7. Parking brake will not stay latched • Worn latch mechanism, no preload (adjust link­ age) or incorrectly adjusted accelerator kick off cam 8. Parking brake will not hold on grade (normal braking O.K.)

• Adjust linkage

A

WARNING

A

IT IS IMPORTANT TO PERFORM THE FOLLOWING BRAKE MAINTENANCE IN THE SEQUENCE DESCRIBED. FAILURE TO FOLLOW THE PRESCRIBED SEQUENCE COULD RESULT IN IMPROPER BRAKE OPERATION THAT COULD CAUSE SEVERE INJURY.

Fig. M-4 Brake Pedal 'Free Travel'

Heavy Shoe Spring 1

Shoe Clamp 5

4

Light Shoe Spring

3

Light Adjuster Spring

Fig. M-3 Wheel Brake Driver's and Passenger Side

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Repair and Service Manual

Page M-5

(See Fig. M-1 "Brake System" on page M-2) (See Fig. M-4 "Brake Pedal 'Free Travel'" on page M-5)

Refer to Periodic Service Schedule for service interval (perform more frequently under severe conditions).

Front of Vehicle

1. Raise the entire vehicle as specified in the Safety Procedures in Section 'B' of this manual.

2. Determine that the free pedal travel is within specifi­ cation {1" to 1 1/2" of movement at the brake pedal before any movement of the brake levers takes place). Adjust if required per 'New Vehicles' else­ where in this section 3. Rotate each rear wheel by hand and feel for smooth rotation of the wheel and brake drum. Any roughness indicates a dragging brake shoe which will require correction.

�

��"' 1

4. Remove the clevis pin from both brake cables where they attach to the wheel brake levers.

5. Rotate the wheel by hand and compare the motion with step # 3.

• If there is no drag in either step 3 or 5, the brake shoes are not dragging and the brake cables are not binding.

• If the brake dragged in step 3, but does not drag when the brake cable is disconnected, the brake cable must be replaced. Brake cable replacement consists of removing the retaining rings (7) at either end of the outer brake cable and removing the rubber plug (8) at the equalizer (2). The cable can then be removed and a new one installed. Do not connect to the brake until the wheel brake has been disassembled and serviced. (Ref. Fig. M-1) • If the brake dragged in step 3, and continues to drag with the brake cable disconnected, the wheel brake is the cause.

2

5

Fig. M-5 Wheel Brake

Castellated Nut (Rotate Counterclockwise)

Ground

Brake Drum Removal (See Fig. M-5 "Wheel Brake" on page M-6) (See Fig. M-6 "Removing Castellated Nut" on page M-6)

Remove the dust cap (1) to gain access to the castel­ lated nut (2) and the cotter pin (3). Remove the cotter pin and remove the castellated nut as shown. Do not apply the brake when removing nut. (Ref. Fig. M-6) Remove the washer (4) and adapter (5).

Slide the hub and drum (6) off the axle shaft. Tap the drum with a plastic hammer to loosen it from the axle shaft or use drum puller (E-Z-GO P/N 15947-G1}.

Page M-6

Fig. M-6 Removing Castellated Nut

rRD@u�

If the hub and drum does not slide from the brake assembly, the brake shoes must be retracted. Rotate the hub so that the approximately 1" hole is in the six o'clock position which is directly over the brake mechanism. Use two small straight blade screwdrivers to move the adjusting lever free from the adjusting wheel while rotating the star wheel upwards.

Repair and Service Manual

EZE:iDii=f:iid•J�I

BRAKES Brake Shoe Removal/Inspection (See Fig. M-3 'Wheel Brake Driver's and Passenger Side" on page M5) (See Fig. M-7 "Brake Shoe Wear'' on page M-7)

DRIVER SIDE ..-11(1---- Forward

wear. Quadrant 'B' will show the second most wear.

Quadrant 'A' and 'B' will always show the most wear.

Remove the three brake shoe springs (1,2,3) being sure to note the location of the heavy spring and the adjuster spring. Hold the shoe clamp pin (4) and compress and rotate the shoe clamp (5) 90 degrees to release it from the shoe clamp pin. Remove the brake shoes.

Measure the brake shoe thickness at the most worn area. Brake shoe thickness must never be less than .060 at any point on the shoe. If the brake shoe thickness is approaching the .060 dimension, it would be prudent to replace the shoes at this time.

C

Backing Plate Inspection/Lubrication (See Fig. M-8 "Lubricating Backing Plate and Adjuster" on page M-8)

A_ WARNING A_ A BACKING PLATE ASSEMBLY THAT SHOWS ANY INDICATION OF GALLING OR GOUGING IS NOT REPAIRABLE AND MUST BE REPLACED

A

WEAR EYE PROTECTION AND A MASK WHEN CLEANING BRAKE COMPONENTS.

B

C

D

A

Forward

--->•

PASSENGER SIDE

Fig. M-7 Brake Shoe Wear The pattern of normal brake shoe wear is shown in quad­ rant 'A', 'B', 'C' & 'D' with quadrant 'A' showing the most

E�ISDii:f:tid•l:I

Operate the brake lever to check for free motion. Remove the rubber boot that covers the adjuster and clean any accumulated brake dust. Check that the star wheel moves freely and clean and lubricate the adjuster mech­ anism. Clean any accumulated brake dust from the back­ ing plate. If the shoes are to be replaced, the adjuster should be returned to minimum extension. Operate the sliding portion of the adjuster against the backing plate and check for free movement. Lubricate the backing plate with a commercially available brake component lubricant in the areas indicated being careful to lubricate the slider completely and the friction surfaces for the brake shoes.

CAUTION IT IS IMPORTANT THAT THE FRICTION AREAS BETWEEN THE BACKING PLATE AND THE BRAKE SHOES BE LUBRICATED. BE CAREFUL NOT TO ALLOW LUBRICANT TO CONTACT THE BRAKING PORTION OF THE BRAKE SHOES OR THE FRICTION SURFACE OF THE BRAKE DRUM

Repair and Service Manual

Page M-7

Backing Plate

Lubricate Areas

Fig. M-9 Backing Plate Installation

Lubricate Surfaces In and Around Slots and Plastic Slide Plate Lubricate These Points

Adjuster Assembly Light Adjuster Spring

Fig. M-8 Lubricating Backing Plate and Adjuster

Light Shoe Spring

Backing Plate Installation (See Fig. M-9 "Backing Plate Installation" on page M-8)

If the backing plate has been removed for replacement or as part of an axle bearing or seal replacement, the hard­ ware (1,2) should be tightened to 23 - 35 ft. lbs torque.

Brake Shoe Installation (See Fig. M-10 "Brake Shoe Installation" on page M-8)

[]\:!]@u�

end of the adjuster spring is inserted through the front of the front shoe and hooked to the adjuster with the hook end facing out.

Install the shoes as indicated ih the note on the previous page and install the shoe clamp (1) over the shoe clamp pin (2) and rotate 90 degrees to lock them in place.

Brake Drum Replacement

The metal frame of the brake shoes differs between the front and rear shoes. The shoe with the straight end engages in the slot in the adjusting screw. The identical end of the shoes engage with the fixed anchor. The shoe with the triangular end engages with the rear of the adjuster mechanism.

The brake springs must be installed with the light spring closest to the adjuster with the long hook installed down through the rear brake shoe. The heavy top spring is installed with the spring hooks facing in. The long hooked Page M-8

Fig. M-10 Brake Shoe Installation

(See Fig. M-5 'Wheel Brake" on page M-6) (See Fig. M-11 "Brake Drum Installation" on page M-9) (See Fig. M-12 "Wheel Brake Lever Adjustmenf' on page M-9)

Clean the axle shaft to remove dirt, grease and any for­ eign matter. Apply a small amount of anti-seize com­ pound to the spline. Retract the brake shoes enough to permit the brake drum to be installed. Install the thin washer (7) and slide the brake drum (6) into place. Install the remaining hardware and tighten the nut to a mini-

Repair and Service Manual

BRAKES Compensating Link Adjustment (See Fig. M-13 "Equalizer Position» on page M-9) (See Fig. M-1 "Brake System» on page M-2)

Castellated Nut (Rotate Clockwise)

1. (Ref. Fig. M-13) Check the position of the equalizer with the parking brake engaged.

Adjust Passenger Side Brake Lever

Adjust Driver Side Brake Lever

t

Front Not to Exceed 1/8"

Ground

Fig. M-11 Brake Drum Installation

View from Below

Fig. M-13 Equalizer Position

Backing Plate

•

If the dimension exceeds 1/8" go to step 2.

•

If dimension is less than 1/8" go to "Adjusting the Compensating Spring" on page H-11.

(Brake Shoes Expanded)

2. (Ref. Fig. M-1) Release the parking brake and remove the wheel indicated by the equalizer position.

Remove the clevis pin (5) and cotter pin (6) from the wheel brake lever.

Fig. M-12 Wheel Brake Lever Adjustment

3. Using a suitable tool such as a hammer handle, actu­ ate the wheel brake lever and release fully. Repeat the process until the brake lever travel becomes· approximately 1/8" which indicates that the brake shoes have adjusted to their correct position.

mum of 70 ft. lbs. torque. Do not apply the brake when installing nut. (Ref. Fig. M-11) Continue to tighten until a cotter pin can be installed through the castellated nut and the hole in the axle. Maximum torque is 140 ft. lbs.

Install a new cotter pin.

Using a suitable tool such as a hammer handle, actuate the wheel brake lever and release fully. Repeat the pro­ cess until the brake lever travel is approximately 1/8" which indicates that the brake shoes have adjusted to their correct position. Install the brake cables using clevis pin and a new cotter pin.

E�laDii:f:tid•l�I

4. Install the brake cable using clevis pin (5) and a new cotter pin (6).

Adjusting the Compensating Spring (See Fig. M-14 "Compensating Spring Adjustment» on page M-10)

In general, no adjustment will need to be made since the spring is factory calibrated. With the parking brake DIS­ ENGAGED check that the compensating spring length is 3 15/16" If an adjustment is required it is made at the

Repair and Service Manual

Page M-9

BRAKES nuts at the spring facing the front of the vehicle. Tighten the jam nut firmly after adjusting.

Jam Nut

3 15/16"

Checking for 'Free Travel' Movement (See Fig. M-16 "Removing the Brake Pedal" on page M-11)

Check that the brake pedal returns against the pedal bumper when released. If the pedal does not release fully or is sluggish, the brake pedal should be inspected.

Check that the torsion spring (4) is hooked around the pedal and the frame. If the spring is correctly installed and the pedal does not return satisfactorily, the pedal will need to be removed.

Brake Pedal Removal (See Fig. M-16 "Removing the Brake Pedal" on page M-11)

1. Remove the compensator spring assembly (1) by removing the cotter pin (2) and the clevis pin (3).

Unplug the wiring harness on Freedom models.

Fig. M-14 Compensating Spring Adjustment

Adjusting Brake Pedal 'Free Travel' (See Fig. M-15 "Brake Pedal 'Free Travel"' on page M-10)

Measure the free play of the pedal and determine if it is between 1" to 1 1/2". If an adjustment is required, it must be made at the spherical nut (1) behind the equalizer.

Release the jam nut (2) and adjust the spherical nut to achieve the correct pedal free play. Tighten the jam nut to 1o - 11 ft. lbs. torque.

2. Unhook the torsion spring (4) by inserting a thin blade screwdriver between the small hook and the bracket.

Move the hook back and to the side to release the tor­ sion spring (4).

3. Remove the lock nut (5) and the shoulder bolt (6) and remove the brake pedal. Inspect the shoulder bolt for signs of corrosion that could bind with the bushings (7). This is a plated bolt, therefore it must be replaced with a new one if corrosion is found. Inspect the bush­ ings (7) for signs of wear resulting from corrosion to the bolt. If any damage is found, replace the bush­ ings.

Parking Brake Pedal Removal (See Fig. M-16 "Removing the Brake Pedal" on page M-11)

Note the location of the two torsion springs (8). Remove the push nut (9) and remove the pin (10).

