EZGO RXV ELECTRIC RXV GOLF CAR RXV FREEDOM RXV SHUTTLE 2+2 TECHNICIAN’S REPAIR AND SERVICE

RXV Electric TECHNICIAN’S REPAIR AND SERVICE MANUAL Electric Powered Vehicle

ISSUED SEPTEMBER 2015

647700-C

REVISED APRIL 2016

SAFETY For any questions about material in this manual, contact an authorized representative.

Read and understand all labels on the vehicle. Always replace any damaged or missing labels.

Steep hills allow the vehicles to move at faster speeds than speeds on a flat surface. To prevent the loss of vehicle control and possible injury, speeds must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICATIONS section. Apply the brake to control the speed.

If you operate the vehicle above the maximum specified speed, you can damage the drivetrain components. The damage caused by speeds more than the maximum specified can cause a loss of vehicle control, is abuse, and will not be covered under the warranty.

Refer to the TRANSPORTING VEHICLE section to learn how to tow or move the vehicle from one location to another location.

Use extra caution when towing the vehicle(s). Do not tow a single vehicle at speeds in excess of 12 mph (19 kph). Do not tow more than three vehicles at a time. Do not exceed 5 mph (8 kph) while towing multiple vehicles. 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 the AC Drive motor must be towed with the run/tow switch, located under the passenger seat, in the TOW position.

If the vehicle is used in a commercial environment, signs must be in position to inform of possible conditions that can be dangerous. Examples shown below.

NOTICES, CAUTIONS, WARNINGS AND DANGERS Read the NOTICES, CAUTIONS, WARNINGS and DANGERS. The person who services a vehicle needs the mechanical skill and experience to see possible hazardous conditions. Incorrect service or repairs can cause damage to the vehicle or make the vehicle dangerous to operate.

A NOTICE indicates and describes information not related to personal injury.

A DANGER indicates a dangerous condition that will cause death or serious injury.

The battery posts, terminals and all related accessories contain lead and lead compounds.

Wash your hands after you contact any of these components.

A CAUTION indicates a dangerous condition that can cause injury that is not life threatening.

A WARNING indicates a dangerous condition that can cause death or serious injury.

NOTICES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER.

REPAIR AND SERVICE MANUAL ELECTRIC POWERED GOLF CARS & PERSONAL VEHICLES

RXV GOLF CAR RXV FREEDOM™ RXV SHUTTLE 2+2

STARTING MODEL YEAR 2016

CALIFORNIA Proposition 65 Warning WARNING:

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

Textron Specialized Vehicles reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously.

The information contained in this manual may be revised periodically by Textron Specialized Vehicles, and therefore is subject to change without notice.

TEXTRON SPECIALIZED VEHICLES DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

These are the original instructions as defined by 2006/42/EC.

CONTACT US: Textron Specialized Vehicles 1451 Marvin Griffin Road.

Augusta, Georgia, USA 30906-3852

GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA).

The standards and specifications listed in the following text originate in the USA unless otherwise indicated.

The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty.

Overfilling battery may void the warranty.

Tampering with or adjusting the governor to permit vehicle to operate above factory specifications will void the vehicle warranty.

When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture.

BATTERY PROLONGED STORAGE Batteries self-discharge over time. The rate of self-discharge varies depending on the ambient temperature, the age and condition of the batteries.

Fully charged batteries will not freeze in winter temperatures unless the temperature falls below -75°F (- 60°C).

BATTERY DISPOSAL Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material such as sand. Dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

Notes:

SAFETY INFORMATION SAFETY INFORMATION

GENERAL

as a ground connection.

Never use the chassis or body

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability, increase the speed or extend the stopping distance beyond factory specifications.

Such modifications can result in serious personal injury or death.

GENERAL OPERATION ALWAYS:

SAFETY INFORMATION

MAINTENANCE ALWAYS:

VENTILATION ALWAYS:

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER LABEL LOCATION

TRANSPORTING THE VEHICLE Towing

Do not ride or allow other people on a vehicle being towed.

DO NOT try to tow the vehicle with ropes, chains or any device other than a tow bar approved by the factory.

DO NOT tow a single vehicle at speeds in excess of 12 mph (19 kph).

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DO NOT exceed 5 mph (8 kph) while towing multiple vehicles.

DO NOT tow more than three vehicles at a time.

Do not tow the vehicle on highways.

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To prevent damage to the electric motor and controller, place the key switch in the N position and the run/tow switch in the TOW position prior to towing the vehicle.

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Do not tow a single vehicle at speeds in excess of 12 mph (19 kph). Do not tow more than three vehicles at a time. Do not exceed 5 mph (8 kph) while towing multiple vehicles. Towing the vehicle above the recommended speed may result in severe injury and/or damage to the vehicle and other property.

Tow bars are not intended for road use.

If a vehicle is towed in excess of 12 mph, the motor brake will engage and slow the vehicle down.

7IVMEP 2YQFIV 0SGEXMSR SR 6IEV *VEQI

Figure 1 Serial Number Location

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Hauling Vehicle with a Trailer

Make sure you secure the vehicle and all items before you transport a vehicle on a trailer.

Do not allow any people on a vehicle being transported on a trailer.

Remove the windshield before you transport a vehicle on a trailer.

Maximum speed with canopy installed is 50 mph (80 kph).

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Figure 2 Run/tow Switch

SERVICING THE VEHICLE

Read all notices, cautions and warnings in this manual before you do any type of service operations.

The drive wheels must be lifted and supported on jack stands before you do any service to the powertrain when the motor is in operation.

To decrease the risk of motor damage, do not operate the vehicle at full throttle for more than 5 seconds with the drive wheels lifted off the ground.

Disconnect the negative (-) battery cable before you service the vehicle to prevent accidental operation.

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Wear eye protection when you service the vehicle. Be careful when you do work around batteries, use solvents or compressed air.

To decrease the risk of an electrical arc, which can cause a battery explosion, disable all electrical loads from the batteries before you remove the battery wires.

Use insulated wrenches to decrease the risk of a short-circuit if a wrench falls across the battery terminals. A battery short-circuit can cause an explosion.

The electrolyte in a battery is an acid solution which can cause burns to the skin and eyes.

Completely clean all electrolyte spills that contact the body and eyes with clear water. Contact a physician immediately.

INITIAL SERVICE CHART Item

Service Operation

Neutralize electrolyte spills with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) mixed in 1 quart (1 liter) of water.

Clean with water.

Be careful when you use aerosol containers near battery terminals. Use a metal container that is insulated to prevent an explosion.

To decrease the risk of damage to the controller or motor, move the run/tow switch to the TOW position before you tow the vehicle.

Before you disconnect or connect battery cables or any other wires, move the run/tow switch to the TOW position.

After you connect a battery cable or any other wires, wait a minimum of 30 seconds before you move the switch to the RUN position.

ROUTINE MAINTENANCE

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

POWERTRAIN MAINTENANCE

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

.

TIRES

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LIGHT BULB REPLACEMENT 6EGO &EPP .SMRX :MI[ JVSQ 9RHIVWMHI SJ :ILMGPI

VEHICLE CLEANING AND CARE

Figure 3 Lubrication Points

REAR AXLE

BRAKES

Always inspect the pedal travel before you operate a vehicle to confirm some brake function is found.

Make sure you do all brake tests in a safe location with regard to the safety of all personnel.

A subtle loss of brake performance can occur over time.

It is important to establish the standard stopping distance with a new vehicle.

To decrease the risk of severe injury, read and understand all instructions supplied by the manufacturer of the pressure washer before use.

When cleaning the outside of the vehicle with a pressure washer, do not use more than 700 psi pressure. Keep a minimum distance of 12 inches from the spray nozzle to the painted surface. Do not clean the plastic parts with abrasive solvents.

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Battery Maintenance Kit (P/N 25587G01)

Plexus Plastic Cleaner and Polish (P/N 606314)

CANOPY AND WINDSHIELD ENVIRONMENTAL CONCERNS

Always be respectful of the environment.

Make sure you are permitted by property owners to operate the vehicle on their property.

There is a risk of fire when the vehicle is operated near combustible material.

Be careful of environmental hazards like steep slopes, tree branches, etc.

The canopy does not provide protection from roll-over or falling objects.

The windshield does not provide protection from tree limbs or flying objects.

Remove the windshield and store securely before transporting the vehicle on a trailer. The windshield is not designed to withstand highway speeds.

Maximum speed with the canopy installed is 50 mph (80 kph).

Battery Disposal

HARDWARE VEHICLE CARE PRODUCTS

Touch-Up Paint (Contact a service parts representative for availability)

Multi-Purpose Battery Protectant (P/N 606312)

Multi-Purpose Hand Cleaner (P/N 607636)

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TORQUE SPECIFICATIONS %00 83659) *-+96)7 %6) -2 *8 0&7 2Q 9RPIWW SXLIV[MWI RSXIH MR XI\X XMKLXIR EPP LEVH[EVI MR EGGSVHERGI [MXL XLMW GLEVX 8LMW GLEVX WTIGMJMIW PYFVMGEXIH XSVUYI JMKYVIW *EWXIRIVW XLEX EVI TPEXIH SV PYFVMGEXIH [LIR MRWXEPPIH EVI GSRWMHIVIH [IX ERH VIUYMVI ETTVS\MQEXIP] SJ XLI XSVUYI VIUYMVIH JSV HV] JEWXIRIVW &308 7->)

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Figure 4 Torque Specifications and Bolt Grades

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

SAFETY NOTICES, CAUTIONS, WARNINGS AND DANGERS

MODIFICATIONS TO VEHICLE

NOTICES, CAUTIONS, WARNINGS, DANGERS

Changes to the weight distribution or the center of gravity decreases the stability of the vehicle and can cause it to easily turn over.

A NOTICE indicates and describes information not related to personal injury.

A CAUTION indicates a dangerous condition that can cause injury that is not life threatening.

A WARNING indicates a dangerous condition that can cause death or serious injury.

GENERAL MAINTENANCE

Always use correct service procedures. Never do any type of service procedure before you read and understand all notices, cautions, warnings and dangers in this manual.

A DANGER indicates a dangerous condition that will cause death or serious injury.

IMPORTANT SAFETY WARNING

BEFORE SERVICING THE VEHICLE

Remove all jewelry before you work on the vehicle.

Do not allow loose clothing or hair to contact the moving parts.

Do not touch hot objects.

Bef or e y ou eng ag e or ad jus t the powertrain, lift and support the vehicle on the jack stands.

Wear OSHA approved clothing and ey e p r o t e ct i o n w h e n w o r ki n g o n anything that could expose the body

SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

or eyes to potential injury. In particular, use care when working around batteries, using compressed air or solvents.

Always remove the key from the key switch before you disconnect an active circuit.

When you connect the battery cables, pay particular attention to the polarity of the battery terminals. Do not confuse the positive and negative cables.

Engage the parking brake, except when the powertrain must be allowed to rotate or the brake system needs service.

If repairs are to be made that requires welding or cutting, the batteries must be removed.

Open flame or sparks can cause an explosion. Keep all flammable materials away from the batteries.

Explosive hydrogen gas is created during the charge cycle of the batteries. Good ventilation can remove gas from the buildings. The air must change every 12 minutes.

Make sure that the key switch is in the OFF position, and the key removed.

Make sure all electrical accessories are disabled before you start to service the vehicle.

The batteries must be removed before any service or repairs that can cause sparks.