Brake Pedal 'Free Travel' 1" to 1 1/2"

Parking Brake Pedal Installation (See Fig. M-16 "Removing the Brake Pedal" on page M-11)

Installation is in the reverse order of disassembly. Use a new push nut.

Brake Pedal Installation (See Fig. M-16 "Removing the Brake Pedal" on page M-11)

Brake pedal installation is in the reverse order of disas­ sembly. Tighten the nut (5) to 25 - 29 ft. lbs. torque and use a new cotter pin when installing the compensator linkage.

Adjusting the Pedal Bumper (See Fig. M-17 "Pedal Bumper Adjustmenf' on page M-11)

Fig. M-15 Brake Pedal 'Free Travel'

Page M-10

When the brake pedal is released it will contact the pedal bumper. The dimension from the top of the pedal arm to the setscrew heads in the kick off cam should be approx­ imately 1/4". If an adjustment to the pedal bumper is

Repair and Service Manual

BRAKES

Fig. M-17 Pedal Bumper Adjustment

Adjusting and Seating Brake Components (See Fig. M-18 "Checking Accelerator Rod Adjustmenf' on page M-11)

1. Engage and release the parking brake 20 times, being sure to release the pedal and allow it to return each time.

2. Engage the parking brake and check that the dimen­ sion behind the compensator linkage frame and the flange on the rod is 3/32". If the dimension is incor­ rect, the free travel must be readjusted until the cor­ rect dimension is achieved.

WITH PARKING BRAKE ENGAGED

"'

Equalizer

Jam Nut

Spherical Nut Flange

Fig. M-18 Checking Accelerator Rod Adjustment

Parking Brake Adjustment Fig. M-16 Removing the Brake Pedal

required, the bumper lock nut should be loosened and the bumper adjusted by rotating it. Tighten the lock nut to 12 - 14 ft. lbs.

E�laClii=F:tid•l:I

1. The parking brake must be adjusted after the service brake has been adjusted.

2. Remove the seat and place the direction selector in the 'F' position. Engage the parking brake and turn the key switch 'ON'.

Repair and Service Manual

Page M-11

BRAKES the set screws to 45-55 in. lbs. torque.

A_ WARNING A_

VEHICLE INADVERTENT PREVENT TO MOVEMENT, BE SURE THAT BOTH REAR WHEELS ARE RAISED BEFORE PERFORMING THIS TEST.

3. Slowly depress the accelerator pedal until the 'click' of the solenoid is heard. If the solenoid is activated after the parking brake has released, the parking brake is functioning correctly. If the solenoid is activated before the parking brake is released, the following must be inspected: •

An improperly adjusted parking brake kick off cam.

• T he catch bracket or latch arm are worn or damaged.

Latch Pedal and Latch Arm Inspection/ Replacement (See Fig. M-19 "Catch Bracket Adjustment" on page M-13)

1. Remove the drivers side front wheel to gain improved access to the brake pedal release mechanism.

Parking Brake Release Linkage Removal (See Fig. M-20 "Parking Brake Release Linkage" on page M-13)

1. To remove the linkage rod (1), remove the cotter pin (2), washers (3) and bushings (4) from linkage rod.

2. Loosen the two setscrews (5) from the cam (6) and remove the cam pivot (7), cam (6) and spacer (8).

3. Inspect the bushings (9, 10) and spacer (8). If they are worn replace them with new ones.

Parking Brake Release Linkage Installation (See Fig. M-19 "Catch Bracket Adjustrnenf' on page M-13) (See Fig. M-20 "Parking Brake Release Linkage" on page M-13)

Installation is in the reverse order of disassembly. Adjust the cam as detailed in Parking Brake Release Linkage Removal

Final Test Lower the vehicle and perform the daily braking test. If the test indicates inadequate brake performance, the brake shoes must be burnished to conform to the brake drum.

Burnishing Brake Shoes

A_ WARNING A_

WORN LATCH ARMS AND CATCH BRACKETS ARE HARDENED PARTS. DO NOT GRIND OR FILE THEM. NEW PARTS MUST BE USED.

2. Inspect the latch bracket and pedal latch arm for signs of wear or damage. If the latch arm requires replacement, refer to "Brake Pedal Removal" page M10.

3. If the catch bracket requires replacement remove the two bolts (1) and nuts (2) which secure the catch bracket. Replace the catch bracket with a new one and tighten the hardware to 85 - 95 in. lbs. torque 4. Inspect the kick off cam (3) for correct adjustment.

With the parking brake engaged and fully latched, there must be no gap between the top of the cam and the latch arm.

5. To adjust the kick off cam (3), engage the parking brake and loosen the two cam set screws (4) and rotate the cam until it contacts the latch arm. Tighten Page M-12

A_ WARNING A_ ALL BRAKE TESTS MUST BE DONE IN A SAFE LOCATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL.

To burnish the brakes, the vehicle must be operated in the forward direction at maximum governed speed and the brakes applied as hard as possible without locking the wheel(s). When the vehicle has come to a full stop, the vehicle should be operated at maximum speed in reverse and the brakes applied as hard as possible with­ out locking the wheel(s). T his braking operation in both directions is considered as one burnishing cycle. Repeat the cy cle a minimum of 50 times for complete seating of brake shoes. If the brake performance is satisfactory after burnishing, the vehicle may be returned to service.

If the performance is not satisfactory, there is a problem with the maintenance and it must be performed again in its entirety.

Repair and Service Manual

E�laDiif:;id•l�I

BRAKES

.03" Max. gap after adjustment of cam

1/4" Max. gap at this point

Fig. M-19 Catch Bracket Adjustment

Accelerator Pedal "-.)

Fig. M-20 Parking Brake Release Linkage

EmE:iDii:f:tid•l:I

Repair and Service Manual

Page M-13

BRAKES Notes: _______________________________

Page M-14

Repair and Service Manual

E�laCJii:£jid•]:I

HORN AND ACCESSORY WIRING

Section

TABLE OF CONTENTS FOR SECTION 'N' SECTION TITLE

PAGE NO.

HORN CIRCUIT (IF EQUIPPED) N -1 Testing the Horn Circuit........................................................................................................ N -1 CHECK FOR LOOSE OR BARE WIRES ................................................................. N -1 CHECK BATTERY CONDITION .............................................................................. N -1 CHECK GREEN POWER WIRE .............................................................................. N - 2 CHECK FUSE .......................................................................................................... N - 2 CHECK WIRE TO SWITCH ...................................................................................... N - 2 CHECK SWITCH ...................................................................................................... N - 2 CHECK YELLOW WIRE TO HORN ......................................................................... N - 2 CHECK BLACK WIRE TO HORN ............................................................................ N - 2 HEADLIGHT AND TAILLIGHT CIRCUIT (IF EQUIPPED) N -2 Testing the Headlights and Taillights Circuit ........................................................................ N - 2 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 2 CHECK BATTERY CONDITION .............................................................................. N - 2 CHECK GREEN POWER WIRE .............................................................................. N - 2 CHECK FUSE .......................................................................................................... N - 5 CHECK POWER TO HEADLIGHTS ......................................................................... N - 5 REMOVE KEY/LIGHT SWITCH PLATE ..•................................................................ N - 5 CHECK BLUE/WHITE WIRE FROM FUSEBLOCK ................................................. N - 5 CHECK KEY/LIGHT SWITCH .................................................................................. N - 5 CHECK BLUE/WHITE WIRE TO HEADLIGHTS ...................................................... N - 5 CHECK BLUE/WHITE WIRE TO TAILLIGHTS ........................................................ N - 5 IF ONE OR MORE LIGHTS ARE OPERATIONAL ................................................... N - 6 BRAKE LIGHT CIRCUIT (IF EQUIPPED) N-6 Testing the Brake Light Circuit ............................................................................................. N - 6 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 6 CHECK BATTERY CONDITION .............................................................................. N - 6 CHECK GREEN POWER WIRE .............................................................................. N - 6 CHECK FUSE .......................................................................................................... N - 6 CHECK FUNCTION OF BRAKE PEDAL MICRO SWITCH ..................................... N - 6 CHECK MICRO SWITCH ......................................................................................... N - 6 CHECK BROWN WIRE ............................................................................................ N - 8 REPLACE LAMP ...................................................................................................... N - 8 IF ONLY ONE BRAKE LIGHT INOPERATIVE ......................................................... N - 8 TURN SIGNALS AND FLASHER CIRCUIT (IF EQUIPPED) N-8 Testing the Turn Signal/Flasher Circuit ................................................................................ N - 8 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 8 CHECK BATTERY CONDITION .............................................................................. N - 8 CHECK GREEN POWER WIRE .........................._.................................................... N - 8 CHECK FUSE ......................................................................................................... : N - 9 CHECK FLASHER ................................................................................................... N - 9 CHECK TURN SIGNAL CONNECTOR .................................................................... N - 9 IF LEFT, RIGHT OR EMERGENCY FLASHER WORKS ......................................... N - 9 HOUR METER CIRCUIT (IF EQUIPPED) N-9 Testing Hour Meter Circuit-Electric Vehicle Only ................................................................. N - 9 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 9 RAISE VEHICLE ...................................................................................................... N - 9 CHECK BATTERY CONDITION ............................................................................ N -10 CHECK HOUR METER .......................................................................................... N -10 Testing Hour Meter Circuit-Gasoline Vehicle Only ............................................................. N -10 CHECK FOR LOOSE OR BARE WIRES ............................................................... N -10 RAISE VEHICLE .................................................................................................... N -10 CHECK BATTERY CONDITION ............................................................................ N -10 CHECK HOUR METER .......................................................................................... N -10

EG!GDii:f:iiit{•l:I

Repair and Service Manual

Page N-i

HORN AND ACCESSORY WIRING TABLE OF CONTENTS FOR SECTION 'N' {CONT.) SECTION TITLE

PAGE NO.

STATE OF CHARGE METER (IF EQUIPPED) - ELECTRIC VEHICLE ONLY N - 11 Testing State of Charge Meter Circuit ................................................................................ N - 11 CHECK FOR LOOSE OR BARE WIRES ............................................................... N - 11 CHECK BATTERY CONDITION ............................................................................. N - 11 CHECK STATE OF CHARGE METER ................................................................... N - 11

LIST OF ILLUSTRATIONS Fig. N-1 Fig. N-2 Fig. N-3 Fig. N-4 Fig. N-5 Fig. N-6 Fig. N-7 Fig. N-8

VOM.................................................................................................................................. N - 1 Accessory Harness Power Connection ............................................................................ N - 1 Electric Vehicle Schematic ............................................................................................... N - 3 Gasoline Vehicle Schematic ............................................................................................. N - 4 Headlight Connector ......................................................................................................... N - 5 Key/Light Switch ............................................................................................................... N - 5 Brake Pedal Micro Switch Operation ................................................................................ N - 7 State of Charge Meter .................................................................................................... N - 11

Page N-ii

Repair and Service Manual

Section

HORN AND ACCESSORY WIRING

U\:IJ@u�

t

This section contains references to components that may be applicable to either gasoline or electric vehicles and may not be appropriate to both.

The VOM shown and recommended is available through the E-Z-GO Service Parts Department as PIN 27481G01. For the purpose of this section, the red probe (+) and black probe (-) are used. Any digital VOM may be used, however the controls, displays, accuracy and fea­ tures may vary depending on the make and model.

Always follow the meter manufacturer's recommenda­ tions and instructions for the use and care of the meter.

Accessory Harness Attachment Front of Vehicle

�

Front of Vehicle

�

BLK GRN Gasoline Vehicle GRN Electric Vehicle

Fig. N-2 Accessory Harness Power Connection

Testing the Horn Circuit Qty. Required

Tool List

Digital VOM .................................................................... 1 1. CHECK FOR LOOSE OR BARE WIRES

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. CHECK BATTERY CONDITION (See Fig. N-1 'VOM" on page N-1) (See Fig. N-2 "Accessory Harness Power Connection" on page N-1)

Fig. N-1 VOM

HORN CIRCUIT (IF EQUIPPED) The horn circuit is a 12 volt system and consists of a horn switch, fuse block, fuse, horn and accessory wiring harness.

When the horn switch is depressed, the horn circuit is completed permitting current to flow from the battery to the fuse and through the horn causing it to sound. The horn will operate if the key switch is in either the 'ON' or 'OFF' position.

Ea-13Diif:iid•l:I

Check for adequate battery volts(nominal 12 VDC) by setting VOM to 30 VDC range and place the red probe (+) on the battery post with the green wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 VDC or greater indicates adequate battery condition. No reading indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty VOM. A voltage reading below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

U\:IJ@u�

Due to the resistance of the wires involved within the har­ ness, voltage readings may be somewhat lower than battery voltage. A reading of 1 volt below battery voltage is accept­ able.

Repair and Service Manual

Page N-1

HORN AND ACCESSORY WIRING 3. CHECK GREEN POWER WIRE

Firmly attach the black probe (-) to the battery post with the black wire attached and the red probe (+) to the green terminal at the fuse block. A reading of bat­ tery voltage indicates that the green wire is in good condition.

�@u�

Testing the Headlights and Taillights Circuit Tool List

Qty. Required

Digital VOM ..................................................................... 1

Green wire supplies power to the entire fuse block.

4. CHECK FUSE

Place the red probe(+) to the orange/white wire ter­ minal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No read­ ing indicates a faulty fuse; replace with a good 15 amp fuse.

5. CHECKWIRE TO SWITCH

Place the red probe (+) to the orange/white connec­ tion at the horn switch. A reading of battery voltage indicates that the orange/white wire supplying power to the switch is in good condition. If no reading is indi­ cated, the orange/white wire is faulty.

6. CHECK SWITCH

Place the red probe(+) to the other horn switch termi­ nal (yellow wire) and depress horn switch button. A reading of battery voltage indicates a good switch. No reading indicates a faulty switch; replace it with a good horn switch.

7. CHECKYELLOW WIRE TO HORN

Place the red probe (+) to the horn terminal with the yellow wire. Depress horn button. A reading of bat­ tery voltage indicates a good yellow wire. No reading of battery voltage indicates a faulty yellow wire.

8. CHECK BLACK WIRE TO HORN

Remove the black wire from the horn. Select continu­ ity (K ohms) 1 position on the VOM. Place the red probe (+) to the terminal of the black wire. A reading of .00 or less than .02 ohms indicates that the black wire is in good condition. All wiring has now been checked; therefore the horn is faulty. Replace with a good horn.

HEADLIGHT AND TAILLIGHT CIRCUIT (IF EQUIPPED) The headlight and taillight circuit is a 12 volt system and consists of a light switch incorporated in the key switch, fuse block, fuse, headlights, taillights and accessory wir­ ing harness.

Page N-2

When the key switch is turned to the 'light' position, the circuit is completed permitting current to flow from the battery to the fuse and through the lights causing them to illuminate.

If the vehicle runs but the headlights and taillights are inoperative: Proceed to Step 1, if any lights are functional proceed to Step 11.

1. CHECK FOR LOOSE OR BARE WIRES

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT.

�@u�

If any VOM readings indicate a faulty wire, it is recom­ mended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct com­ ponents and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends pro­ tected with vinyl electrical tape.

2. CHECK BATTERY CONDITION (See Fig. N-1 "VOM" on page N-1) (See Fig. N-2 "Accessory Harness Power Connection" on page N-1)

Check for adequate battery volts(nominal 12 VDC) by setting VOM to the 30 voe range and place the red probe (+) on the battery post with the green wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 voe or better indicates adequate battery condition. No read­ ing indicates (a) a poor- connection between the probes and the battery terminals;(b) a faulty VOM. A voltage reading below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

�@u�

Due to the resistance of the wires involved within the har­ ness, voltage readings may be somewhat lower than battery voltage. A reading of 1 volt below battery voltage is accept­ able.

3. CHECK GREEN POWER WIRE

Firmly attach the black probe (-) to the battery post with the black wire attached to perform Steps 3

Repair and Service Manual

E�liDiif:iid•l:I

HORN AND ACCESSORY WIRING

ELECTRIC VEHICLE

,lff' Jl Jl Headlight

Driver Tum Marker

"

O

GRN

LK

� ED

i__ -- --- _i

I ____ i __

Marker Passenger Turn

Headlight

RED I-' I

I_____ I

BLK

™1

�-

LK -

-----

YEL

RED

--- ' I '

---

_I

GAN

RED

+ 12V

BLK

GAN

l!ll

GAN RED

Turn Signal Switch YEL +36V RED

BLK :!:_3��EQ Key Switch

State Of Charge BLU/WHT BLK

BAN BL �WHT

Tai.11.ight

WHT RED

Driver Turn Signal

BAN

YEL BAN RE

Passenger Tum Signal

BLK �WHT

..

Taillight

For vehicles without turn signals, remove WHT wire from left rear turn signal remove YEL wire from right rear turn signal connect BAN wire to RED

• Indicates butt connection within wiring harness

Fig. N-3 Electric Vehicle Schematic

E.ZGDii:f:iilM:I

Repair and Service Manual

Page N-3

HORN AND ACCESSORY WIRING

GASOLINE VEHICLE Driver Turn

Marker

<c

GRN

F t<t:t

!1-� I__ __

___

_I

RED

RED BLK

Flasher

YEL

GRN RED BRN

Tum Signal Switch -,--0 RED ---=-="'-----'� I

BLK

Oil Pressure

� 2�0"'-<)___!:!_E� Key Switch

Solenoid

Oil Sender BLU/WHT BLK BRN BRN BL HT W � Ta,·ir19 ht

YEL BRN

WHT RED Driver Tum Signal

BLK RE �WHT

Passenger Tum Signal

For vehicles without tum signals remove WH T wire from left rear tum signal remove YEL wire from right rear turn signal connect BAN wire to RED - - Indicates wire not included in harness • Indicates butt connection within wiring harness

Fig. N-4 Gasoline Vehicle Schematic

Page N-4

Repair and Service Manual

..

Taillight

HORN AND ACCESSORY WIRING through 4 and the red probe(+) to the green terminal at the fuse block. A reading of battery voltage indi­ cates that the green wire is in good condition.

[Rf]@u�

This wire supplies power to the entire fuse block.

4. CHECK FUSE

Place the red probe(+) to the blue/white wire terminal on the fuse block. A reading of battery voltage indi­ cates that the fuse is in good condition. No reading indicates a faulty fuse, replace with a good 15 amp fuse.

7. CHECK BLUE/WHITE WIRE FROM FUSEBLOCK (See Fig. N-6 "Key/Light Switch" on page N-5)

With the key switch 'OFF', place the red probe(+) to the blue/white connections at the key switch and the black probe (-) to the battery post with the black wire attached to perform steps 7 - 11. A reading of battery voltage from one of these connections indicates that the blue/white wire from the fuse is in good condition.

If no battery voltage is indicated, the blue/white wire from the fuse is faulty and must be replaced.

Viewed from Rear Side

5. CHECK POWER TO HEADLIGHTS (See Fig. N-5 "Headlight Connector" on page N-5)

Key Switch with Lights

Turn lights on and disconnect a connector at the headlamp. Place the red probe (+) to the blue/white wire end and the black probe(-) to the black wire end of the harness going to the headlamps. If battery volt­ age is indicated then the key switch is good and the bulb must be replaced. If NO voltage is indicated then the switch is suspect and must be checked.

BLU/WHT BLU/WHT

Black Probe(-) to BLACK Wire Terminal

Fig. N-6 Key/Light Switch 8. CHECK KEY/LIGHT SWITCH

Red Probe(+) to BLUE/WHITE Wire Terminal

Place the red probe(+) to the blue/white wire terminal that did not have voltage and turn the key switch to lights. An indication of battery voltage indicates a good key switch. No voltage indicates a faulty switch.

9. CHECK BLUE/WHITE WIRE TO HEADLIGHTS

Turn lights on and move the red probe(+) to each of the blue/white wire terminals at the connections of the headlights. If no battery voltage is shown it indicates that the blue/white wire is faulty and must be replaced. T he blue/white wires are joined internally in the harness. One may be faulty and the other good.

Fig. N-5 Headlight Connector 6. REMOVE KEY/LIGHT SWITCH PLATE

Drive out the plastic push rivets on the key switch plate and pull out the key switch plate.

10. CHECK BLUE/WHITE WIRE TO TA ILLIGHTS

Turn lights on and place the red probe(+) at the blue/ white wire connections at the taillights. If battery volt­ age is not indicated, the blue/white wire is faulty and must be replaced.

Repair and Service Manual

Page N-5

HORN AND ACCESSORY WIRING 11. IF ONE OR MORE LIGHTS ARE OPERATIONAL

Check for faulty wiring or a faulty bulb. Turn lights on and check for battery voltage at each of the blue/ white terminals at the headlights and taillights. Place the red probe(+) on the blue/white wire terminals and the black probe (-) on the battery post with the black accessory harness wire attached. A reading of bat­ tery voltage indicates that either the socket is cor­ roded or faulty, or that the bulb is faulty. Replace the bulb after inspecting the socket and reconnect the wiring.

BRAKE LIGHT CIRCUIT (IF EQUIPPED) The brake light circuit is a 12 volt system and consists of a brake pedal operated micro switch, a fuse block, fuse, brake lights and an accessory wiring harness.

When the service brake pedal is depressed, a micro switch is closed which completes the brake light circuit which permits current to flow to the brake lights. The brake lights will operate if the key switch is in either the 'ON' or 'OFF' position.

A difference does exist in the brake/turn signal wiring. In vehicles with turn signals, the brown wire to the taillights will be disconnected, and the white wire on the driver's side and the yellow wire on the passenger side will be connected to the red wires from the taillight.

Testing the Brake Light Circuit Tool List

Qty. Required

Digital VOM ....................................................................1 If the vehicle runs but the headlights and taillights are inoperative: Proceed to Step 1, if any lights are functional proceed to Step 9.

1. CHECK FOR LOOSE OR BARE WIRES

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. CHECK BATTERY CONDITION (See Fig. N-1 "VOM" on page N-1) (See Fig. N-2 "Accessory Harness Power Connection• on page N-1)

Check for adequate battery volts(nominal 12 VDC) by setting VOM to the 30 VDC range and place the red probe (+) on the battery post with the green wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 VDC or better indicates adequate battery condition. No read­ ing indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty VOM. A Page N-6

voltage reading below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

[R!]@v�

Due to the resistance of the wires involved within the har­ ness, voltage readings may be somewhat lower than battery voltage. A reading of 1 volt below battery voltage is accept­ able.

3. CHECK GREEN POWER WIRE

Firmly attach the black probe (-) to the battery post with the black wire attached to perform Steps 3 through 4 and the red probe(+) to the green terminal at the fuse block. A reading of battery voltage indi­ cates that the green wire is in good condition.

[R!]@v�

This wire supplies power to the entire fuse block.

[R!]@v�

If any VOM readings indicate a faulty wire, it is recom­ mended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct com­ ponents and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends pro­ tected with vinyl electrical tape.

4. CHECK FUSE

Place the red probe(+) to the red wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a faulty fuse, replace with a good 15 amp fuse.

5. CHECK FUNCTION OF BRAKE PEDAL MICRO SWITCH

Depress service brake pedal and listen for audible click from micro switch. Release pedal and listen for an audible click. An audible click in both the up and down pedal positions indicates a correct micro switch adjustment. If the switch is not activated and released correctly, it may be adjusted by loosening the two bolts that secure the micro switch and moving the switch until the appropriate adjustment is achieved. If the switch is in correct adjustment and the brake lights are not activated, it is necessary to check for faulty wiring or components.

6. CHECK MICRO SWITCH

Set the VOM to the 30 VDC range and attach the black probe (-) to the negative battery post with the

Repair and Service Manual

HORN AND ACCESSORY WIRING

NORMAL DRIVING POSITION

Micro Switch Open

BRAKING POSITION

Micro Switch Closed and Brake Lights Activated

PARK BRAKE ENGAGED

. Micro Switch Open

NOTE: Audible click while applying and releasing brakes indicates proper switch adjustment.