Never disconnect an active circuit at a battery terminal.

The batteries are heavy. Use proper lifting techniques to l if t t h e b at t e r i e s.

Always lift the battery with a commercially available battery lifting device. Make sure that you do not tilt the batteries during removal or installation. An electrolyte spill can cause burns and damage.

The electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes.

Always use clean water to wash electrolyte from your body or eyes. Get medical assistance immediately.

When you service the vehicle, always wear eye protection. Be careful when working around batteries or using solvents or compressed air.

Any electrolyte spills should be neutralized with a solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1 1/2 gallons (6 liters) of water and flushed with water.

Use insulated wrenches to prevent the possibility of a dropped wrench causing a short-circuit if it falls across the battery terminals.

Aerosol containers of battery terminal protectant must be used with extreme care. Insulate any metal container to prevent the container from contacting battery terminals which could result in an explosion.

Make sure that you fill the batteries to a level of 1/2 inch (13 mm) above the plates. Electrolyte more than 1/2 inch (13 mm) above the plates can cause a spill from the battery during the charge cycle. A spill of electrolyte can cause damage to the vehicle and storage facility.

SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

LIFTING THE VEHICLE

To reduce possibility of severe injury or death resulting from a vehicle falling from a jack: Set the park brake.

The vehicle is not stable during the lifting process.

Make sure the vehicle is on a hard and level surface.

Never get below a vehicle that is supported by a jack only.

Make sure a vehicle that is supported on jack stands is stable before you get below the vehicle.

Put wheel chocks in front and behind the wheels that remain on the ground.

Do not allow any person in or on the vehicle being lifted.Use extreme care since the vehicle is extremely unstable during the lifting process.

When lifting the vehicle, position jacks and jack stands only in the areas indicated.

How to Lift the Entire Vehicle Lifting the Vehicle Tool List

Qty.

SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

How to Lift the Rear of the Vehicle Only

How to Lift the Front of the Vehicle Only

Lower the Vehicle

SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

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Figure 1 Body

GENERAL

erate sparks or repairs that require welding or cutting.

Vehicle accessories, such as the canopy and windshield, need to be removed before removing many body components.

Hardware (nuts, washers, etc.) that is removed must always be installed in their original positions unless otherwise specified. Non-specified torques are shown in the table in the GENERAL INFORMATION AND MAINTENANCE Section.

To prevent possible injury or death from a battery explosion, batteries should always be removed before any servicing that could gen-

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Figure 2 Ratchet Rivet Removal

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BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BODY COMPONENT REPLACEMENT Front Bumper Tool List

Qty.

ITEM

TORQUE SPECIFICATION

ITEM

TORQUE SPECIFICATION

Figure 4 Rocker Panel Removal

Floormat

Tool List

Qty.

I

Figure 3 Front Bumper

Rocker Panels Tool List

Qty.

Figure 5 Floormat Fastener Removal

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Figure 6 Floormat

Cowl and Instrument Panel Tool List

Qty.

Figure 7 Cowl and Instrument Panel Trim

Using an insulated wrench, disconnect the battery cable at the negative (BL-) battery terminal.

Figure 8 Instrument Panel and Cup Holder

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

To prevent the possibility of injury or death, the correct safety label must be on the instrument panel cup holder at all times.

ITEM

TORQUE SPECIFICATION

Front Splash Guard Tool List

Qty. Figure 9 Front Splash Guard

Figure 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Sweater Basket Tool List

Qty.

Rear Body Tool List

ITEM

Qty.

TORQUE SPECIFICATION

Seat Back Assembly Tool List

ITEM

Qty.

TORQUE SPECIFICATION

Fender Liner Tool List

Qty.

.

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ITEM

TORQUE SPECIFICATION

Rear Bumper Tool List

Qty.

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TORQUE SPECIFICATION

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Figure 11 2 + 2 Rear Facing Seat & Foot Rest

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

2 + 2 REAR FACING SEAT AND FOOT REST Tool List

Qty.

Figure 13 Rear Facing Seat Back

Figure 12 Rear Facing Seat Bottom

Figure 14 Rear Facing Seat Hip Restraint

Figure 15 Upper Hip Restraint Bolts

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Figure 18 Foot Rest Removal

Figure 16 Front Seat Back

Figure 17 Rear Facing Seat Foot Rest Figure 19 Seat Back Support

ITEM

TORQUE SPECIFICATION

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FLOORBOARD Tool List

Qty.

Figure 21 Bagwell Closeout

Bagwell Closeout Tool List

Qty.

Installation is in the reverse order of removal. Replace any worn or damaged hardware.

BODY CARE MAINTENANCE Figure 20 Seat Support and Floorboard ITEM

Cleaning Tools & Supplies List

TORQUE SPECIFICATION

cleaners or solvents.

Do not use abrasive

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Larger Scratches Test the wax on an inconspicuous area before applying to the entire vehicle. Buff the wax by hand.

Do not use a power buffer to remove wax from the body panels.

PAINTING

All painting must be done in an area with adequate ventilation to safely disperse harmful vapors.

Wear eye protection and a respirator to protect from overspray and airborne mist.

Provide protection from overspray to vehicle and surrounding area.

Minor Scratches Complete Panel Repair

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BATTERIES AND CHARGING Safety

If you fill the batteries with electrolyte above the maximum level, you can cause an electrolyte spill during the charge cycle. An electrolyte spill can cause damage to the vehicle and storage facility.

To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks away from the batteries.

Hydrogen gas is made as batteries are charged. Do not charge batteries without good ventilation. A 4% concentration of hydrogen gas is explosive.

Be careful when you use aerosol containers near the battery terminals. Insulate the container to prevent an explosion.

Use insulated wrenches to decrease the risk of a short-circuit if a wrench falls across the battery terminals. A battery short-circuit can cause an explosion.

Battery Disposal

Make sure that the key switch is in the OFF position and all electrical accessories are off before you start to work on the vehicle.

Turn off all accessories before disconnecting from the battery terminal.

Use safe procedures to move the batteries.

Always lift the battery with a commercially available battery lifting device.

Do not tilt the batteries during removal or installation. An electrolyte spill can cause burns and damage.

The electrolyte in a storage battery is an acid solution which can cause 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 you add water or charge the batteries.

Neutralize electrolyte spills with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) mixed in 1 quart (1 liter) of water. Clean with water.

Battery

BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Battery Maintenance Tool List

Quantity

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Electrolyte Level and Water

DO NOT overfill batteries. The charge cycle will expel electrolyte and cause component damage.

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BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

To clean an electrolyte spill, use a solution of 2 teaspoons (10 ml) sodium bicarbonate (ba ki n g soda) m ixed with 1 quart (1 liter) of water.

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Always wear a safety shield or approved safety goggles when you add water or charge the batteries.

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To prevent battery damage, make sure you correctly install all battery caps.

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To decrease the risk of damage to vehicle or floor, neutralize acid before you spray the battery with water.

The watering device must only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates.

To decrease the risk of damage to the electrical components while cleaning, do not use a pressure washer.

The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Clean all electrolyte spills to the body and eyes with clear water. Contact a physician immediately.

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BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Be careful when you use aerosol containers near the battery terminals. Use a container with insulation to prevent an explosion.

Battery Removal and Installation Tool List

Quantity

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Figure 1 Battery Removal

Batteries are heavy. Use correct lifting methods when you move them.

Always lift the battery with a commercially available battery lifting device. Be careful not to tilt batteries when you remove or installing them; spilled electrolyte can cause burns and damage.

Hardware that is removed must be installed in its original position unless otherwise specified. If torque values are not specified, refer to the Torque Specifications table.

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BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Aerosol containers of battery protector spray must be used with extreme care. Insulate the metal container to decrease the risk of container from contacting battery terminals which could result in an explosion.

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BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

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Disconnect the battery charger, controller and other electronic devices for extended storage. All connected electronic components cause the discharge of batteries.

Put the run/tow switch in the RUN position for extended storage of the vehicle to prevent draining of the batteries.

Battery Charging

Do not overfill batteries. The charge cycle will expel electrolyte and cause component damage.

BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

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;IMKLX 8LIVQSQIXIV

To prevent battery explosion, never insert a metal thermometer into a battery. Use a hydrometer with a built in thermometer that is designed for testing batteries.

BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

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 for the water to adequately mix with the electrolyte.

Using A Hydrometer )PIGXVSP]XI 8IQTIVEXYVI * '

i

i

i

i i i i i i i i i i i i i i

)<%140) )PIGXVSP]XI 8IQTIVEXYVI %FSZI * ' )PIGXVSP]XI XIQTIVEXYVI * ' ,]HVSQIXIV VIEHMRK !

GSVVIGXIH WTIGMJMG KVEZMX]

Battery Charger Maintenance )<%140) )PIGXVSP]XI 8IQTIVEXYVI &IPS[ * ' )PIGXVSP]XI XIQTIVEXYVI * ' ,]HVSQIXIV VIEHMRK !

GSVVIGXIH WTIGMJMG KVEZMX]

BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BATTERY CHARGER

sparks, flames and flammable materials away from batteries.

Risk of electric shock.

Connect the charger power cord to an outlet that is correctly installed and connected to an electrical ground according to all codes and regulations.

A grounded outlet is necessary to decrease the risk of electric shock.

Do not use ground adapters or replace the plug.

Supply enough ventilation during the charge cycle.

Never charge a frozen battery.

Read all of the manufacturers specified precautions for the battery. For example, recommended rates of charge and removal of cell caps during charge cycle.

charger.

A dedicated circuit is necessary for the

Do not touch parts of output connector or battery terminals that do not have insulation.

Disconnect the DC plug before you make or break the connections to a battery that is charging.

Do not open or disassemble the charger.

Do not operate the charger if the AC cord is damaged.

Make sure qualified personnel does all repair work to the charger.

Do not allow children to use the charger.

Keep the air fins clear to prevent the charger from over-heating that can cause damage to the charger and possible fire. Install portable chargers on a platform above the ground to allow maximum air flow around and below the charger.

Use the charger on 48-volt battery systems only. Other use can cause personal injury and damage to the vehicle.

Lead acid batteries can create explosive hydrogen gas during normal operation. Keep

Put the DC cord through the center of the steering wheel to remind you to put the cord away when finished with the charger. You can damage the DC plug if you drive over or catch the cord on the vehicle when you drive away.

BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

LED Operation Codes

To decrease the possibility of electrical shock or electrocution, make sure that the charger plug is not damaged and is correctly connected to a grounded outlet.

The power AC cord has a plug with a ground post. Do not remove, cut or bend the ground post.

The charger DC cord has a polarized connector which fits into a receptacle on the vehicle.

If the vehicle is charged with a charger different from the one supplied with the vehicle, refer to the instructions supplied with the charger used.

UNDERSTAND THE CHARGER

LED Fault Codes

BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

To decrease the possibility of electrical shock or electrocution, make sure that the charger plug is not damaged and is correctly connected to a grounded outlet.

The power AC cord has a plug with a ground post. Do not remove, cut or bend the ground post.

HOW TO USE THE CHARGER

'LEVKIV 6IGITXEGPI

CHARGER MAINTENANCE

BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ELECTRICAL SYSTEM

-RWXVYQIRX 4ERIP

;MVMRK ,EVRIWW

1SXSV

'LEVKIV 6IGITXEGPI &EXXIVMIW

MAIN WIRING HARNESS

Replacing the Main Wiring Harness Tool List

Qty.