Fig. N-7 Brake Pedal Micro Switch Operation

E�GDiifiilM:I

Repair and Service Manual

Page N-7

HORN AND ACCESSORY WIRING black wire attached. Place the red probe (+} to the micro switch terminal with the brown wire attached.

Depress the brake pedal. A reading of battery voltage indicates that the service brake micro switch is oper­ ating correctly. If no voltage is indicated, the micro switch must be tested. Move the red probe(+} to the service brake micro switch terminal with the red wire attached. A reading of battery voltage indicates that the red wire is in good condition. Move the red probe (+) to the other terminal of the service brake micro switch and manually activate the switch by pressing the roller of the actuating arm toward the switch until an audible click is heard. A reading of battery voltage indicates that the switch is in good condition. No read­ ing indicates that the micro switch needs replace­ ment.

7. CHECK BROWN WIRE

Move to the rear of the vehicle and access the tail­ lights. Move the red probe (+) to the brake light con­ nector at the brown wire. Depress the service brake.

A reading of battery voltage indicates that the brown wire is in good condition. No voltage indicates the brown wire is faulty. Replace. Check both brake lights.

If either brake light does not come on, replace bulb.

8. REPLACE LAMP

Testing the Turn Signal/Flasher Circuit A difference does exist in the turn signal wiring in that vehicles with turn signals, the brown wire to the taillights will be disconnected and the white wire on the driver's side and the yellow wire on the passenger side will be connected to the red wires from the taillight.

Tool List

Qty. Required

Digital VOM .....................................................................1 If the vehicle runs but all turn signals and flasher are inoperative: Proceed to Step 1, if any lights are functional proceed to Step 7.

1. CHECK FOR LOOSE OR BARE WIRES

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. CHECK BATTERY CONDITION (See Fig. N-1 'VOM" on page N-1)

Unplug the lamp from the plug and replace with new bulb. Replace all wires disconnected in the test.

9. IF ONLY ONE BRAKE LIGHT INOPERATIVE

The overall system is functional; therefore the follow­ ing steps should be followed. Assure that the brown wire from the harness is attached to the white wire from the inoperative lamp plug. If the lamp still fails to light when the brake pedal is depressed, separate the brown wire from the lamp connector. Select the 30 VDC range of the VOM. Place the red probe(+) to the brown wire and the black probe (-) to the black wire connection at the battery. Depress the brake pedal. A reading of battery voltage indicates that the lamp is faulty. Replace lamp and reconnect all wires discon­ nected in the test.

TURN SIGNALS AND FLASHER CIRCUIT (IF EQUIPPED) The turn signal and flasher is a 12 volt system and con­ sists of a turn signal/flasher switch, fuse block, fuse, front and rear lamps and an accessory wiring harness.

When the turn signal/flasher switch is activated, the cir­ cuit is completed permitting current to flow from the bat­ tery to the fuse and through the flasher causing the Page N-8

appropriate lights to flash. The turn signal/flasher will operate if the key switch is in either the 'ON' or 'OFF' position.

(See Fig. N-2 "Accessory Harness Power Connection" on page N-1)

Check for adequate battery volts(nominal 12 VDC) by setting VOM to the 30 VDC range and place the red probe (+) on the battery post with the green wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 VDC or better indicates adequate battery condition. No read­ ing indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty VOM. A voltage reading below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

ffii](gJiJ�

Due to the resistance of the wires involved within the har­ ness, voltage readings may be somewhat lower than battery voltage. A reading of 1 volt below battery voltage is accept­ able.

3. CHECK GREEN POWER WIRE

Firmly attach the black probe (-) to the battery post with the black wire attached to perform Steps 3 through 4 and the red probe(+) to the green terminal at the fuse block. A reading of battery voltage indi­ cates that the green wire is in good condition.

Repair and Service Manual

E�DiDiif:;id•]:I

HORN AND ACCESSORY WIRING [RI]@TIT�

This wire supplies power to the entire fuse block.

[RI)@1f�

Select the 30 VDC range of the VOM. Place the black probe(-) to the black wire connection at the negative post of the battery and place the red probe(+) to: Left front .................................................... Red wire

If any VOM readings indicate a faulty wire, it is recom­ mended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct com­ ponents and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends pro­ tected with vinyl electrical tape.

4. CHECK FUSE

Place the red probe(+) to the red wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a faulty fuse, replace with a good 15 amp fuse.

5. CHECK FLASHER

Drive out the plastic push rivets on the key switch plate and pull out the key switch plate. The wiring to the flasher is most easily reached by accessing the harness in this position. Reach through the opening and gently pull harness out of the opening in the con­ sole of the key switch plate until the flasher is seen.

Remove the flasher from its socket. Select K ohms (continuity) position on the VOM. Place the red probe (+) on one of the flasher terminals and the black probe (-) on the other flasher terminal. A reading of .00 to .20 indicates that the flasher is in good condi­ tion. Inspect the flasher socket for corrosion before replacing the flasher.

6. CHECK T URN SIGNAL CONNECTOR

Separate the harness to turn signal connector and inspect for corrosion and correct placement of pins and sockets in the connector housing. Check that the black wire from the flasher socket is attached to the red wire from the harness and that the white wire from the turn signal is attached to the black wire from the harness, and the yellow wire from the flasher is attached to the turn signal. If the system does not function after the above check, the turn signal switch must be replaced.

E�GCii#=ii1t•):i

7. IF LEFT, RIGHT OR EMERGENCY FLASHER WORKS

Left rear................................................... White wire Right front ...............................................Green wire Right rear ............................................... Yellow wire Turn on the appropriate turn signal. A pulsating read­ ing of the battery voltage indicates that power is avail­ able to the light, therefore, the light module is faulty. If no voltage is present a faulty wire is indicated.

[RI]@1f�

If any VOM readings indicate a faulty wire, it is recom­ mended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct com­ ponents and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends pro­ tected with vinyl electrical tape.

HOUR METER CIRCUIT (IF EQUIPPED) The hour meter circuit is a 36 volt system for electric vehicles and a 12 volt system for gasoline vehicles. Both consists of a hour meter and an accessory wiring har­ ness.

The hour meter will only operate when the vehicle is run­ ning.

Testing Hour Meter Circuit-Electric Vehicle Only Tool List

Qty. Required

Digital VOM .................................................................... 1 If the vehicle runs but the hour meter is inoperative: 1. CHECK FOR LOOSE OR BARE WIRES

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. RAISE VEHICLE

Raise the vehicle (see Safety procedures in Section B)

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HORN AND ACCESSORY WIRING

_A WARNING _A TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LISTING PROCEDURE IN SECTION "B" OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF AND BEHIND THE REAR WHEELS AND CHECK THE STABILITY OF THE VEHICLE ON THE JACK STANDS BEFORE STARTING ANY REPAIR PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE. THIS TEST WILL CAUSE VEHICLE WHEELS TO TURN. BE SURE THAT VEHICLE IS ADEQUATELY SUPPORTED WITH BOTH REAR WHEELS CLEAR OF FLOOR. KEEP CLEAR OF ROTATING WHEELS. CLOTHING BECOMING TRAPPED BY WHEEL COULD CAUSE SERIOUS PERSONAL INJURY. 3. CHECK BATTERY CONDITION

Check for adequate battery volts(nominal 36 VDC) by setting VOM to 36 VDC range to 300 VDC range, unplug the yellow and gray wires from the rear of the hour meter. Place the black probe(-) on the gray wire terminal. Place the red probe (+) on the yellow wire terminal. Turn key switch to ON and depress acceler­ ator pedal. A reading of 31.5 VDC or better indicates adequate battery condition. No reading indicates(a) a poor connection between the probes and the termi­ nals; (b) a faulty VOM. A voltage reading below 31.5 volts indicates poor battery charge and the vehicle should be recharged before proceeding with the test.

4. CHECK HOUR METER

If battery voltage is in excess of 31.5 VDC and the hour meter does not function, the hour meter should be replaced being careful to rewire with gray to the negative terminal (-) and yellow to the positive termi­ nal(+).

Testing Hour Meter Circuit-Gasoline Vehicle Only Tool List

Qty. Required

Digital VOM .................................................................... 1 If the vehicle runs but the h our meter is inoperative: 1. CHECK FOR LOOSE OR BARE WIRES

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the Page N-10

frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. RAISE VEHICLE

Raise the vehicle (see Safety procedures in Section B)

_A WARNING _A TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LISTING PROCEDURE IN SECTION "B" OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF AND BEHIND THE REAR WHEELS AND CHECK THE STABILITY OF THE VEHICLE ON THE JACK STANDS BEFORE STARTING ANY REPAIR PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE. THIS TEST WILL CAUSE VEHICLE WHEELS TO TURN. BE SURE THAT VEHICLE IS ADEQUATELY SUPPORTED WITH BOTH REAR WHEELS CLEAR OF FLOOR. KEEP CLEAR OF ROTATING WHEELS. CLOTHING BECOMING TRAPPED BY WHEEL COULD CAUSE SERIOUS PERSONAL INJURY. 3. CHECK BATTERY CONDITION

Check for adequate battery volts(nominal 12 VDC) by setting VOM to 30 VDC range, unplug the yellow and gray wires from the rear of the hour meter. Place the black probe (-) on the gray wire terminal. Place the red probe (+) on the yellow wire terminal. Turn key switch to ON and depress accelerator pedal. A read­ ing of 11 VDC or better indicates adequate battery condition. No reading indicates (a) a poor connection between the probes and the terminals; (b) a faulty VOM. A voltage reading below 11 volts indicates poor battery charge and the vehicle should be recharged before proceeding with the test.

4. CHECK HOUR METER

If battery voltage is in excess of 11 VDC and the hour meter does not function, the hour meter should be replaced being careful to rewire with gray to the nega­ tive terminal(-) and yellow to the positive terminal(+).

Repair and Service Manual

E.ZGDii:f:ii1M:I

HORN AND ACCESSORY WIRING STATE OF CHARGE METER (IF EQUIPPED) - ELECTRIC VEHICLE ONLY The state of charge circuit is a 36 volt system and con­ sists of a state of charge meter and accessory wiring har­ ness and indicates the charge condition of the battery set. The state of charge meter will only operate if the key switch is in the 'ON' or 'LIGHT' position.

ness; (c) a faulty VOM; (d) faulty red wire from key switch. A voltage reading below 34 volts indicates poor battery charge and the vehicle should be recharged before proceeding with the test.

State of Charge Meter

Testing State of Charge Meter Circuit Tool List

Qty. Required

Digital VOM ................................................................... 1 If the vehicle runs but the state of charge meter is inoperative: 1. CHECK FOR LOOSE OR BARE WIRES Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. CHECK BATTERY CONDITION With the key switch on, check for adequate battery volts (nominal 36 VDC) by setting VOM to 36 VDC range, unplug the red and black wires from the rear of the state of charge meter. Place the red probe(+) on the red wire terminal. Place the black probe(-) on the black wire terminal. A reading of 36 VDC ± 2V or bet­ ter indicates adequate battery condition. No reading indicates (a) a poor connection between the probes and the battery terminals;(b) a broken wire in the har-

E.Z.ESiDii+:tid•l:I

RED

(to Key Switch)

Fig. N-8 State of Charge Meter 3. CHECK STATE OF CHARGE METER If battery voltage meets the criteria specified and the state of charge meter does not function, the state of charge meter should be replaced being careful to rewire with black to the #2 terminal and red to the #1 terminal, and the red from the key switch to the #4 ter­ minal.