Using an insulated wrench, disconnect the battery cable at the negative (BL-) battery terminal.

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

7IRWSV 6IWMWXSV 7SPIRSMH

'SRXVSPPIV

Figure 1 Instrument Panel & Trim

6IH ;MVI XS &EXXIV] &0

Figure 2 Controller

Figure 3 Run / Tow Switch

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

7TPEWL 7LMIPH

1SXSV

Figure 5 Motor Connections

Installation

7IRWSV 6IWMWXSV

&YW FEV 7SPIRSMH XS 'SRXVSPPIV &

'SRXVSPPIV 6IH ;MVI XS &EXXIV] &0

Figure 4 Solenoid Connections

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Figure 7 Cup Holder

Figure 6 Harness Routing & Pedal Connections

Figure 8 Front Splash Shield

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

7TPEWL 7LMIPH

Figure 9 Charger Receptacle Figure 11 Reverse Warning Indicator & Fuse

.

7IRWSV 6IWMWXSV

&YW FEV 7SPIRSMH XS 'SRXVSPPIV &

'SRXVSPPIV

ITEM 6IH ;MVI XS &EXXIV] &0

Figure 10 Controller Connections

TORQUE SPECIFICATION

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REPLACING ELECTRICAL COMPONENTS Run / Tow Switch Tool List

Qty.

Figure 12 Run / Tow Switch

Use an insulated wrench to disconnect the battery cable at the negative (BL-) battery terminal.

ITEM

TORQUE SPECIFICATION

Reverse Warning Indicator Tool List

Qty.

Use an insulated wrench to disconnect the battery cable at the negative (BL-) battery terminal.

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

7TPEWL 7LMIPH

Figure 15 State of Charge Meter

Figure 13 Reverse Warning Indicator

ITEM

TORQUE SPECIFICATION

State of Charge Meter Replacement Tool List

Qty.

ITEM

Figure 14 Trim Panel Hardware

TORQUE SPECIFICATION

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Figure 16 Main Wiring Harness Diagram

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

36%2+) 6)( ;,-8) 6)(

6)(

&0%'/

+6))2 &09) ;,-8) &09)

&0%'/ ;,-8)

&0%'/

&0%'/

&0%'/

&0%'/

+6))2

6)(

+6%= 49640)

Figure 17 Accessory Wiring Harness Diagram

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

,IEHPMKLX 8YVRWMKREP

6IPE] *YWI ,SPHIVW

%GGIWWSV] ,EVRIWW

,SVR *VSRX 7TPEWL 7LMIPH ,SVR &YXXSR

6IEV 7TPEWL 7LMIPH

&VEOI 0MKLX 8YVR 7MKREP

Figure 18 Accessory Wiring Harness and Accessories

ACCESSORY WIRING HARNESS Use an insulated wrench to disconnect the battery cable at the negative (-) battery terminal.

To access the accessory wiring harness for replacement, it is necessary to remove the upper and lower rocker panels, the floormat, the front cowl, the top portion of the cup holder and the seat bottom. See the Body Section in this manual for instructions on removal and replacement of these items.

Replacing the Accessory Wiring Harness Tool List

Qty.

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Installation Figure 19 Brake Light Relay

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REPLACING ELECTRICAL ACCESSORIES

Turn Signal Bulb Replacement (if equipped)

Use an insulated wrench to disconnect the negative (-) cable from the battery.

Headlight Bulb Replacement (if equipped)

To decrease the risk of premature bulb failure, do not allow your fingers to contact new bulbs. Use clean, dry paper or paper towels to touch the glass part of the bulb.

Taillight Bulb Replacement (if equipped)

Figure 20 Headlight and Turn Signal Bulb

Headlight Switch Replacement Tool List

Qty.

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Turn Signal Switch Replacement

Figure 21 Trim Panel Hardware

Figure 22 Head Light Switch

Turn Signal Flasher Unit Replacement

ITEM

TORQUE SPECIFICATION

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Horn Button Replacement

AWG TO METRIC CONVERSIONS AWG

METRIC (MM2)

VOLTAGE TEST FOR BATTERIES

Hydrogen gas formed during battery charging is explosive.

Horn Replacement

Keep electrical sparks or open flames away from batteries.

If the temperature of the battery or the ambient temperature is below 60° F (15.55° C), the capacity of the battery will be less and require more time to charge.

Do not overcharge batteries.

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Due to the resistance of the wires in the harness, voltage readings can be somewhat lower than battery voltage. A reading of 1 volt below battery voltage is acceptable.

MAIN HARNESS Power Supply Tool List

Qty.

The power wire supplies power to the entire fuse block.

Bare wires can cause a short circuit.

If any DVOM readings indicate a faulty wire, check the condition of the terminals and wire junction. A faulty wire must be replaced.

Use of a fuse with an incorrect rating can damage the electrical components.

Accessory Wiring

Faulty Wire Replacement

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FAULT TESTING General

Continuity Check

To prevent possible injury or death caused by a battery explosion, disconnect the electrical power. Use an insulated wrench to remove the negative (BL-) wire from the battery.

Testing a Switch for Continuity

Testing Battery Voltage

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

4VIWW XS EGXMZEXI W[MXGL

Figure 23 Continuity Check of Switch

Testing a Solenoid for Continuity

Figure 24 Continuity Check of Solenoid

ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ELECTRONIC SPEED CONTROL 6IZIVWI ;EVRMRK -RHMGEXSV

'SRXVSPPIV

6YR 8S[ 7[MXGL

%GGIPIVEXSV 4IHEP 4IHEP 'SZIV

Fig. 1 Electronic Speed Control

GENERAL Hardware (nuts, washers, etc.) that are removed must always be installed in their original positions unless otherwise specified. Non-specified torques are shown in the table in the GENERAL INFORMATION AND ROUTINE MAINTENANCE Section.

6EXGLIX *EWXIRIV

2SXGLIH 4V] &EV

To prevent possible injury or death from battery explosion, batteries should always be removed before any servicing that could generate sparks or repairs that require welding or cutting.

Figure 2 Ratchet Rivet Removal

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

4IHEP 'SZIV 6EXGLIX 6MZIX

Fig. 3 Pedal Cover

Accelerator Pedal Assembly Tool List

Qty.

Installation Using an insulated wrench, disconnect the battery cable at the negative (BL-) battery terminal.

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Solenoid Replacement Tool List

Qty.

Using an insulated wrench, disconnect the battery cable at the negative (BL-) battery terminal.

Solenoid Removal

Figure 4 Accelerator Pedal

.

ITEM

TORQUE SPECIFICATION

Figure 5 Solenoid

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Use an insulated wrench to disconnect the battery cable at the negative (BL-) battery terminal.

Make sure that the run/tow switch is in the RUN position, turn the key to R (reverse) and wait for the reverse warning indicator sound to stop.

Solenoid Installation

Controller Removal

Replace worn or damaged hardware.

ITEM

7TPEWL 7LMIPH

TORQUE SPECIFICATION

Controller Tool List

Qty.

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

7SPIRSMH 6IWMWXSV

6IH ;MVI XS &EXXIV] &0 'SRXVSPPIV

Fig. 6 Controller and Solenoid

Controller Installation

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ITEM

TORQUE SPECIFICATION

Resistor and Heat Shield Installation

.

6)7-7836 ,)%8 7,-)0( %77)1&0= 6IWMWXSV

,EVH[EVI

'SRXVSPPIV

1SYRXMRK &VEGOIXW

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BRAKES GENERAL

Hardware (nuts, washers, etc.) that are removed must always be installed in their original positions unless otherwise specified. Non-specified torques are shown in the table in the GENERAL INFORMATION AND ROUTINE MAINTENANCE section.

To prevent possible injury or death from a battery explosion, batteries should always be removed before any servicing that could generate sparks or repairs that require welding or cutting.

Brake Pedal Assembly Tool List

Qty.

Use an insulated wrench to disconnect the battery cable at the negative (BL-) battery terminal.

Figure 1 Pedal Cover

BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ITEM

Fig. 2 Brake Pedal Return Spring

Figure 3 Brake Pedal

TORQUE SPECIFICATION

BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FRONT SUSPENSION AND STEERING

Fig. 1 Front Suspension and Steering

MAINTENANCE Hardware (nuts, washers, etc.) that are removed must always be installed in their original positions unless otherwise specified. Non-specified torques are shown in the GENERAL INFORMATION AND ROUTINE MAINTENANCE section.

To prevent possible injury or death, follow the lifting procedure in the SAFETY section of this manual. Place wheel chocks in front 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.

Tire Wear Diagnosis

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

-2(-'%8)7 %6)%7 3* )<')77-:) 8-6) ;)%6 238) -PPYWXVEXMSRW EVI HMWXSVXIH JSV GPEVMX] (YI XS XLI PS[ [IMKLX SJ XLI

Fig. 2 Tire Wear

Wheel Alignment (Figure 3)(Figure 4)

Tool List

Qty.

<

*6328 3* :),-'0) < r QQ r QQ

Figure 3 Wheel Alignment

Failure to turn both tie rods the same number of turns will result in poor turning radius.

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ITEM ITEM

TORQUE SPECIFICATION

TORQUE SPECIFICATION

Spindle Assembly (Figure 5)

Tool List

Qty.

Figure 4 Tie Rod Jam Nut

Hub Assembly

(Figure 5)

(Figure 5)

Tool List

Qty.

.

Lock nuts must be replaced after a maximum of five removals.

ITEM

TORQUE SPECIFICATION

Struts Tool List

Qty.

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

(Figure 5)

ITEM

TORQUE SPECIFICATION

Figure 5 Hub, Spindle, Strut and Control Arm Assemblies

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Control Arm Assembly (Figure 5)

Tool List

Qty.

To maintain correct orientation when replacing steering wheel, turn the wheels straight ahead.

To prevent damage to the clipboard perform the following removal procedure. Do not use a screwdriver to push or pry the retaining tabs.

7XIIVMRK ;LIIP 'PMTFSEVH

When reinstalling the urethane bushings (14 & 16) coat the contact surfaces with a commercially available antiseize compound. Make sure that compound does not get on the bolt or nut threads.

7XIT

7XIT

Figure 6 Clipboard Removal ITEM

TORQUE SPECIFICATION

Do not remove nut at this time.

.

Clipboard and Steering Wheel (Figure 6) (Figure 7)(Figure 8)

Tool List

Qty.

Figure 7 Loosen Steering Wheel

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Installation

Figure 9 Lower Cross Bolt Figure 8 Steering Wheel

7XIIVMRK 'SPYQR

ITEM

TORQUE SPECIFICATION

Steering Column Assembly and Yoke (Figure 9) (Figure 10)(Figure 11)

Tool List

Qty. Figure 10 Steering Column Assembly Screws

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

-RXIVQIHMEXI 7LEJX ITEM

=SOI

TORQUE SPECIFICATION

Tie Rod End / Ball Joint Tool List

=SOI Figure 11 Upper Cross Bolt

Qty.

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Steering Box (Figure 12)

Tool List

Qty.

ITEM NO

8MI 6SH )RH

Figure 12 Steering Box

TORQUE SPECIFICATION

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

MOTOR GENERAL Motor Removal

Disconnect the negative (BL-) battery cable with an insulated wrench before attempting to disconnect wires from the motor (see safety procedures in SAFETY section of this manual).

Tool List

Qty.

1SXSV

Figure 1 Motor Connections

MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

A drive belt or woven strap may be used as a sling to help support the motor during removal.

Figure 3 Motor Bolt Tightening Sequence

Figure 2 Motor

1SXSV 8IVQMREP

;MVI 1EVOIV

*VSQ 'SRXVSPPIV

9

9

9

:

:

:

;

;

;

Figure 4 Motor Wiring The motor must be examined every 20,000 AMP-Hours for wear.

Motor Installation

Figure 5 Motor to Controller Connections

MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

ITEM

TORQUE SPECIFICATION

Motor Brake

Figure 6 Motor Brake

Disconnect the negative (BL-) battery cable with an insulated wrench before attempting to disconnect wires from the motor (see safety procedures in SAFETY section of this manual).

Tool List

Qty.

DO NOT drop the brake assembly. Dropping or hitting the brake assembly will cause damage.

Motor Brake Installation

Motor Brake Removal

ITEM

TORQUE SPECIFICATION

MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Speed Sensor Removal

Disconnect the negative (BL-) battery cable with an insulated wrench before attempting to disconnect wires from the motor (see safety procedures in SAFETY section of this manual).

Tool List

Qty.

3 VMRK

1SXSV

Figure 7 Speed Sensor Removal

Speed Sensor Installation

MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REAR AXLE 1SXSV

1SXSV &VEOI

%\PI

,YF Fig. 1 Rear Axle

REAR AXLE MAINTENANCE

Checking the Torque to Rotate Tool List

Replacing the Lubricant Qty.

Tool List

Qty.

REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REAR AXLE DISASSEMBLY To reduce the possibility of personal injury, follow the lifting procedure in SAFETY section of this manual. Place wheel chocks in front 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.

The rear axle is a precision assembly and therefore any repair or replacement of parts must be done with extreme care in a clean environment. Before attempting to perform any service on the axle, read and understand all of the following text and illustrations before disassembling the unit.

Handle all splines with extreme care.

Snap rings must be removed and installed with care to prevent damage to the bearings, seals and bearing bores. .

It is recommended that whenever a bearing seal or oring is removed, it be replaced with a new one regardless of the mileage. Always wipe the seals and o-rings with a light oil before installing.

Fill Procedure

and replace the fill

plug.

To reduce the possibility of personal injury, follow the lifting procedure in the SAFETY section of this manual. Place wheel chocks in front 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.

Rear Hub Tool List

*MPP 4PYKW

Figure 2 Fill Plug

Qty.

REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Figure 4 Outer Snap Ring

Figure 3 Hub

Figure 5 Remove Axle Shaft ITEM

TORQUE SPECIFICATION

Axle Shaft, Bearing and Seal Removal and Disassembly Tool List

&IEVMRK 7ITEVEXSV

Qty.

Figure 6 Press Bearing from Shaft

REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Use care to prevent damage to the inner surface of the axle tube at the seal area.

Figure 7 Oil Seal Removal

Figure 8 Seal Installation

To prevent damage to the oil seal, lightly coat the axle shaft with bearing grease and support the shaft during installation.

REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REAR SUSPENSION

*VEQI

0IEJ 7TVMRK &VEGOIX

7LSGO %FWSVFIV

0IEJ 7TVMRK

7LEGOPI 6IEV %\PI

Figure 1 Rear Suspension

GENERAL Hardware that is removed must always be installed in its original position unless otherwise specified. Non specified torques are shown in the table contained in the GENERAL INFORMATION section.

To reduce the possibility of personal injury, follow the lifting procedure in the SAFETY section of this manual. Place wheel chocks in front 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.

SHOCK ABSORBER Tool List

Qty.

Using an insulated wrench, disconnect the battery cable at the negative (BL-) battery terminal.

REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

If both leaf springs are to be replaced and the rear axle is not being removed, remove and replace one leaf spring at a time. It is recommended that leaf springs be replaced in pairs.

Removal

Installation

Figure 2 Shock Absorber

REAR LEAF SPRING Tool List

Qty.

REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Removal and installation of the leaf spring is the same for both sides of the vehicle.

Replace any worn or damaged hardware as required. It Lock nuts must be replaced after a maximum of five removals.

ITEM

TORQUE SPECIFICATION

Figure 3 Rear Leaf Spring

REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

WHEELS AND TIRES WHEEL AND TIRE SERVICE Tools List

Qty. All four tires

Tire Repair

To decrease the risk of tire explosion, add small amounts of air to the tire at intervals to seat the tire beads. Over inflation of small tires can occur in a few seconds.

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

Do not over inflate the tires. Excess pressure can cause the tire to separate from the wheel or explode.

Protect face and eyes when removing a tire valve core.

Use only sockets made for use with impact wrenches to decrease the risk of injury caused by a broken socket.

Do not use tires that have a recommended tire inflation pressure less than the tire pressure recommended in the GENERAL INFORMATION AND MAINTENANCE section.

To prevent injury, be sure the mounting/demounting machine is anchored to the floor. Wear OSHA approved safety equipment when mounting or demounting tires.

WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Wheel Installation

Do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.

Always follow the cross sequence pattern when installing the lug nuts to make sure the wheel is evenly seated against the hub.

Item

Torque Specification

0YK 2YX

'VSWW 7IUYIRGI

:EPZI 7XIQ

2SXI 8MVI [LIIP WX]PI QE] ZEV]

Fig. 1 Wheel and Tire Installation

WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

WEATHER PROTECTION 'ERST]

;MRHWLMIPH

Figure 1 Canopy and Windshield

CANOPY AND WINDSHIELD

The canopy does not provide protection from roll over or falling objects.

The windshield does not provide protection from tree limbs or flying objects.

The canopy and windshield are for weather protection only.

Clean the windshield with water and a clean cloth.

Remove minor scratches with a commercial plastic polish or Plexus plastic cleaner, available from the service parts department.

Transporting the Vehicle

To prevent personal injury to occupants of other highway vehicles, be sure that the vehicle and contents are secured to trailer.

Do not ride on a vehicle being transported.

Remove the windshield before transporting.

Maximum speed with canopy installed is 50 mph (80 kph).

103

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

If the vehicle is being transported on a trailer at highway speeds, remove the windshield and canopy and secure the seat bottoms. Always check that the vehicle and contents are secured before transporting the vehicle.

The rated capacity of the trailer must be more than the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load.

Engage the parking brake and secure the vehicle to the trailer with ratchet tie downs.

WINDSHIELD Tool List

Qty.

Torx Bit, 50 IP .............................................................. 1 Ratchet ........................................................................ 1 Torque Wrench, in.-lbs................................................. 1 Rubber Mallet .............................................................. 1 Flat Screwdriver........................................................... 1 Fig. 2 Windshield Do not over tighten or compress the windshield grommets when installing on windshield.

1.

Remove two Torx head screws (1) from the lower portion of the windshield.

2.

Release the rubber latches (2) and fold the top portion of the windshield down.

3.

Carefully pull the outer edge of the windshield sash (3) forward and slide the flat screwdriver into the opening. Pull toward the front of the vehicle, separating the sash from the front strut. Repeat for the other side.

4.

To reinstall the windshield, hang the windshield on the front strut using the rubber latches (2) on the top portion of the windshield.

5.

Align the holes in the lower section with the holes in the front strut. Alignment guides (long thin screwdriver or bolts) may be helpful in keeping the holes aligned as the windshield is carefully pushed onto the front strut.

6.

104

Install two Torx head screws (1) carefully. Do not over tighten.

ITEM 1

TORQUE SPECIFICATION 124 - 142 in. lbs (14 - 16 Nm)

GOLF CAR CANOPY Tool List

Qty.

Socket, 15 mm .............................................................1 Ratchet ........................................................................1 Ratchet Extension........................................................1 Wrench, 15 mm............................................................1 Torque Wrench, in. lbs .................................................1 Flat Screwdriver ...........................................................1 If vehicle is equipped with a windshield, remove it before working with the top.

Removal 1.

Remove six flanged hex nuts (1) and the hex bolts (2) securing the canopy to the struts.

2.

Lift the top off the struts and set aside.

3.

Remove the access cover (5) by sliding a flat screwdriver under the edge and prying away from the instrument panel. Repeat on the other side of vehicle.

4.

Remove the two hex head bolts (6) from each side that secure the front strut to the vehicle. Lift the strut until it clears the instrument panel and cowl.

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

5.

Remove the rubber grommets (7) from the front strut holes if they did not come off with the struts.

6.

Remove four flanged hex nuts (3) from inside the sweater basket. Remove the four hex head bolts (4) that slide through the rear top strut. Lift the strut to clear the sweater basket. Repeat for the other side.

Installation 1.

Place the rubber grommets (7) into the holes in each side of the front cowl The grommets should follow the contour of the body.

2.

Position the front strut with the bend pointing toward the rear of the vehicle. Slide the strut through the grommets and into position. Align the holes in the strut with the holes in the frame. Insert the hex head bolts (6). Do not tighten hardware.

3.

Position the rear struts so that the bends are toward the outside of the vehicle and the top legs point toward the front of the vehicle. Align the mounting holes in each strut with the matching holes in the sweater basket and seat back support. Secure with the hex head bolts (5) and nuts (4). Finger tighten hardware to allow for adjustment.

4.

Place the canopy onto the struts. Secure with six hex head bolts (2) places down through the top and through the struts. Secure with nuts (1). Finger tighten hardware to allow for adjustment.

5.

Make sure that the grommets (7) on the front strut are in place.

6.

Tighten all fasteners to the correct torque.

7.

Replace the access covers (5) in the instrument panel.

DO NOT over tighten fasteners. Exceeding the specified torque value will crush the strut tubes.

ITEM

TORQUE SPECIFICATION

2, 4

71 - 98 in. lbs (8 - 11 Nm)

6

177 - 203 in. lbs (20 - 23 Nm)

105

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Figure 3 Golf Car Canopy

2 + 2 CANOPY Tool List

Qty.

Socket, 15 mm............................................................. 1 Ratchet ........................................................................ 1 Ratchet Extension ....................................................... 1 Wrench, 15 mm ........................................................... 1 Torque Wrench, in. lbs................................................. 1 Flat Screwdriver........................................................... 1

106

If vehicle is equipped with a windshield, remove it before working with the canopy.

Removal 1.

Remove four hex nuts (10) and the hex bolts (8) securing the rear of the top (3) to the struts (5 & 6).

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

2.

Remove two hex nuts (10) and hex bolts (13) and spacers (12) securing the front of the canopy (3) to the strut (4).

Figure 4 2 + 2 Canopy 3.

Lift the top (3) off of the struts and set it aside.

6.

4.

Remove the access cover (1) by sliding a flat screwdriver under the edge and prying away from the instrument panel. Repeat for the other side.

Remove the rubber grommets (14 & 15) from the front strut holes if they did not come off with the struts.

7.

5.

Remove the two hex head bolts (11) from each side that secure the front strut to the vehicle. Lift the strut (4) until it clears the instrument panel and cowl.

Remove two hex bolts (9) from one rear strut (5 or 6). Repeat for the other side.

107

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Installation 1.

Place the rubber grommets (14, 15) into the holes in each side of the front cowl. The grommet should follow the contour of the body.

2.

Position the front strut (4) with the bend pointing toward the rear of the vehicle. Slide the strut through the grommets and into position. Align the holes in the strut with the holes in the frame and insert the hex head bolts (11). Do not tighten hardware.