Repair and Service Manual

Page N-11

HORN AND ACCESSORY WIRING

Notes: ___________________________

Page N-12

Repair and Service Manual

E�laDii:t:;i;t•]:I

TABLE OF CONTENTS FOR SECTION 'P' SECTION TITLE REAR SUSPENSION

PAGE NO. P- 1

GENERAL P-1 Shock Absorber Removal ......................................................................................................P - 1 Shock Absorber lnstallation ...................................................................................................P - 1 Rear Spring Removal ............................................................................................................ P - 1 Rear Spring Installation ......................................................................................................... P - 1 Rear Axle Assembly Removal ............................................................................................... P - 2 Rear Axle Installation ............................................................................................................ P - 2

LIST OF ILLUSTRATIONS Fig. P-1 Motor Wiring ......................................................................................................................P - 2 Fig. P-2 Motor Wiring (DCS Models) ............................................................................................... P - 2 Fig. P-3 Rear Suspension ............................................................................................................... P - 3

E�E:iDii:f:;id•PI

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Page P-i

REAR SUSPENSION Notes: ______________________________

Page P-ii

Repair and Service Manual

Section

REAR SUSPENSION REAR SUSPENSION

instructions provided in Section "B" (Safety) of this man­ ual and support the rear of the vehicle on the outer ends of the rear bumper.

[R!]@urn

In the following text, there are references to removing/install­ ing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in their original posi­ tions unless otherwise specified. Non specified torque speci­ fications are as shown in the table contained in Section ''.A".

Remove the bottom shock absorber nut (1).

Compress the shock absorber (2) and remove the top shock absorber nut (3).

Remove the shock absorber (2).

Shock Absorber Installation

GENERAL

(See Fig. P-3 "Rear Suspension" on page P-3)

(See Fig. P-3 "Rear Suspension" on page P-3)

Qty. Required

Tool List

Wheel chocks .............................................................. 4 Jack stands ................................................................. 4 Floor jack ..................................................................... 1 Wrench, 1/2" ............................................................... 1

Shock absorber installation is in the reverse order of dis­ assembly except that the shock absorber nuts (1,3) must be tightened until the shock absorber bushings (4) expand to the diameter of the shock absorber washer (5).

Rear Spring Removal (See Fig. P-3 "Rear Suspension" on page P-3)

[R!]@urn

Wrench, 9/16" ............................................................. 1 Wrench, 3/4" ............................................................... 1 Socket, 1/2", 3/8" drive ................................................ 1 Socket, 9/16", 3/8" drive .............................................. 1 Socket, 9/16", deepwell, 3/8" drive .............................. 1 Extension, 3", 3/8" drive .............................................. 1 Ratchet, 3/8" drive ....................................................... 1 Torque wrench, in. lbs., 3/8" drive ............................... 1 Torque wrench, ft. lbs., 3/8" drive ................................ 1 The rear suspension consists of the rear axle and attach­ ments that secure it to the springs and shock absorbers.

Rear axle removal is covered in section "S".

Shock Absorber Removal

WARNING

Remove the bottom shock absorber nut (1).

Place a floor jack under the center section of the rear axle (6) and raise just enough to place a second set of Jack stands under the axle tubes. With both the rear axle and the frame supported, the 'U' bolt (7) and the hard­ ware (8) can be removed.

Remove the rear spring shackle assembly (9) and the front spring mounting hardware (10).

Remove the spring (11).

(See Fig. P-3 "Rear Suspension" on page P-3)

A

It is not required to completely remove the shock absorber for rear spring removal.

If both springs are to be replaced and the rear axle is not to be removed, it is important to remove and replace one spring at a time.

A

TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LIFTING PROCEDURE IN SECTION "B" OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF AND BEHIND THE FRONT WHEELS AND CHECK THE STABILITY OF THE VEHICLE ON THE JACK STANDS BEFORE STARTING ANY REPAIR PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE.

Raise the rear of the vehicle in accordance with the

Rear Spring lnstalla�ion (See Fig. P-3 "Rear Suspension" on page P-3)

Spring installation is in the reverse order of disassembly.

[R!]@urn

When installing the rear spring shackles, be sure that the cupped side of the shackle plate faces the spring.

The shock absorber nuts (1,3) must be tightened until the shock absorber bushings (4) expand to the diameter of the shock absorber washer (5).

Tighten the front spring hardware (10} to 21 - 25 ft. lbs. torque.

Tighten all other hardware to 18 - 22 ft. lbs. torque

Repair and Service Manual

Page P-1

tl

P1

REAR SUSPENSION Rear Axle Assembly Removal

Rear Axle Installation

(See Fig. P-3 "Rear Suspension" on page P-3)

(See Fig. P-1 "Motor Wiring" on page P-2)

A

WARNING

A

THE REAR AXLE ASSEMBLY IS TOP HEAVY. TO REDUCE THE POSSIBILITY OF PERSONAL INJURY WHILE REMOVING THE REAR AXLE, BE SURE TO SUPPORT THE AXLE AND MOTOR ASSEMBLY WHEN REMOVING THE SPRINGS. IF NO LIFTING DEVICE IS AVAILABLE, A SECOND PERSON SHOULD HOLD THE MOTOR IN THE CORRECT POSITION UNTIL THE SPRINGS ARE REMOVED. BOTH PERSONS SHOULD REMOVE THE REAR AXLE AND MOTOR ASSEMBLY.

(See Fig. P-2 "Motor Wiring (DCS Models)" on page P-2) (See Fig. P-3 "Rear Suspension" on page P-3)

Installation is in the reverse order of disassembly. Tighten motor terminal hardware to 66 in. lbs. torque.

MOTOR TERMINAL

WIRE MARKER

S1

S1

Direction Selector "D"

S2

S2

Direction Selector "B"

A1

A1

M - at ESC Controller

A2

A2

Direction Selector "C"

Disable the electrical system to the motor by turning the key switch to the 'OFF position and remove battery wire.

Remove the wires to the motor, being careful to prevent the axle assembly (6) from rotating, remove the bottom shock mounting hardware and the springs from the rear axle as detailed elsewhere in this section.

The rear axle and motor assembly can now be lifted from the jack stands and lowered to the floor.

�@u�

To remove the rear axle assembly wi/1 require the use of an overhead hoist that can support the motor. T he position of the motor will cause the rear axle assembly to rotate when the 'U' bolts (7) are removed. If no hoist is available, the motor may be held in position by a second person. With the springs removed, both persons can lift the entire assembly from the jack stands and lower it to the floor.

Page P-2

FROM

Fig. P-1 MotorWiring

MOTOR WIRE TERMINALS MARKER

FROM

S1

S1

Direction Selector "B"

S2

S2

Direction Selector "D"

A1

A1

B+ at Controller

A2

A2

A2 at Controller

Fig. P-2 MotorWiring (DCS Models)

Repair and Service Manual

E�GCJiit:iid•l:I

REAR SUSPENSION I

�

/, /, ,, ,,/

, / ,/ / ,

,

,

,

2

Fig. P-3 Rear Suspension

Eii!HiCiiUit!•W

Repair and Service Manual

Page P-3

Notes: __________________________________

Page P-4

Repair and Service Manual

REAR AXLE

Section TABLE OF CONTENTS FOR SECTION 'R' SECTION TITLE

PAGE NO.

REAR AXLE DISASSEMBLY R- 1 Axle Shaft Removal and Disassembly ................................................................................. R - 1 Axle Shaft Seal Removal and Replacement ........................................................................ R - 2 Axle Shaft Replacement ....................................................................................................... R - 3

LIST OF ILLUSTRATIONS Fig. R-1 Fig. R-2 Fig. R-3 Fig. R-4 Fig. R-5 Fig. R-6 Fig. R-7

E-2-l!iDii:f:iid•l:I

Removing/Installing Outer Snap Ring .............................................................................. R - 1 Removing/Installing Axle Shaft ......................................................................................... R - 1 Pressing Bearing from Axle Shaft..................................................................................... R - 2 Removing/Installing Inner Snap Ring ............................................................................... R - 2 Removing Seal ................................................................................................................. R - 2 Installing Seal ................................................................................................................... R - 3 Cut Away of Outer Bearing and Brake Drum.................................................................... R - 3

Repair and Service Manual

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REAR AXLE

Notes: ______________________________

Page R-ii

Repair and Service Manual

E.ZGDii:f:iit{•]:I

Section

REAR AXLE For further axle information, see Electric Rear Axle Manual E-Z-GO P/N 28147-G01.

Refer to rear suspension (Section P) for axle removal.

REAR AXLE DISASSEMBLY

Tool List

Qty. Required

Arbor press .................................................................. 1 Needle nose pliers....................................................... 1 Internal snap ring pliers ............................................... 1 Slide hammer, E-Z-GO P/N 18753-G1 ........................ 1 F or BRAKE DRUM REMOVAL, see page H-7.

CAUTION

Remove the outer snap ring from the axle tube. (Ref. Fig. R-1)

THE REAR AXLE/MOTOR 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 PERFORM ANY SERVICE ON THE AXLE, READ AND UNDERSTAND ALL OF THE FOLLOWING TEXT AND BEFORE ADJUSTING ILLUSTRATIONS OR DISASSEMBLING THE UNIT. SNAP RINGS MUST BE REMOVED/INSTALLED WITH CARE TO PREVENT DAMAGE OF BEARINGS, SEALS AND BEARING BORES.

It is recommended that whenever a bearing, seal or 'O' ring is removed, it be replaced with a new one regardless of mile­ age. Always wipe the seals and 'O' rings with a light oil before installing.

A

WARNING

A

TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LIFTING PROCEDURE IN SECTION "B" OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF AND BEHIND THE FRONT WHEELS AND CHECK THE STABILITY OF THE VEHICLE ON THE JACK STANDS BEFORE STARTING ANY REPAIR PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE.

Fig. R-1 Removing/Installing Outer Snap Ring Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube. (Ref. Fig. R-2)

Axle Shaft Removal and Disassembly (See Fig. R-1 "Removing/Installing Outer Snap Ring" on page R-1) (See Fig. R-2 "Removing/Installing Axle Shaff' on page R-1) (See Fig. R-3 "Pressing Bearing from Axle Shaff' on page R-2) (See Fig. R-7 "Cut Away of Outer Bearing and Brake Drum" on page R3)

E.ZlaDli=Eiht•i:I

Fig. R-2 Removing/Installing Axle Shaft

Repair and Service Manual

Page R-1

REAR AXLE Remove the bearing by supporting the inner race of the bearing on an arbor press bed and apply pressure to the threaded end of the axle shaft. (Ref. Fig. R-3)

\ Fig. R-4 Removing/Installing Inner Snap Ring Fig. R-3 Pressing Bearing from Axle Shaft

Axle Shaft Seal Removal and Replacement (See Fig. R-4 "Removing/Installing Inner Snap Ring" on page R-2) (See Fig. R-5 "Removing Sear on page R-2) (See Fig. R-6 "Installing Seal" on page R-3) (See Fig. R-7 "Cut Away of Outer Bearing and Brake Drum" on page R3)

Qty. Required

Tools List

Internal snap ring pliers ............................................... 1 Seal puller ................................................................... 1 Seal installer, E-2-GO P/N 18739-G1 ......................... 1 Ball peen hammer ....................................................... 1

CAUTION USE CARE TO PREVENT DAMAG E TO THE INNER SURFACE OF THE AXLE T UBE AT THE SEALING AREA.

Fig. R-5 Removing Seal

Remove the inner snap ring. (Ref. Fig. R-4)

To install the seal, use the special E-2-GO seal installer to drive the seal into its correct position. (Ref. Fig. R-6)

Use a puller to remove the seal. (Ref. Fig. R-5)

Install the inner snap ring.

Page R-2

Repair and Service Manual

REAR AXLE Coat the outboard spline of the axle with an anti-seize compound. Install the brake hub and drum, thrust washer, nut and new cotter pin.

Tighten the castellated axle nut to 70 ft. lbs. torque minimum, 140 ft. lbs. torque maximum. Continue to tighten until the slot in the nut aligns with the cotter pin hole.

Washer

Fig. R-6 Installing Seal

CAUTION TO PREVENT SEAL DAMAGE, LIGHTLY COAT THE AXLE SHAFT WITH BEARING GREASE AND SUPPORT THE SHAFT DURING INSTALLATION.