3.

Position the rear struts (5 & 6) so that they are bent to the outside of the vehicle and the top legs point to the rear of the vehicle. Align the mounting holes in each strut with the matching holes in the seat back support, install the hex head bolts (9) finger tight only.

4.

Place the canopy onto the struts and install two hex head bolts (13) and spacers (12) at the front through the struts. Install the nuts (10) finger tight.

5.

Install four hex head bolts (8) and hex nuts (10) through the rear struts (5 & 6) finger tight.

6.

Make sure that the grommets (14 & 15) on the front strut (4) are in place.

7.

Tighten all fasteners to the correct torque.

8.

Replace the access covers (1) in the instrument panel.

•

Place mirror bracket (2) up to strut and feed bolt (3) through existing hole in the mirror bracket (2).

•

Secure mirror bracket (2) tightly to strut using the nut (4). Be sure to point mirror bracket outwards from the vehicle

Figure 5 Rear View Mirror DO NOT over tighten fasteners. Exceeding the specified torque value will crush the strut tubes.

7XVYX

ITEM

TORQUE SPECIFICATION

10

133 - 159 in. lbs (15 - 18 Nm)

9, 11

177 - 203 in. lbs (20 - 23 Nm)

*VSRX SJ :ILMGPI

REAR VIEW MIRROR WITH CANOPY Tool List

Qty.

Wrench, 12mm ............................................................ 1 Wrench, 15mm ............................................................ 1 Ratchet Handle, 3/8”.................................................... 1 Drive T-45 Torx Bit, 3/8” ............................................... 1 Phillips Bit, #2 .............................................................. 1 Wheel Chocks ............................................................. 1

Mirror Bracket Installation •

108

Attach the mirror bracket (2) to the strut by feeding the torx bolt (3) through the existing slot located on left and right front strut (Figure 6) (Figure 7).

Figure 6 Mirror brackets Installation

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REAR VIEW MIRROR WITHOUT CANOPY

7XVYX

Tool List *VSRX SJ :ILMGPI

Qty.

Socket, 15 mm.............................................................1 Ratchet ........................................................................1 Ratchet Extension........................................................1 Wheel Chock ...............................................................4 •

Remove driver side plugs from dash (Figure 9).

Figure 7 Mirror brackets Installation

Figure 9 Dash plug removal

Mounting Mirror to Bracket

•

•

Remove the bolt that is already attached to the mirror’s mounting arm. Keep the bolt for later installation.

Slide driver-side grommet approximately 12 in. (305 mm) up driver-side of front strut.

•

Remove driver-side, passenger-side panels and Hex head bolts from dash (Figure 10).

•

Slide the mirror’s mounting arm into open slot on bracket (2).

•

Lower front strut (1) into openings revealed.

•

•

Using the existing bolt (A) from mirror (1), secure mirror to mirror bracket (2) and tighten the bolt (A) to the torque value specified below

Insert existing bolts (4) through upper and lower holes, and secure to pre-installed weld nuts. Access holes through openings revealed in previous steps.

•

Tighten the bolt (5) to the torque value specified below

Item A

•

Torque Specification

Item

2 - 5 ft. lbs (3 - 7 Nm)

5

Use Phillips bit to adjust the direction of the mirror.

Torque Specification 15 - 17 ft. lbs (20 - 23 Nm)

•

Replace dash panels.

•

To install rear view mirror. See “Mirror Bracket Installation” on page 108. and See “Mounting Mirror to Bracket” on page 109.

1SYRXMRK %VQ

Figure 8 Mounting Mirror to Bracket

109

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

(VMZIV 7MHI

4EWWIRKIV 7MHI

Figure 10 Side Panel removal form dash •

Place the cap (2) on the top of the strut (Figure 11).

Figure 11 Strut with end cap •

Completed mirror and strut is as shown below (Figure 12).

*VSRX SJ :ILMGPI

*VSRX SJ :ILMGPI

Figure 12 Strut with Rear View Mirror installed.

110

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

111

WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

112

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

HANDHELD DIAGNOSTICS DIGITAL VOLT OHM METER A typical DVOM (digital volt ohm meter) is shown. A recommended model is available through the Service Parts Department (P/N 27481G01). For the purpose of this section, the red probe (+) and black probe (-) are used. Any DVOM may be used, however the controls, displays, accuracy and features may vary depending on the make and model. Always follow the meter manufacturer’s recommendations and instruction for the use and care of the meter.

'3:)6 (-+-8%0 (-740%=

(%8% , 7;-8', 6%2+) 7;-8',

'328-29-8= 8)78 (-3() 8)78 %' (' '966)28 83++0) 7;-8', 86%27-7836 73'/)8

*92'8-32 7)0)'836 7;-8',

8)78 0)%(

8)78 0)%(

8)78 6)')48%'0)7

Fig. 1 DVOM

FAULT DIAGNOSIS To troubleshoot the circuits that include the horn, lighting, brake/turn signals and gages, the technician must be able to use the wiring diagram and a DVOM.

If power is not present but the other headlight functions, a wiring problem is indicated between the two headlights.

In some cases where battery voltage is expected, the easiest way to test the circuit is to set the DVOM to DC volts and place the negative (-) probe of the DVOM to the negative battery terminal. Move the positive (+) probe to each wire termination starting at the battery and working out to the device that is not working. Be sure to check both sides of all switches and fuses.

When no battery voltage is found, the problem lies between the point where no voltage is detected and the last place that voltage, was detected. In circuits where no voltage is expected, the same procedure may be used except that the DVOM is set to continuity. Place the negative (-) probe on a wire terminal at the beginning of the circuit and work towards the device that is not working with the positive (+) probe. When continuity is no longer indicated, a failed conductor or device is indicated.

ACCESSORY WIRING HARNESS After determining that there is power to the fuse and the fuse is good, continue checking the circuit using the procedures previously used to check the power supply, i.e. loose or rusted connections, bare wires, continuity of the wiring from terminal to terminal, operating condition of switch, etc.

Use the wiring diagram to check correct wiring and wire routing. If there is power at the fuse end of the wire, there must also be power at the other end of the wire at the switch or electrical accessory, and eventually at the ground connection. Electricity must flow from the fuse through the full length of the circuit to the ground connection. Any interruption of electricity flow must be corrected, whether by repairing or replacing the wire, the switch or the accessory.

The technician should use simple logic troubleshooting in order to reduce the number of steps required to isolate the problem.

Example 1: If the vehicle will not start or none of the lights function (or burn dimly) the battery should be tested before trying to troubleshoot the lighting circuit.

Example 2: If a problem occurs in the lighting circuit that results in only one of the headlights not working, there is no reason to check battery wiring or the fuse since it is obvious that voltage is present. Since bulbs will burn out over time, the obvious place to start is at the headlight that is not functioning. if power is present at the connector and the ground wiring is satisfactory, the only possibilities that exist are a burned out bulb or a poor contact between the connectors and the headlight.

113

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

POWER SUPPLY Tool List

Qty. 7SJX /I]W

DVOM.......................................................................... 1

Check For Loose or Bare Wires

(MWTPE] 7GVIIR

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. Bare wires can cause a short circuit.

2EZMKEXMSR /I]

If any DVOM readings indicate a faulty wire, it is recommended 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 wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

HOW TO USE THE HANDHELD PROGRAMMER The Curtis handheld Programmer is used for programming, testing, fault testing, tuning, diagnosing and parameter adjustments of the speed controller and auxiliary devices.

4S[IV *EZSVMXIW 1IRY ERH ,IPT /I]

4S[IV 'SVH

Check Battery Condition Check for adequate battery volts (nominal 12 VDC) by setting the DVOM to the 30 VDC range. 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 12 VDC or greater indicates adequate battery condition. No reading indicates a poor connection between the probes and the battery terminals or a faulty DVOM. A voltage reading below 12 volts indicates poor battery condition. The vehicle should be recharged before proceeding with the test.

(EXE -RGVIEWI SV (EXE (IGVIEWI /I]

Figure 2 Curtis 1313 Hand held Programmer E-Z-GO utilizes a ‘Molex to Tyco’ adapter connected to the power cord to connect to the vehicle diagnostic port provided under the seat.

Plug the Curtis handheld programmer into the programmer port only. If plugged into the wrong port, voltage from other interface circuits may result in permanent damage to the programmer.

The main menu appears after the data is uploaded from the controller unit.

Primary Connection: 4 PIN TYCO •

Located under passenger seat

•

Remove protective water cap

•

Use both harness adapters

•

Align white dots on connector

•

Engage and twist sleeve to secure, a slight snap or click may be heard/felt

Figure 3 Primary Connection

114

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Navigation With the four arrow keys, you can scroll up and down, and right and left, within the dis0)*8 6-+,8 play. In the Main Menu, you can use the arrow keys to highlight one of (3;2 th menus. Open the highlighted menu using the “Select” soft-key. Within menus (other than the Main Menu), the left arrow key is used to navigate backward within menus, the right arrow key is used to navigate forward to open the highlighted sub-menus or items.

94

eral aspects of the handheld programmer’s functionality.

•

FILE MANAGER - With File Manager you can create, delete, move, copy and paste files and folders.

•

PLOT & LOG - Through the Plot & Log menu, you can use the Plot program to plot real-time variables, or use the Log program to create a log of variable values to view later in a spreadsheet program on your PC.

Changing Data Value Press the Data Increase or Data Decrease key to change the value of the parameter.

Bookmark The bookmark key is an alternate way to bring up the Favorites menu. you can access the Favorites menu by selecting its icon in the Main Menu, or by using the Favorites key. To set a favorite, navigate to the menu desired and select the soft-key “add to”. Use the soft key “select” to select “Favorites”. Choose the soft key “add” and then “finish”.

Main Menu Definitions •

SYSTEM INFO - The System Info menu opens directly to a detail screen providing information about the motor controller to which the programmer is connected.

•

PARAMETERS - This is where you can adjust the settings of the control system’s adjustable parameters.

•

MONITOR - Show vehicle real-time diagnostics.

•

DIAGNOSTICS - Show active and past faults.

•

PROGRAMMING - Through the Programming menu, you can save and restore your parameter sttings files (.cpf files).

•

FAVORITES - The Favorites menu consists of the custom set of items you have created.

•

HHP SETTINGS - This menu allows you to adjust the appearance of the screen displays and also sev-

115

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Menu 1313

System Information

Parameters

116

Sub Menu 1

Sub Menu 2

Sub Menu 3

Data Range Default value Display the controller model Model Number number Display the controller protocol Protocol Version version Display the controller serial Serial Number number Display controller date of Mfg Date Code manufacture Display the controller Hardware Version hardware version Display controller operating OS Number system Display controller OS build Build Number number Supervisor Version Display supervisor version Display controller supervisor Supervisor Build No. build number.