Axle Shaft Replacement

Bearing

(See Fig. R-1 "Removing/Installing Outer Snap Ring" on page R-1) (See Fig. R-7 "Cut Away of Outer Bearing and Brake Drum" on page R3)

Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with the differential side gears. Install the outer snap ring.

E.ZGDii:f:iid•]:I

Fig. R-7 Cut Away of Outer Bearing and Brake Drum

Repair and Service Manual

Page R-3

REAR AXLE

Notes: ______________________________

Page R-4

Repair and Service Manual

PAINT

Section TABLE OF CONTENTS FOR SECTION 'S' SECTION TITLE PAINTING

E.ZlaDii+:tid•l:I

Repair and Service Manual

PAGE NO. S -1

Page S-i

PAINT Notes: _______________________________

Page S-ii

Repair and Service Manual

E�l3Dii:f:;i;{•l:I

PAINT

Section

PAINTING For small scratches, E-Z-GO suggests that rough edges be removed by lightly sanding with sandpaper not exceeding 120 grit. Clean the area with alcohol and thor­ oughly dry.

Using the brush in the cap of touch up paint, apply the paint to the scratch. In cases of deep scratches, multiple coats may be applied to build up the area. Always remember to shake the bottle for a minimum of one minute to mix the paint and achieve the best color match.

For larger abrasions, E-Z-GO suggests that rough edges be removed by lightly sanding with sandpaper not exceeding 120 grit. Clean the area with alcohol and thor­ oughly dry.

Apply spray touch up paint in light even overlapping strokes. Multiple coats may be applied to provide ade­ quate 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.

E.ZlaDii:f:Jid•l:I

In situations where large areas must be painted, touch up paint is not recommended. In such cases professional painting or panel replacement is called for. E-Z-GO sug­ gests body panel replacement be considered as a cost effective alternative to painting. If the decision to repaint is taken, the task can be accomplished by any paint and body shop with experience in painting 'TPE' panels. TPE is a common material in modern automobile bodies and all body shops should be familiar with the materials and processes required.

The finish will include an application of a primer coat, a base color coat and a clear coat. E-Z-GO does not sup­ ply these materials due to the variety of paint manufac­ turers and the preferences of the individual painter.

Most paint manufacturers can perform a computer paint match to assure accurate color matching.

PPG Industries have color matched the vehicle colors and assigned the following part numbers: Green PPG P/N E-Z-GO 100 Champagne PPG P/N E-Z-GO 400

Repair and Service Manual

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PAINT Notes: _______________________________

Page S-2

Repair and Service Manual

EZlaDii:f:;id·l�I

Section

TROUBLESHOOTING

TABLE OF CONTENTS FOR SECTION 'T' SECTION TITLE

PAGE NO.

LIST OF ILLUSTRATIONS ELECTRICAL SYSTEM

T-1

SUSPENSION AND STEERING

T-3

Repair and Service Manual

Page T-i

TROUBLESHOOTING Notes: _________________________________

Page T-ii

Repair and Service Manual

� TROUBLESHOOTING

Section

ELECTRICAL SYSTEM

VEHICLE WILL NOT MOVE

r

Key 'OFF' or no direction selected

Turn key 'ON' and select direction

Batteries discharged

Charge batteries

Batteries unable to be charged

Replace batteries

Corroded or loose battery connection

Clean and tighten battery connection Apply a coat of commercial terminal protectant to all terminals

Corroded or loose battery connections Repair or replace faulty wiring to ESC controller, direction switch or motor

VEHICLE SPEED ERRATIC

Solenoid has failed

Replace solenoid

Key switch has failed

Replace key switch

Micro switch MS2 at direction switch has failed

Replace micro switch

Connector loose or separated

Install connector correctly

Faulty motor

Repair or replace motor Test by checking continuity of field coils (S1 - S2} and armature (A1 - A2 Check for continuity of armature to ground and field coils to ground which indicates a shorted condition

Faulty ESC system

Test and replace components as indi­ cated by test procedure

Ignition interlock switch has failed

Replace

DCS system failure (DCS vehicles only)

See Section E

Faulty ESC system

Test and replace components as indi­ cated by test procedure

DCS system failure (DCS vehicles only)

See Section E

NO REDUCED SPEED IN REVERSE Faulty ESC system MOTOR NOISY

Test and replace components as indi­ cated by test procedure

Damaged bearing

Replace bearing

Raised commutator bar(s)

Repair or replace motor

Loose motor mounting hardware

Tighten

Repair and Service Manual

Page T-1

I

TROUBLESHOOTING

BATTERIES WILL NOT CHARGE

Page T-2

Charger not functioning correctly

Repair or replace charger

Vehicle charging wiring faulty

Repair or replace wiring

Vehicle/charger connector damaged

Repair or replace connector

Battery case damage

Replace battery

Low electrolyte level

Maintain correct electrolyte level

Battery capacity deficient

Hydrometer/load test Replace battery if required

Repair and Service Manual

TROUBLESHOOTING SUSPENSION AND STEERING

UNEVEN TIRE WEAR STIFF STEERING

Incorrect tire pressure

Inflate to recommended pressure

Improper alignment (Incorrect toe in)

Align vehicle

Water has entered steering box and may freeze in cold condition

Remove steering column, pinion and bearing and remove water before add ing grease Inspect gasket for good seal

Excessive grease in steering box has Raise the vehicle and observe the migrated into steering rack bellows or rack bellows while moving the steering from lock to lock rack cover Any distortion of the bellows may indi cate that an excess of grease has built up in the bellows Remove the bellows and remove ex­ cess grease

PLAY IN STEERING

VIBRATION

STEERING PULLS TO ONE SIDE

E�l5Dii:f:9id•l:I

Insufficient lubricant in spindle pins, rod ends, idler bushing or steering bo

Add one shot of lubricant to each grease fitting and operate steering from lock to lock. DO NOT OVER GREASE If steering does not return to accept­ able condition proceed to next step

Bent rack

Remove rack and place on flat surface with rack teeth up If a .015" feeler gauge will pass under the rack, the rack must be replaced

Steering wheel loose

Inspect splines - replace if required Tighten steering wheel nut

Steering components worn

Repair or replace

Loose wheel bearings

Adjust or replace

Steering components worn

Repair or replace

Damaged wheel bearings

Adjust or replace

Out of round tires, wheels, or brake drums

Inspect and replace if required

Loose lug nuts

Tighten to 50 - 60 ft. lbs.

Incorrect tire pressure

Inflate to recommended pressure

Dragging wheel brakes

Adjust

Suspension component failure

Repair

Improper alignment

Align

Repair and Service Manual

Page T-3

TI

� TROUBLESHOOTING

Notes: ________________________________

PageT-4

Repair and Service Manual

E�l3Dii:f:iid•HI

LIGHTNING PROTECTION AND GROUNDING

Section

TABLE OF CONTENTS FOR SECTION 'U' SECTION TITLE

PAGE NO.

Grounding Requirements ................................................................................................................ U - 1 Ground Systems ............................................................................................................................ U - 1 Lightning Protection Requirements ................................................................................................ U - 1 Equipment Fault and Personal Safety System ............................................................................... U - 1 Ground Network Requirements ...................................................................................................... U - 2 External Grounding Requirements ................................................................................................. U - 2 Materials ......................................................................................................................................... U - 2 Earth Electrode System ................................................................................................................. U - 2 Lightning Protection System .......................................................................................................... U - 3 Equipment Fault and Personal Safety System ............................................................................... U - 3

E�ESDii:f:iid•l:I

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Page U-i

LIGHTNING PROTECTION AND GROUNDING

Notes: __________________________

Page U-ii

Repair and Service Manual

E�ESEJii:f:iid•l:I

LIGHTNING PROTECTION AND GROUNDING I GS-726-006

l

EFFECTIVE: 10/19/92

-------SUPERCEDES: -------REVISION:

Section

TITLE:

General Specification: Lightning Protection and Grounding

1. Grounding Requirements For the purpose of this specification, building ground systems should serve two primary functions: personal safety and equipment protection. In order to be effective, all elements and functions of building ground system must receive equal consideration in design and installation. Once installed, it is up to the owner to adequately maintain the sys­ tem by implementing periodic inspections and ground tests in order to determine its effectiveness.

2. Ground Systems All electronic equipment is inherently related to earth by capacitive coupling, accidental or incidental contact and intentional connection. The earth forms a natural readily available form of common potential reference for all electri­ cal circuits. For maximum effectiveness, grounding must be looked at from a total system viewpoint, with various sub-systems comprising the total facility ground system. The interconnection of the various sub-systems into a build­ ing ground system will provide a direct path, of known low impedance, between earth and the various electrical and other equipment. This effectively extends an approximation of ground reference throughout the building. The total building ground system is composed of an earth electrode system, a lightning protection system and an equipment fault protective system.

Resistance To Earth: The resistance to earth of the ground system should not exceed 1O ohms. Where the resis­ tance of 1o ohms cannot be obtained due to high soil resistivity, rock formations or other abnormal conditions, alter­ nate methods for reducing the resistance to earth must be considered.

Chemical Treatments: No salt, coke or other chemicals may be used to treat the soil in order to obtain the required ground resistance readings. Approved methods of enhancement are bentonite clay or the GEM product for ground enhancement as manufactured by Erico Products of Solon, Ohio.

Ground Tests: The resistance to earth of the ground system shall be measured by the "Fall of Potential Method".

Acceptable resistance meters/testers are those manufactured by Biddle or AEMC.

3. Lightning Protection Requirements The external lightning protection system shall be designed and installed by a contractor who specializes in the light­ ning protection field. The contractor must be listed with Underwriters Laboratories Inc. and be in good standing. All work shall be under the direct supervision of a Certified Master Installer with current credentials from the Lightning Protection Institute.

The materials and design for the structure will comply with the most recent edition of the National Fire Protection Association Lightning Protection Code, NFPA 780 and the Materials Standard for Safety from Underwriters Labora­ tories UL96. Materials for this project may be those of Harger Lightning Protection, 1066 Campus Drive, Mundelein, Illinois (800-842-7437).

Upon completion of the project, the contractor will supply to the owner the Master Label issued by Underwriters Lab­ oratories.

4. Equipment Fault and Personal Safety System The standard method of providing an equipment fault protection ground network is to run a good ground conductor (green wire) through the conduit together with the AC distribution system. This method is required for all types of conduit, including metallic.

EmliDiif:tid•J�I

Repair and Service Manual

Page U-1

LIGHTNING PROTECTION AND GROUNDING

I

I

GS-726-006 EFFECTIVE: 10/19/92

REVISION:

--------

TITLE:

General Specification: Lightning Protection and Grounding

--------

SUPERCEDES:

,,, ,

5. Ground Network Requirements Install the conduit in accordance with local regulations or as prescribed by the National Electrical Code.

6. External Grounding Requirements For optimum results, earth electrode installation must be accomplished early in the construction of a new site. The earth electrode system should be established at the same time utilities are installed to insure proper interconnection of all utility grounds/systems.

For existing sites, the earth electrode installation shall be constructed using the most economical means possible in order to meet the intent of this specification.

Prior to the installation or design of the ground system, a survey should be taken in order to determine the earth resistivity, types of soil or any man-made features that may have a significant effect upon the efficiency of the grounding system. Based on the information gathered, deviations from this specification (Exceeding normal require­ ments) may be necessary in order to achieve desired results.

7. Materials Ground Rod Electrodes: Ground rod electrodes shall have a minimum diameter of 5/8" and be no less than 10'-0" in length. Rods may be copper, copper-clad steel or stainless steel. Galvanized steel rods are not permitted unless it is determined that the galvanized rod will have a longer life expectancy due to soil conditions.

Ground Rod Spacing: Ground rods shall not be spaced at intervals exceeding 60'-0" around the perimeter of the structure.

Ground Loop Conductor: In no case shall the ground loop conductor be smaller than a 2/0 AWG bare, stranded, soft drawn copper wire. The ground loop must be installed at least 24" below grade and be at least 24" away from the structure. All bends in the conductor shall have a minimum radius of 8" and be no less than 90 degrees.

Ground Mats: In areas where electrodes cannot be driven, a ground mat consisting of a #6 solid copper or a copper­ copper clad steel mesh, utilizing a 12" x 12" cross pattern may be used. All inter-connections in the mesh shall be brazed or silver soldered.

Ground Plates: Ground plates if utilized shall be 24" x 24" x .032" thick solid copper. Ground plates should only be used if a ground rod cannot be driven.

Ground Connections: Unless otherwise specified or approved by the owner, all connections below grade shall be by exothermic weld (Cadweld). Where exothermic welds may not be practical, UL approved grounding clamps that uti­ lize two bolts for pressure may be used. NOTE: Prior approval must be obtained in order to use a mechanical con­ nection below grade.

8. Earth Electrode System The earth electrode system consists of a network of earth electrode rods, plates, mats or grids and their intercon­ necting conductors. The extensions into the building are used as the principle grounding point for connecting to the ground system serving the building. Ground potential is established by electrodes in the earth.

Page U-2

Repair and Service Manual

E�laDii=f:iit{•J�I

LIGHTNING PROTECTION AND GROUNDING �7

GS-726-006

REVISION:

EFFECTIVE:

SUPERCEDES:

10/19/92

--·-----

--------

TITLE:

General Specification: Lightning Protection and Grounding

An electrode may be a metallic water pipe that has no isolation joints, a system of buried, driven rods interconnected with a bare wire that normally forms a ring around the building or a ground plane of horizontal buried wires. Depend­ ing upon soil conditions, building design and the existing water pipe networks, an electrode may be a combination of any of the above mentioned systems.

9. Lightning Protection System The lightning protection system provides a non-destructive path to ground for lightning energy contacting or induced onto or in a building. To effectively protect from lightning damage, air terminals are installed according to the National Fire Protection Association Lightning Protection Code (NFPA 780). Air terminals will intercept the dis­ charge to keep it from penetrating or structurally damaging the building. This is done by providing a low impedance path from the air terminals to the earth electrode system.

10. Equipment Fault and Personal Safety System The equipment fault protective system ensures that personnel are protected from shock hazard and equipment is protected from damage or destruction resulting from faults (lightning induced surges) that may develop in the electri­ cal system. Deliberately engineered ground conductors (green wire safety ground) shall be provided throughout the AC distribution system to afford electrical paths of sufficient capacity, so that protective devices can operate promptly and efficiently. The use of conduit for grounding in lieu of a dedicated green wire is unacceptable.

Install the green wire ground (#6 stranded) with the AC power distribution conductors. There shall be no green wires spliced within the conduit. All splices shall be performed at the appropriate junction boxes.

Bond the ground conductor to all pull boxes, junction boxes and power panels.

In existing facilities where an existing conduit is not large enough to accommodate an additional ground conductor, or where a conduit section is insulated from other conduit sections, an external ground conductor may be installed to maintain continuity. All mounting hardware and connectors shall be UL approved.

All DC chargers are to be grounded to the green wire ground using UL approved connectors. At no point should the chargers be isolated from the grounding system.

All interior grounding should return to a single ground point. From this location it is then connected to the exterior ground system.

Optional Interior Ground Halo: If an interior ground halo is to be installed around the inside perimeter of the struc­ ture, this conductor (#2/0 green insulated minimum) shall be securely fastened to the structure. All connections to the halo shall be made using UL listed connectors.

E.ZEiDii:f:iid·l�I

Repair and Service Manual

Page U-3

LIGHTNING PROTECTION AND GROUNDING GS-726-006 EFFECTIVE: 10/19/92

REVISION:

--------

--------

SUPERCEDES:

TITLE:

General Specification: Lightning Protection and Grounding

Transient Voltage Surge Suppression: TVSS shall be provided at the main electrical service entrance panel. Protection at this point shall be as follows: UL 1449 Listed device 25,000 ampere surge capacity with maximum 495 volt clamping voltage Protection should be Line to Ground, Neutral to Ground and Line to Neutral Internally fused for safety Failure mode indicator lights

Suppression may be as the 14000 series of Harger Lightning Protection, Inc., 1066 Campus Drive, Mundelein, IL (800-842-7437), or MBP 120EFI series from EFI Electronics Corporation, 2415 South 2300 West, Salt Lake City, UT (801-977-9009).

Page U-4

Repair and Service Manual

GENERAL SPECIFICATIONS

Section

TABLE OF CONTENTS FOR SECTION 'V' SECTION TITLE . TXT ELECTRIC

PAGE NO. V -1

TXT ELECTRIC -FREEDOM

V-3

TXT ELECTRIC -4 CADDY

V-5

TXT DCS ELECTRIC

V-7

TXT DCS ELECTRIC - FREEDOM

V -9

LIST OF ILLUSTRATIONS Fig. V-1 Vehicle Dimensions .........................................................................................................V -11 Fig. V-2 Vehicle Dimensions and Incline Specifications ...............................................................V -12 Fig. V-3 Vehicle Turning Radius ...................................................................................................V -13

Ea.liDii:f:iitt•l:I

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Page V-i

GENERAL SPECIFICATIONS

Notes: ___________________________

Page V-ii

Repair and Service Manual

11 GENERAL SPECIFICATIONS

Section

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TXT ELECTRIC WEIGHT (without batteries) ....................................................... 550 lbs. (25 kg) LENGTH .................................................................................... 92.6 in. (233 cm) WIDTH ....................................................................................... 46.5 in. (118 cm) HEIGHT (at top of steering wheel) ............................................. 48.6 in. (123 cm) WHEEL BASE ............................................................................ 65.5 in. (166 cm) FRONT WHEEL TREAD ............................................................ 33.5 in. (85 cm) REAR WHEEL TREAD .............................................................. 38 in. (97 cm) TURNING CLEARANCE DIAMETER ........................................ 18.9 ft. (5.72 m) TIRES (4 ply rated)···································································· 18 x 8.50 x 8 TIRE PRESSURE ...................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ........................... 800 lbs. (362 kg) CHASSIS ................................................................................... Welded high yield strength tubular steel with powder coat paint BODY & FINISH ......................................................................... Durashield™ body of automotive quality injection molded TPE (thermoplastic elastomer). Molded in color with automotive color coat/clear coat finish SAFETY ..................................................................................... Dash mounted key switch, reverse warning indicator, 'deadman' accelerator control, integral handgrip on hip restraints, manual forward/reverse selector with 'neutral' STEERING WHEEL ................................................................... Dual handgrips and pencil holder integrated with scorecard clip/holder BRAKES .................................................................................... Dual rear wheel mechanical drum brakes, self­ adjusting with non-asbestos linings. Automatic park brake release with self-compensating system FRONT SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers REAR SUSPENSION ................................................................ Leaf springs with hydraulic shock absorbers STEERING................................................................................. Self-compensating single reduction rack and pinion DASH PANEL ............................................................................. Scuff resistant tee, ball and four drink holders SEATING .................................................................................... Formed fabric backed vinyl covers over cushion foam.

Seating for operator and one passenger

Repair and Service Manual

Page V-1

GENERAL SPECIFICATIONS MOTOR ...................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper windings. 2 hp (1.5 kw} at 2800 rpm and 3 hp (2.2 kw} at 2350 rpm DRIVE TRAIN ............................................................................. Direct motor shaft connected to transaxle pinion shaft ELECTRICAL SYSTEM ............................................................. 36 volt DC, six, 6 volt deep cycle storage batteries SPEED CONTROL. .................................................................... Solid State continuously variable speed controller CHARGER ................................................................................. Refer to specifications of charger supplied with vehicle TRANSAXLE .............................................................................. High efficiency differential with helical gears, 12.44:1 ratio SPEED ....................................................................................... 12 - 14 mph (19 - 23 kph)

* Specifications subject to change without notice

Page V-2

Repair and Service Manual

V

GENERAL SPECIFICATIONS TXT ELECTRIC - FREEDOM

WEIGHT (without batteries) ....................................................... 560 lbs. (254 kg) LENGTH .................................................................................... 92.6 in. (235 cm) WIDTH ....................................................................................... 46.5 in. (118 cm) HEIGHT (at top of steering wheel) ............................................. 48.6 in. (123 cm) WHEEL BASE ............................................................................ 65.5 in. {166 cm) FRONT WHEEL TREAD ............................................................ 33.5 in. (85 cm) REAR WHEEL TREAD .............................................................. 38 in. (97 cm) TURNING CLEARANCE DIAMETER ........................................ 18.9 ft. {5.72 m) TIRES (4 ply rated) ········· ··························································· 18 x 8.50 x 8 TIRE PRESSURE ...................................................................... 18 - 22 psi {124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ............................ 800 lbs. (362 kg) CHASSIS ................................................................................... Welded high yield strength tubular steel with powder coat paint BODY & FINISH ......................................................................... Durashield™ body of automotive quality injection molded TPE (thermoplastic elastomer). Molded in color with automotive color coat/clear coat finish SAFETY ..................................................................................... Dash mounted key switch, reverse warning indicator, 'deadman' accelerator control, integral handgrip on hip restraints, manual forward/reverse selector with 'neutral', electric horn LIGHTING PACKAGE ................................................................ Headlights, taillights, brake lights, optional turn signals and horn CONVENIENCE ......................................................................... State of charge meter on dash STEERING WHEEL ................................................................... Dual handgrips and pen9il holder integrated with scorecard clip/holder BRAKES .................................................................................... Dual rear wheel mechanical drum brakes, self­ adjusting with non-asbestos linings. Automatic park brake release with self-compensating system FRONT SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers REAR SUSPENSION ................................................................ Leaf springs and hydraulic shock absorbers STEERING................................................................................. Self-compensating single reduction rack and pinion DASH PANEL............................................................................. Scuff resistant tee, ball and four drink holders SEATING .................................................................................... Formed fabric backed vinyl covers over cushion foam.

Seating for operator and one passenger

E�GiCU:f:fot•W

Repair and Service Manual

Page V-3

GENERAL SPECIFICATIONS MOTOR ...................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper windings. 2 hp (1.5 kw) at 2800 rpm and 3 hp (2.2 kw) at 2350 rpm DRIVE TRAIN ............................................................................. Direct motor shaft connected to transaxle pinion shaft ELECTRICAL SYSTEM ............................................................. 36 volt DC, six, 6 volt deep cycle storage batteries SPEED CONTROL. .................................................................... Solid State continuously variable speed controller CHARGER ................................................................................. Refer to specifications of charger supplied with vehicle TRANSAXLE .............................................................................. High efficiency differential with helical gears,12.44:1 ratio SPEED ....................................................................................... 12 - 14 mph (19 - 23 kph)

* Specifications subject to change without notice

Page V-4

Repair and Service Manual

GENERAL SPECIFICATIONS TXT ELECTRIC - 4 CADDY WEIGHT (without batteries) ....................................................... 646 lbs. (293 kg) LENGTH (including footrest) ...................................................... 105 in. (2.7 m) WIDTH ....................................................................................... 46.5 in. (118 cm) HEIGHT (at top of steering wheel} ............................................. 48.6 in. (1.23 m) WHEEL BASE ............................................................................ 65.5 in. (1.66 m) FRONT WHEEL TREAD ............................................................ 33.5 in. (85 cm) REAR WHEEL TREAD .............................................................. 38 in. (96.7 cm) TURNING CLEARANCE DIAMETER ........................................ 18.9 ft. (5.72 m) TIRES (4 ply.rated)···································································· 18 x 8.50 x 8 TIRE PRESSURE ...................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ............................. 800 lbs. (362 kg) CHASSIS ................................................................................... Welded high yield strength tubular steel with powder coat paint BODY & FINISH ......................................................................... Durashield™ body of automotive quality injection molded TPE (thermoplastic elastomer). Molded in color with automotive color coat/clear coat finish SAFETY ..................................................................................... Dash mounted key switch, reverse warning indicator, 'deadman' accelerator control, integral handgrip on hip restraints, manual forward/reverse selector with 'neutral' LIGHTING PACKAGE ................................................................ Headlights, taillights, brake lights, optional turn signals and horn CONVENIENCE ......................................................................... State of charge meter on dash STEERING WHEEL ................................................................... Dual handgrips and pencil holder integrated with scorecard clip/holder BRAKES .................................................................................... Dual rear wheel mechanical drum brakes, self-adjusting with non-asbestos linings. Automatic park brake release with self-compensating system FRONT SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers REAR SUSPENSION ................................................................ Heavy duty leaf springs with hydraulic shock absorbers STEERING ................................................................................. Self-compensating single reduction rack and pinion DASH PANEL............................................................................. Scuff resistant tee, ball and four drink holders

E.ZGDii:f:fot•W

Repair and Service Manual

Page V-5

GENERAL SPECIFICATIONS SEATING .................................................................................... Formed fabric backed vinyl covers over cushion foam.