HW Version Display controller HW version Battery Reset Volts Per Cell 0.900V-3.00V 2.090V Full Volts Per Cell 0.900V-3.00V 2.040V Empty Volts Per Cell 0.900V-3.00V 1.730V Discharge Time 0-600 25Mn BDI Reset Percent 0-100 75% Reset Controller 0-1 0 Figure 4 CURTIS Hand Held 1313 Controller Main/Sub-menus

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Menu 1313

Sub Menu 1

Sub Menu 2

Sub Menu 3

Solenoid Coil

Rear Node Select Solenoid PWM Rear Controller

Inputs Monitor

Outputs

Battery

Motor

Run/Tow Switch Key Switch Economy Mode Switch Forward Switch Reverse Switch Throttles Raw Primary Throttle Mapped Primary Throttle Raw Redundant Throttle Mapped Redundant Throttle Throttle Command Mapped Throttle Throttle Pot Pot2 Raw Interlock Analog 2 5 Volts 12 Volts Ext Supply Current Pot Low BDI Capacitor Voltage Keyswitch Voltage Motor RPM Temperature Motor Speed A

Data Range Default value On - Off On On - Off On 0-100 0% On - Off Off On - Off Off On - Off Off On - Off Off On - Off Off 0.00 - 5.00 0.73V 0 -1 00 0.00% 0.00 - 5.00

0.37V

0 - 100

0%

0 - 100 0 - 100 0.00 - 5.50 0.00 - 5.50 On - Off 0.00 - 10.00 0.00 - 6.25 0.00 - 12.00 0 - 200 0.00 - 6.25 0 - 100 0.0 - 105.0 0.0 - 105.0 -12000 -12000

0% 0% 0.73V 0.37V Off 1.24V 4.94V 12.42V 63mA 0.20V 75% 3.1V 77.0V 0 RPM

-100 - 300 -12000 12000 -12000 Motor Speed B 12000 Figure 4 CURTIS Hand Held 1313 Controller Main/Sub-menus (Continued)

29 oC 0 RPM 0 RPM

117

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Menu 1313

Sub Menu 1 Controller

Sub Menu 2 Current (RMS) Modulation Depth Frequency Temperature Regen Cutbacks

Monitor (continued) Vehicle

Vehicle Speed Vehicle Odometer Braking Distance Distance Since Stop

Diagnostics Programming

Favorites

Present Errors Fault History Save .cpf file

....

Sub Menu 3

Motor Temp Cutback Controller Temp Cutback Under voltage Cutback Over voltage Cutback

Data Range Default value 0.0 - 1000.0 0.1A 0.0 - 100 0.00% -300.0 - 300.0 0.0Hz -100 - 300 33ºC On - Off On 0 - 100 100% 0 - 100

100%

0 - 100 0% 0 - 100 100% -3276.8 3276.7 0 0.010000000.0 0 0.0 1000000.0 0 0.0 1000000.0 Display active faults.

Display non - active faults

Display Favorite Menus LCD Contract -300 0 Program Language English English Set Security Code Set user lock code Display fault history of Faults Fault History HANDHELD Clear Fault History Yes/No Information OEM Info Display OEM information *Reconfigured Display reconfigure status Display handheld model Model Number number Display handheld serial HHP Settings Serial Number number Display handheld Manufacturing Date manufacture date Display handheld software Software Version version Display handheld hardware Hardware Version version MC-Protocol Version Display MC-Protocol version ES-Protocol Version Display ES-Protocol version S-Protocol Version Display S-Protocol version Device Type Display device type Display to create folder Display to plot & log Figure 4 CURTIS Hand Held 1313 Controller Main/Sub-menus (Continued)

118

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

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

! RSRI ! TIVGLEVKI ! [IPHGLIGO ! GPSWMRKHIPE] ! QMWWMRKGLIGO ! GPSWIH [LIR 1EMR )REFPI ! 3R ! HIPE] ! EVGGLIGO ! STIRHIPE] ! GPSWIH [LIR 1EMR )REFPI ! 3JJ

119

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

DIAGNOSTIC FAULTS

1311 Display

Explanation

Controller Response

Recover When

Possible Cause

For Testing See Page

BRAKE INPUT SUPERVISION

Supervisor fault

Vehicle Disabled

Condition clears

1. Mismatch in Analog / Digital value 2. Check wiring 3. Check brake sensor 4. Replace controller

40 43

BRAKE LIGHT COIL MISSING

Brake light relay coil missing

Beeping (LSV only)

Brake light relay detected

1. Voltage at pin 4 too low when driver is OFF

50

BRAKE LIGHT DRIVER OC

Over current on relay driver

Brake Light Driver OFF

KSI cycled

1. Brake light relay current detected > 1 Amp 2. Check relay 3. Check shorted wiring 4. Check brake sensor if other faults are found

50

BRAKE WIPER

Brake Pedal input Shutdown voltage outside active Throttle range

Voltage recovers to active range and Throttle reapplied

1. Brake pot wiper voltage too low (< 0.35V) 2. Brake pot wiper voltage too high (> 4.8V) 3. Check pedal operation

43

BUZZER DRIVER OC

Excessive current on Reverse Buzzer driver

KSI cycled

1. Buzzer current detected > 200 mA 2. Check wiring 3. Check buzzer

36

BUZZER DRIVER OFF

Reverse Buzzer does Limp Home + not turn on Fwd Only

Condition clears

1. Buzzer current < 3 mA when driver commanded ON 2. Incomplete buzzer circuit 3. Verify continuity of reverse buzzer and replace if open

36

BUZZER DRIVER ON

Reverse Buzzer stuck No Action ON

Condition clears

1. Buzzer current > 3 mA when driver is OFF 2. Buzzer shorted to ground 3. Check driver output 4. Replace controller

36

CHARGER INPUT SUPERVISION

Supervisor fault

Condition clears

1. Mismatch in switch status 2. Check voltage on ignition interlock.

Should be < 4V with charger plugged in.

Should be > 16V unplugged

37

CONTROLLER OVERCURRENT

Excessive Motor Cur- Vehicle rent Disabled

KSI cycled

1. Current on Controller Phase U, V, or W above 315 Amps 2. Check for bad motor wiring 3. Check for mechanical block 4. Check for low output voltage

38 46 48

CONTROLLER OVERTEMP CUTBACK

Controller temperature high

Temperature falls below 85C

1. Controller temperature > 85C (185F) 2. Check heat sink temp 3. Verify mechanical load 4. Verify slow operation 5. Check heat sink airflow 6. Possible resistor fault

39 48 49

120

Limp Home + Fwd Only

Vehicle Disabled

Current Cutback

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

1311 Display

Explanation

Controller Response

Recover When

Possible Cause

For Testing See Page

CONTROLLER SEVERE OVERTEMP

Controller temperature above maximum threshold

Vehicle Disabled

Temperature falls below 95C and KSI cycled

1. Controller temperature > 95C (203F) 2. Check heat sink temp 3. Verify mechanical load 4. Verify slow operation 5. Check heat sink airflow 6. Possible resistor fault

39 48 49

CONTROLLER SEVERE UNDERTEMP

Controller temperature below minimum threshold

No Action

Temperature rises above 40C and KSI cycled

1. Controller temperature < -40C (-22F) 2. Verify temp at heat sink 3. Warm controller if climate is too cold

39

CURRENT SENSOR FAULT

Phase current measurement offset error

Vehicle Disabled

KSI cycled

1. Current measurement when motor open exceeds thresholds 2. Check motor connections 3. Check motor field for open 4. Replace the controller if motor test is good

38

DIRECTION ERROR

Invalid direction detected

Shutdown Throttle

Direction in Neutral

1. Forward/Reverse are both high for > 1 second 2. Check wiring 3. Check direction selector

44

EEPROM FAILURE

Failure in reading Controller non-volatile EEPROM Inoperative memory

KSI cycled and EEPROM read successfully

1. Failure to read EEPROM or checksum error detected 2. Cycle key switch 3. Replace controller if unsuccessful

44

EM BRAKE COIL MISSING (Park Brake)

EM Brake coil open or Shutdown EM missing Brake + Shutdown Throttle + Full Brake

KSI cycled

1. Voltage on pin 5 is low when driver is OFF 2. Check for open brake circuit 3. Verify by putting vehicle in tow and try to roll 4. Inspect park brake

40 42

EM BRAKE DRIVER OC (Park Brake)

Driver current too high when driver is OFF

Shutdown EM Brake + Shutdown Throttle + Full Brake

KSI cycled

1. Current detected > 3 Amps 2. Dead short in park brake circuit 3. Check wiring 4. Check brake driver coil.

40 42

EM BRAKE DRIVER OFF (Park Brake)

EM Brake driver does Shutdown EM not turn ON Brake + Shutdown Throttle + Full Brake

KSI cycled

1. Driver current below 320 mA when driver commanded ON 2. Check for open brake circuit.

3. Check park brake 4. Check voltage output to brake 5. Replace controller

40 42

EM BRAKE DRIVER ON (Park Brake)

EM Brake driver does Shutdown EM KSI cycled not turn OFF Brake + Shutdown Throttle + Full Brake

1. Driver current above 320 mA when driver commanded OFF 2. Verify output driver voltage 3. Replace controller if faulty

40

121

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

1311 Display

Explanation

Controller Response

Recover When

Possible Cause

For Testing See Page

EM BRAKE FAILED EM Brake failure to TO SET (Park stop motor rotation Brake)

Shutdown KSI cycled Throttle + Shutdown EM Brake + Pulse reverse alarm at 0.5Hz

1. Wheel rotation exceeds 1/4 revolutions 2. Check for park brake slip

40

EM BRAKE TEST FAILED (Park Brake)

Motor rotation detected during EM Brake test

KSI cycled Full Brake+ Shutdown EM Brake + Pulse reverse alarm at 0.5Hz

1. Motor rotation exceeds 2 revolutions 2. Check for park brake slip during start up

40

ENCODER DIRECTION

Rapid direction changes detected from speed sensor

Vehicle Disabled

KSI cycled

1. Confirm encoder wiring 2. Replace encoder

ENCODER FAULT

1) Missing Encoder Pulses OR 2) Encoder disconnected

Shutdown Motor+ Shutdown+ EM Brake

KSI cycled

1. Motor pulses missing while driving 2. check encoder 3. Verify wiring

41

Vehicle Disabled

Condition clears

1. Motor RPM measurements between Supervisor and Main processors mismatch 2. Verify encoder 3. Verify wiring 4. Replace controller

41

FAN COIL MISSING Fan coil open or miss- No Action ing (2Five Only)

Fan Coil detected

1. Voltage on pin 3 is low when driver is OFF 2. Check fan 3. Check wiring

FAN DRIVER OC (2Five Only)

Driver current too high

No Action

KSI cycled

1. Fan relay current detected > 1 Amp 2. Check for short in fan circuit

FAN DRIVER OFF (2Five Only)

Fan driver does not turn ON

No Action

Condition clears

1. Fan relay current below 35 mA when driver commanded ON 2. Check wiring for complete circuit 3. Replace controller

FAN DRIVER ON (2Five Only)

Driver does not turn OFF

No Action

Condition clears

1. Fan relay current above 35 mA when driver commanded OFF 2. Check fan circuit 3. Replace controller

FULL BRAKE CHECK

Brake limit switch mismatch with brake pot input

No Action

Condition clears

1. EM Brake Switch Hi & Brake Input = 100% 2. EM Brake Switch Low & Brake Input < 90% 3. Check brake pedal switch 4. Check for pedal box debris 5. Check pedal operation 6. Replace brake limit switch if defective

ENCODER SUPER- Supervisor Detection VISION of motor speed error

122

42 43

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

1311 Display

Explanation

Controller Response

Recover When

Possible Cause

For Testing See Page

Condition clears

1. Mismatch in switch status 2. Check operation on hand held 3. Check direction selector wiring 4. Check direction selector switch

44

Shutdown Throttle % is > HPD Throttle threshold and/or the throttle switch is closed prior to 1. Turning on vehicle 2. Selecting direction OR Throttle % is > HPD threshold with throttle switch open

Throttle percentage is under the HPD threshold and the pedal switch is detected open for at least 64 ms

1. Pedal switch detected as closed on power up 2. Check for pedal depression at start up 3. Check for pedal return 4. Check for sticking pedal switch 5. Replace Throttle switch if defective

45

KEYSWITCH SUPERVISION

Supervisor fault

Vehicle Disabled

Condition clears

1. Mismatch in AD value 2. Cycle key switch to clear 3. Check wiring 4. Check key switch 5. Replace key switch if defective 6. Replace Controller if unable to clear fault

44

MAIN COIL MISSING

Contactor coil open or Vehicle missing Disabled

Condition clears

1. Voltage on pin 6 is low when driver is OFF 2. Check solenoid for open primary coil 3. Check for open wiring on coil circuit 4. Check coil input voltage

46 47

MAIN CONTACTOR DID NOT CLOSE

Main contactor remains open when closed

Vehicle Disabled

KSI cycled

1. Capacitor voltage < (KSI voltage - 2 volts) when contactor closed 2. Check voltage across contactor secondary circuit 3. Replace contactor if >2V drop

46 47

MAIN CONTACTOR DROPPED

Contactor drops when Vehicle Disabled in operation

KSI cycled

1. Capacitor voltage < (KSI voltage - 5 volts) after contactor initially detected as closed 2. Check for battery voltage loss 3. Check for secondary voltage loss during operation 4. Replace contactor if driver voltage is OK

46 47

MAIN CONTACTOR WELDED

Contactor cannot be opened

Vehicle Disabled

KSI cycled

1. Capacitor voltage within 1 volt of previous measured capacitor voltage when contactor opened 2. Check secondary contactor terminals for volt loss when key is off 3. Replace contactor if voltage does not drop

46 47

MAIN DRIVER OC

Driver current too high

Vehicle Disabled

KSI cycled

1. Main coil current detected > 2 Amps 2. Check for short in contactor circuit 3. Check for short in contactor coil

46 47

FWD SWITCH SUPERVISION

Supervisor fault

HPD/SEQUENCING FAULT

Vehicle Disabled

123

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

1311 Display

Explanation

Controller Response

Recover When

Possible Cause

For Testing See Page

MAIN DRIVER OFF

Driver does not turn ON

Vehicle Disabled

KSI cycled

1. Current below 65 mA when driver commanded ON 2. Check wiring at contactor for good voltage.

3. Check key switch 4. Replace controller

44 46 47

MAIN DRIVER ON

Driver does not turn OFF

Vehicle Disabled

KSI cycled

1. Current driver above 65 mA when driver commanded OFF 2. Check wiring at contactor for good voltage.

3. Check key switch 4. Replace controller

44 46 47

MOTOR OPEN

Motor phase U,V,or W Vehicle Disabled detected open

KSI cycled

1. Single motor phase current measured as less than 20 Amps while other phase currents > 100 Amps OR All phase currents measured < 5 Amps.

2. Check for open motor circuit on U,V, & W

38

MOTOR TEMP HOT CUTBACK

Motor temperature too hot

Current Cutback

Motor temperature drops below set point

1. Motor temperature is above the programmed setting (140C) 2. Check mechanical load 3. Verify sensor resistance 4. Check for voltage loss / bad connection at motor 5. Replace motor

48 49

OVERVOLTAGE CUTBACK

Excessive voltage

Current Cutback

Voltage below set point

1. Capacitor voltage > 72V 2. Check resistor circuit function 3. Verify extreme down hill use

46 47 49

PEDAL SWITCH SUPERVISION

Supervisor fault

Vehicle Disabled

Condition clears

1. Mismatch in switch status 2. Check for good voltage at the pedal switch 3. Check wiring 4. Verify I/O with Handheld

45

PRECHARGE FAILED

Controller does not precharge

Vehicle Disabled

KSI cycled

1. Capacitor voltage below 75% of battery voltage after precharge 2. Check battery voltage 3. Check battery / contactor wiring 4. Check contactor operation 5. Replace controller if failed

46 47

RESISTOR DRIVER OC

Driver current too high

Shutdown KSI cycled Throttle + Shutdown EM Brake

1. Current exceeds comparator trip point 2. Verify driver function on hand held 3. Replace controller

49

RESISTOR DRIVER OFF

Driver does not turn ON

Shutdown Throttle

1. Resistor driver current below limit when driver commanded ON 2. Verify over-temp or over voltage faults 3. Replace controller

49

124

KSI cycled

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

1311 Display

Explanation

Controller Response

Recover When

Possible Cause

For Testing See Page

RESISTOR DRIVER ON

Resistor driver does not turn OFF

Controller Inoperative

KSI cycled

1. Resistor driver current above limit when driver commanded OFF 2. Verify terrain conditions 3. Verify resistor heat 4. Check controller command on hand held

49

RESISTOR MISSING

Resistor missing

Shutdown Throttle

KSI cycled

1. Voltage on bus bar is low when driver is OFF 2. Check wire to resistor 3. Check resistor ohm range .86 ohms

49

REV SWITCH SUPERVISION

Supervisor fault

Vehicle Disabled

Condition clears

1. Mismatch in switch status 2. Verify operation on hand held 3.Check wiring 4. Check Direction selector

44

SEVERE OVERVOLTAGE

Excessive voltage

Vehicle Disabled

KSI cycled

1. Capacitor Voltage > set point + 10 Volts 2. Check resistor circuit function 3. Verify extreme down hill use 4. Verify battery voltage

49

SEVERE UNDERVOLTAGE

Very Low Battery Voltage

No Action

KSI cycled

1. Voltage below 20V 2. Check battery voltage 3. Check wiring 4. Check contactor 5. Check charger

46 47

STALL DETECTED 1. Motor / ENCODER FAULT stall condition detected 2. Missing encoder Pulses.

3. Encoder Disconnected

Shutdown Motor + Shutdown EM Brake

KSI cycled

1. Motor pulses missing while driving 2. Check for mechanical bind 3. Check for high mechanical load 4. Verify encoder wiring 5. May show motor over current fault.

6. Verfy encoder wiring.

41 48

SUPERVISOR COMMS

Supervisor fault

No Action

Condition clears

1. Communication error 2. Check for HPD fault 3. This may happen after controller sleep mode

45

SUPERVISOR WATCHDOG

Supervisor fault This is an internal controller check

Vehicle Disabled

Condition clears

1. Missing watchdog pulses 2. Cycle the key switch 3. Replace the controller

44

THROTTLE SUPERVISION

Supervisor fault

Vehicle Disabled

Condition clears

1. Mismatch in AD value 2. Verify sensor voltages-% on hand held 3. Check the 5V circuit

45

Shutdown Throttle

Voltage recov- 1. Throttle pot wiper voltage too low ers to active (< 0.35V) range 2. Throttle pot wiper voltage too high (> 4.8V) 3. Verify sensor operation on hand held 4. Check pedal operation

THROTTLE WIPER Pedal input (16) voltage is out of active range

45

125

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

1311 Display

Explanation

Controller Response

Recover When

Possible Cause

For Testing See Page

THROTTLE ZERO CHECK

Throttle reading and switch do not match

Shutdown Throttle

Condition clears

1. Throttle switch closed and throttle position sensor reads <0% 2. Throttle switch open and throttle position sensor reads > 9% 3. Verify sensor operation on hand held 4. Check pedal operation

45

TOW SWITCH SUPERVISION

Supervisor fault

Vehicle Disabled

Condition clears

1. Mismatch in switch status 2. Check switch operation on hand held 3.Check for brake unlock in "Tow" 4. Check tow switch 5. Check tow switch wiring

40

UNDERVOLTAGE CUTBACK

Low Battery Voltage

Drive current cuts back to maintain set point

Voltage above 1. Below set point (42V) set point (42V) 2. Check for good charging 3. Check battery condition 4. Possible wiring 5. Possible contactor

CONTROLLER RESPONSE DEFINED Controller Response No Action Shutdown Motor Shutdown Main Contactor Shutdown EM Brake Shutdown Throttle ShutdownDriver1 (Main Contactor) ShutdownDriver2 (Brake Coil) ShutdownDriver3 (Brake Light Relay) ShutdownDriver4 (Fan) ShutdownDriver5 (Reverse Alarm) Shutdown Driver6 Full Brake Limp Home Fwd Only Controller Inoperative Vehicle Disabled Current Cutback

126

Description Information Only Motor Drive disabled Main Contactor Open EM Brake Voltage Removed Throttle set to 0 Driver Shutdown Driver Shutdown Driver Shutdown Driver Shutdown Driver Shutdown Braking Resistor Shutdown Brake set to 100% Slow Speed Limit Forward Operation Only All Drivers OFF. No Operation.

Throttle set to 0. Full Brake. EM Brake Voltage Removed Derating of motor currents

37 46 47

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

CONTROLLER PIN VOLTAGES Pin #

Signal Name

1 2 3 4 5 6 7 8 9 10 11

KSI Buzzer NC BLR EMB Main Ground Temp Sensor Pedal Tow Charger

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Brake Switch NC NC 5V + Throttle Brake Throttle GND NC Switch_Bat NC FWD CAN Hi NC 12V + 5V + NC TX RX SOC ENC A ENC B Rev GND CAN Low

Voltage 48V - 48V 12 - 15V 48V - 48V - 48V 5V 48V 48V

48V

5V 0 - 5V 0 - 5V -5V 48V 48V 48V 12V 5V

0-5V 0-5V 0-5V 48V - 48V

Description Key switch input Low side driver for buzzer Not connected Brake light relay Low side driver for electric park brake Low side driver for main solenoid System Ground Motor temp sensor Switch input - Pedal Switch input - Tow Charger interlock input < 4V with charger plugged in. Should be > 16Vunplugged Brake limit switch Not connected Not connected 5V output to throttle and brake sensors Analog throttle input Analog brake input Ground connection for throttle and brake Not connected High side 48V output (GPS) Not connected FNR Switch input CAN communications (GPS) Not connected 1311 Communication 5V output for encoder Not connected 1311 Communication 1311 Communication Analog output 0 -5V Encoder signal A Encoder signal B FNR Switch input 1311 Communication CAN communications

127

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

&0/ :

&0/ :

08 +62 :

4-2/ :

&0/ :

6)( :

08 &09) :

&0/ :

&0/ :

08 &09)

49640) : =)0 : &0/ : ;,8 :

+62 :

6)( :

6)( ;,8 :

36+ :

36+ 6)( :

49640) :

+62 ;,8 36+ :

;,8 :

=)0 36+

128

+6%= :

&09 ;,8 :

;,8 :

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REVERSE BUZZER TEST 1.

2.

Verify voltage output on pins 1 & 2 of the controller connector. Make sure voltage is present with the key switch in the reverse position.

Check voltage on the ignition interlock. Place the negative (-) probe of the voltmeter on the negative #4 battery terminal. Use a back probe pin with the positive (+) meter probe to check the voltage of the blue interlock wire on the back side of the receptacle.

The voltage should be <4V with the charger plugged in and should be >16V unplugged.

Back probe pins are required to perform electrical tests via wire harness connectors.

Verify operation of components with the Handheld in addition to testing with a volt meter.

MOTOR TEST

Verify operation of components with the Handheld in addition to testing with a volt meter.

2.