Seating for operator and one passenger. Flip up rear seat for storage access.

MOTOR ...................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper windings. 2 hp at 2800 rpm and 3 hp at 2350 rpm DRIVE TRAIN ............................................................................. Direct motor shaft connected to transaxle pinion shaft ELECTRICAL SYSTEM ............................................................. 36 volt DC, six, 6 volt deep cycle storage batteries SPEED CONTROL..................................................................... Solid State continuously variable speed controller CHARGER ................................................................................. Refer to specifications of charger supplied with vehicle TRANSAXLE .............................................................................. High efficiency differential with helical gears, 12.44:1 ratio SPEED ....................................................................................... 12 -14 mph (19 -23 kph)

* Specifications subject to change without notice

Page V-6

Repair and Service Manual

GENERAL SPECIFICATIONS TXT DCS ELECTRIC WEIGHT (without batteries) ....................................................... 550 lbs. (250 kg) LENGTH .................................................................................... 92.6 in. (235 cm) WIDTH ....................................................................................... 46.5 in. (118 cm) HEIGHT (at top of steering wheel) ............................................. 48.6 in. (123 cm) WHEEL BASE ............................................................................ 65.5 in. (166 cm) FRONT WHEEL TREAD ............................................................ 33.5 in. (85 cm) REAR WHEEL TREAD .............................................................. 38 in. (97 cm) TURNING CLEARANCE DIAMETER ........................................ 18.9 ft. (5.72 m) TIRES (4 ply rated)···································································· 18 x 8.50 x 8 TIRE PRESSURE ...................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ............................ 800 lbs. (362 kg) CHASSIS ................................................................................... Welded high yield strength tubular steel with powder coat paint BODY & FINISH ......................................................................... Durashield™ body of automotive quality injection molded TPE (thermoplastic elastomer). Molded in color with automotive color coat/clear coat finish SAFETY ..................................................................................... Dash mounted key switch, reverse warning indicator, 'deadman' accelerator control, integral handgrip on hip restraints, manual forward/reverse selector with 'neutral', electric horn CONVENIENCE ......................................................................... State of charge meter on dash STEERING WHEEL ................................................................... Dual handgrips and pencil holder integrated with scorecard clip/holder BRAKES .................................................................................... Dual rear wheel mechanical drum brakes, self­ adjusting with non-asbestos linings. Automatic park brake release with self-compensating system FRONT SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers REAR SUSPENSION ................................................................ Leaf springs and hydraulic shock absorbers STEERING ................................................................................. Self-compensating single reduction rack and pinion DASH PANEL ............................................................................. Scuff resistant tee, ball and four drink holders SEATING .................................................................................... Formed fabric backed vinyl covers over cushion foam.

Seating for operator and one passenger MOTOR ...................................................................................... 36 volt DC high efficiency shunt wound, brazed armature, solid copper windings.

E�GiDii:f:iilM:I

Repair and Service Manual

Page V-7

GENERAL SPECIFICATIONS DRIVE TRAIN............................................................................. Direct motor shaft connected to transaxle pinion shaft ELECTRICAL SYSTEM ............................................................. 36 volt DC, six, 6 volt deep cycle storage batteries SPEED CONTROL..................................................................... Solid State continuously variable speed controller CHARGER ................................................................................. Refer to specifications of charger supplied with vehicle TRANSAXLE .............................................................................. High efficiency differential with helical gears, 12.44:1 ratio SPEED ....................................................................................... 12 -14 mph (19 -23 kph)

* Specifications subject to change without notice

Page V-8

Repair and Service Manual

GENERAL SPECIFICATIONS TXT DCS ELECTRIC - FREEDOM WEIGHT (without batteries) ....................................................... 550 lbs. (250 kg) LENGTH .................................................................................... 92.6 in. (235 cm) WIDTH ....................................................................................... 46.5 in. (118 cm) HEIGHT (at top of steering wheel) ............................................. 48.6 in. (123 cm) WHEEL BASE ............................................................................ 65.5 in. (166 cm) FRONT WHEEL TREAD ............................................................ 33.5 in. (85 cm) REAR WHEEL TREAD .............................................................. 38 in. (97 cm) TURNING CLEARANCE DIAMETER ........................................ 18.9 ft. (5.72 m) TIRES (4 ply rated) ···································································· 18 x 8.50 x 8 TIRE PRESSURE ...................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ............................ 800 lbs. (362 kg) CHASSIS ................................................................................... Welded high yield strength tubular steel with powder coat paint BODY & FINISH ......................................................................... Durashield™ body of automotive quality injection molded TPE (thermoplastic elastomer). Molded in color with automotive color coat/clear coat finish SAFETY ..................................................................................... Dash mounted key switch, reverse warning indicator, 'deadman' accelerator control, integral handgrip on hip restraints, manual forward/reverse selector with 'neutral', electric horn LIGHTING PACKAGE ................................................................ Headlights, taillights, brake lights, optional turn signals and horn CONVENIENCE ......................................................................... State of charge meter on dash STEERING WHEEL ................................................................... Dual handgrips and pern�il holder integrated with scorecard clip/holder BRAKES .................................................................................... Dual rear wheel mechanical drum brakes, self­ adjusting with non-asbestos linings. Automatic park brake release with self-compensating system FRONT SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers REAR SUSPENSION ................................................................ Leaf springs and hydraulic shock absorbers STEERING ................................................................................. Self-compensating single reduction rack and pinion DASH PANEL............................................................................. Scuff resistant tee, ball and four drink holders SEATING .................................................................................... Formed fabric backed vinyl covers over cushion foam.

Seating for operator and one passenger

E:.ZGDiiUM•m

Repair and Service Manual

Page V-9

�1

GENERAL SPECIFICATIONS

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MOTOR ...................................................................................... 36 volt DC high efficiency shunt wound, brazed armature, solid copper windings.

DRIVE TRAIN ............................................................................. Direct motor shaft connected to transaxle pinion shaft ELECTRICAL SYSTEM ............................................................. 36 volt DC, six, 6 volt deep cycle storage batteries SPEED CONTROL.. ................................................................... Solid State continuously variable speed controller CHARGER ................................................................................. Refer to specifications of charger supplied with vehicle TRANSAXLE .............................................................................. High efficiency differential with helical gears, 12.44:1 ratio SPEED ....................................................................................... 12 - 14 mph (19 - 23 kph}

* Specifications subject to change without notice

Page V-10

Repair and Service Manual

e�Gt:ni:f:Utt·m

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GENERAL SPECIFICATIONS 1

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= SHADED AREA INDICATES 4CADDY OUTLINE

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Fig. V-1 Vehicle Dimensions

E�GCii:f:fot•m

Repair and Service Manual

Page V-11

� GENERAL SPECIFICATIONS

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Rear

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RECOMMENDED MAX RAMP 25%GRADE 14° MAX

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Fig. V-2 Vehicle Dimensions and Incline Specifications

Page V-12

Repair and Service Manual

GENERAL SPECIFICATIONS

TURNING CLEARANCE DIAMETER 18.9 ft. (5.8 m)

Fig. V-3 Vehicle Turning Radius

E�GDii=Ui,!•):i

Repair and Service Manual

Page V-13

�1

GENERAL SPECIFICATIONS

Notes: ________________________________

Page V-14

Repair and Service Manual

Read and understand the following warnings before attempt­ ing to operate the vehicle:

_A WARNING _A ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION.

_A WARNING _A WHEN VEHICLE IS TO BE LEFT UNATTENDED, MOVE DIRECTION SELECTOR TO NEUTRAL POSITION, TURN KEY TO 'OFF' POSITION, REMOVE KEY AND ENGAGE PARKING (PARK) BRAKE. DRIVE VEHICLE ONLY AS FAST AS TERRAIN AND SAFETY CONSIDERATIONS ALLOW. CONSIDER THE TERRAIN AND EXISTING TRAFFIC CONSIDER CONDITIONS. ENVIRONMENTAL FACTORS WHICH EFFECT THE TERRAIN AND YOUR ABILITY TO CONTROL THE VEHICLE. AVOID DRIVING FAST DOWN HILL. SUDDEN STOPS OR CHANGE OF DIRECTION MAY RESULT IN A LOSS OF CONTROL. USE BRAKE TO CONTROL SPEED WHEN TRAVELING DOWN AN INCLINE. USE EXTRA CARE AND REDUCED SPEED WHEN DRIVING ON POOR SURFACES, SUCH AS LOOSE DIRT, WET GRASS, GRAVEL, ETC. ALL TRAVEL SHOULD BE DIRECTLY UP OR DOWN HILLS. USE EXTRA CARE WHEN DRIVING THE VEHICLE ACROSS AN INCLINE. STAY IN DESIGNATED AREAS AND AVOID STEEP SLOPES. USE THE PARKING BRAKE WHENEVER THE VEHICLE IS PARKED. KEEP FEET, LEGS, HANDS AND ARMS INSIDE VEHICLE AT ALL TIMES. .AVOID EXTREMELY ROUGH TERRAIN. CHECK AREA BEHIND THE VEHICLE BEFORE OPERATING IN REVERSE. MAKE SURE THE DIRECTION SELECTOR IS IN CORRECT POSITION BEFORE ATTEMPTING TO START THE VEHICLE. SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. ALWAYS BRING VEHICLE TO A COMPLETE STOP BEFORE SHIFTING THE DIRECTION SELECTOR. STANDARD VEHICLE IS LIMITED TO TWO (2) OCCUPANTS MAXIMUM PER SEAT.

Read and understand the following text and warnings before attempting to service the vehicle:

In any product components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

It is virtually impossible to anticipate all possible compo­ nent failures or the manner in which each component may fail.

Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there­ fore may be considered potentially hazardous. Use extreme care when working on any vehicle. When diag­ nosing, removing or replacing any components that are not operating correctly, take time to consider the safety ramifications should the component move unexpectedly.

Some components are heavy, spring loaded, highly cor­ rosive, explosive or may produce amperage or reach high temperatures. Battery acid and hy drogen gas could result in serious bodily injury to the technician/mechanic and bystanders if not treated with the utmost caution. Be careful not to place hands, face, feet or body in a location that could expose them to injury should an unforeseen situation occur.

_A WARNING _A BEFORE WORKING ON VEHICLE: REMOVE ALL JEWELRY (RINGS, WATCHES, ETC.) RAISE REAR OF VEHICLE AND SUPPORT ON JACK STANDS BEFORE ATTEMPTING TO RUN OR ADJUST POWERTRAIN-.

WEAR EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE EYES TO POTENTIAL INJURY. IN PARTICULAR USE CARE WHEN WORKING AROUND BATTERIES, USING SOLVENTS OR COMPRESSED AIR. HYDROGEN GAS IS FORMED WHEN CHARGING BATTERIES. DO NOT CHARGE BATTERIES WITHOUT ADEQUATE VENTILATION. DO NOT PERMIT OPEN FLAME OR ANYONE TO SMOKE IN AN AREA THAT IS BEING USED FOR CHARGING BATTERIES. CONCENTRATIONS OF 4% HYDROGEN GAS OR MORE IS EXPLOSIVE.

a ii#:fo!·mCotnpany E-2-GO Division of Textron Inc. P.O. Box 388 Augusta, Georgia 30903-0388 USA

Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc. Technical Communications Department