Check buzzer wires for shorts or breakage. If voltage is correct and buzzer fails to sound, cycle the key and verify if the condition clears. If not, replace the buzzer.

Back probe pins are required to perform electrical tests via wire harness connectors.

CHARGER RECEPTACLE

1.

1.

Turn key to the OFF position and back to the ON position to reset the controller. If the car runs, return to service. If not, proceed to the remaining steps.

2.

Disconnect all three motor wires. Contact the "V" wire lug to the meter probe. Contact the "U" lug to the other meter probe. Check for open or shorted readings.

Place the positive (+) meter probe A on the lower left terminal of the charger receptacle. Place the negative (-) probe B on the lower right terminal. Battery voltage should be observed. If not, check loaded battery pack voltage, then replace the receptacle.

129

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

3.

4.

Contact the "U" wire lug to the meter probe. Contact the "W" lug to other meter probe. Check for open or shorted readings.

Contact the "W" wire lug to the meter probe. Contact the "V" lug to the other meter Verify there is no short to the motor case (ground) on U, V, and W. If short to ground is found, replace motor.

8EOI 8IQT 6IEHMRK ,IVI

2.

3.

Reduce the payload or loading.

Verify the bi-metal switch is not at fault by substituting it with a known, good unit.

Motor resistance between U,V and W is 6.8 – 8.36 milliohms. Most DVMs will not read this. Test for open or shorted readings.

Ohm readings will vary with the quality of the test equipment. Do not condemn the motor unless the ohm range is great or shows a short.

CONTROLLER TEMPERATURE TEST Fault caused by: Controller reaching >85 Celsius (185)

Controller Sever Overtemp means > 95C (203F).

Controller under temperature is <40c (-22F).

1.

130

Verify controller heat sink surface temperature. The temperature should read between <85 Celsius (185 Fahrenheit) and <40 Celsius (-22F). Make sure there is good air flow and the cooling fins are clean.

ELECTRIC MOTOR BRAKE TEST 1.

Place the Tow/Run switch in the TOW position.

2.

Turn the key to the F (forward) position and try to push the car. The vehicle should be able to be rolled.

3.

Turn key switch to the OFF position and the Tow/Run switch to RUN position. Turn the key to the ON position. The motor brake should set at this point. The car should not be able to be pushed.

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BRAKE PEDAL TEST 1.

4.

Verify brake switch operation at the brake pedal.

Check the Ohm value when the pedal is at rest.

Ohms should be 0 – 0.1.

Check wires and verify the brake circuit voltage under no load. 48V should be observed.

b. When the brake pedal is pressed approximately 90% and engages the brake switch, the Ohm reading should be OPEN LEAD.

5.

3 0

Verify the ohms reading of the brake coil. Place the meter leads on the internal terminals of the power connector on the brake. The resistance reading should be 25.5 ohms @ 20 degrees Celsius. Check for a shorted or open circuit.

Verify the operation of components with the handheld in addition to testing with a volt meter.

c.

Check the pedal area for debris. Check the operation of the pedal.

131

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

vii. Leave the pin probes in place. Slowly press the pedal to the floor. Voltage should steadily increase from .5V to between 4.5V and 4.8V.

d. Replace the limit switch if it is defective.

This test can also be performed using the hand held tool and scrolling down to the I/O functions. v.

Verify the pedal stop bumper is in the correct position. If not, correct and secure in place.

This test can also be performed using the hand held tool while verifying throttle percentage.

KEY (FNR) SWITCH TEST 1.

Verify operation with the handheld. Remove the key switch. Turn the key to the F (forward) position.

Place the positive (+) meter probe A on the A pin of the switch. Place the negative (-) meter probe B on the C pin. Full continuity should be observed on the multi-meter. Go to step 2.

& %

vi. Place the positive (+) meter probe A on the green wire of the brake sensor. Place the negative (-) probe B on the black wire of the sensor. With the harness connected, voltage should be between 0.38V and 0.56V. If good, go to step 3. If bad, verify a 5V supply to the sensor.

2.

132

&

Place the negative (-) meter probe B on the D pin of the switch. The meter should now read full continuity with the key turned in the opposite direction. If continuity can be read on all three pins in the same key direction F (Forward), replace the switch.

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

This test can also be performed using the hand held tool and scrolling down to the I/O functions.

3. Verify throttle switch continuity. Ohms should be open lead at rest and 0 ohms at throttle activation.

THROTTLE PEDAL TEST 1.

With the key switch in the ON position, verify the voltage to the throttle pedal sensor. Check between the black and orange connections. Voltage should be no >5.0V.

4. Check for free movement of pedals and clear all debris. Replace switches) if defective.

2.

Check for voltage at the wiper switch with the back probe pin. With the key in the ON position, the voltage should range from no <0.35 volts with pedal at rest to no >4.8 volts at full throttle. Verify 0-100% on the handheld.

133

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

This test can also be performed using the hand held tool and scrolling down to the I/O functions.

MAIN CONTACTOR (SOLENOID) TEST 1. Verify BRV. Place meter + probe to #1 battery +post and meter - lead to #4 battery - post.

4.

Check the voltage output on the secondary (to controller) this should be BRV. The voltage should be the same as battery in-bound of secondary by no < 1 volt. The voltage should zero out on the secondary output when Key is turned off, or a welded solenoid may exist.

2. Verify voltage to primary circuit. Place the positive meter probe on the + primary solenoid terminal. Place the negative meter probe on the – solenoid terminal.

Voltage should be approx 25 volts at key on with the contactor closed.

Verify operation of components with the Handheld in addition to testing with a volt meter.

5.

3.

134

Check the secondary input voltage. Place the negative meter probe on the – #4 battery post. The positive probe should be placed on the in-bound secondary circuit post of the solenoid. This voltage needs to be equal to BRV readings at the batteries.

Check wire if it is not.

Verify solenoid primary coil resistance. Remove primary wires from the solenoid and test resistance between the primary circuit posts. The resistance should be 96.6 – 113.4 ohms.

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Verify operation of components with Handheld in addition to DVOM test.

Meter readings can vary greatly based upon the quality of the meter.

STALL DETECTED 1.

Check speed sensor and handheld for sensor faults.

3.

Verify load.

4.

Check for motor faults.

RESISTOR

2.

1.

Verify connections at resistor. Inspect for debris and breakage.

2.

Check the temperature on the heat shield. Verify BRV is not >72 volts. Check all connections.

3.

Remove both resistor leads from the controller and verify continuity. The leads are connected to the Bus Bar connection of the controller and the bottom terminal marked RES. Resistance should read around .86 ohms.

Check wires in the brake circuit for a short. Verify motor brake is not causing friction drag. Make sure axle bearings are good. Check for any signs of mechanical failures or issues. Verify mechanical resistances.

135

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BRAKE LIGHT CIRCUIT TEST

Verify operation of components with Handheld in addition to test.

&

136

%

1.

Verify that the brake relay is properly plugged into the vehicle harness. If yes proceed to step 2.

2.

Unplug the relay from the harness. Place the positive probe of meter on the 85 terminal. Place the negative probe of the meter on the 86 terminal. Verify 1-50 ohms resistance. If not, replace the relay. (Shorted) If good, go to step 3.

3.

Place the positive probe of the meter on the red wire terminal of the relay harness. Place the negative probe on the purple wire terminal. Press the brake pedal. 48 VDC should be observed. If good, replace the relay. If bad, go to step 4.

4.

Check the continuity between the 86 terminal on the harness and pin #22 (purple wire) of the controller plug connector. Check the continuity between the 85 terminal of the harness and pin #1 (red wire) of the controller plug connector. If continuity is not found, replace the harness. If a short is found between 85 and 86 with the controller plug unplugged, replace the harness. If continuity is good in the harness, replace the controller.

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

137

HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

138

FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FAULT TESTING ELECTRICAL SYSTEM Condition

Possible Cause

Basic Electrical Power System Fault Testing

Basic Electrical Fault Testing for Accessories

Correction

FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

SUSPENSION AND STEERING Condition

Possible Cause

Correction

Do not over grease

FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

GENERAL SPECIFICATIONS

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1SXSV &EXXIV] 'LEVKIV )PIGXVMGEP 7]WXIQ (VMZI 8VEMR 8VERWE\PI &VEOIW &SH] 4VSXIGXMSR

%QT %' 'SRXVSPPIV *YPP XSVUYI VIHYGIH WTIIH VIZIVWI 7IEPIH ,EPP IJJIGX XLVSXXPI WIRWSV *YPP HMEKRSWXMG GETEFMPMX] ,ERH LIPH HMEKRSWXMG YRMX 7M\ JMIPH WIPIGXEFPI WTIIHW [MXL LERH LIPH HMEKRSWXMG YRMX

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} TS[HIV GSEX +IEV 7IPIGXMSR (EWL 1SYRXIH *SV[EVH 2IYXVEP 6IZIVWI &SH] *MRMWL -RNIGXMSR QSPHIH 843 6IEV %\PI 6EXMS

7XERHEVH 'SPSV *SVIWX +VIIR ') 2SMWI :MFVEXMSR ,EVWLRIWW 2SMWI 7SYRH TVIWWYVI GSRXMRYIH % [IMKLXIH IUYEP XS HF % :MFVEXMSR ;&: 8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW Q W :MFVEXMSR ,%: 8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW PIWW XLER Q W 8LI YRGIXEMRX] SJ QIEWYVIQIRX MW Q W 7SQI MXIQW WLS[R QE] FI STXMSREP IUYMTQIRX

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

13()0 6<: *6))(31v 8=4) )0)'86-' 4)6732%0 +30* '%6 13()0 =)%6 4EVX 2S +

463(9'8 74)'-*-'%8-32 '32*-+96%8-32 ,-+,0-+,87 4VSKVEQQEFPI %' (VMZI 7]WXIQ *EGXSV] TVSKVEQQEFPI XS ETTPMGEXMSR 7SPMH 7XEXI ZEVMEFPI JVIUYIRG] %' WTIIH GSRXVSPPIV (VMZI F] [MVI IPIGXVSRMG XLVSXXPI GSRXVSP (EWL QSYRXIH HMVIGXMSR WIPIGXSV W[MXGL *SV[EVH 2IYXVEP 6IZIVWI (IWGIRX WTIIH GSRXVSP ERH EYXSQEXMG LMPP LSPH *YPP XMQI VIKIRIVEXMZI FVEOMRK 1SXSV &EXXIV] 'LEVKIV )PIGXVMGEP 7]WXIQ (VMZI 8VEMR 8VERWE\PI &VEOIW &SH] 4VSXIGXMSR

%QT %' 'SRXVSPPIV *YPP XSVUYI VIHYGIH WTIIH VIZIVWI 7IEPIH ,EPP IJJIGX XLVSXXPI WIRWSV *YPP HMEKRSWXMG GETEFMPMX] ,ERH LIPH HMEKRSWXMG YRMX 7M\ JMIPH WIPIGXEFPI WTIIHW [MXL LERH LIPH HMEKRSWXMG YRMX

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} TS[HIV GSEX +IEV 7IPIGXMSR (EWL 1SYRXIH *SV[EVH 2IYXVEP 6IZIVWI &SH] *MRMWL -RNIGXMSR QSPHIH 843 6IEV %\PI 6EXMS

7XERHEVH 'SPSV *SVIWX +VIIR ') 2SMWI :MFVEXMSR ,EVWLRIWW 2SMWI 7SYRH TVIWWYVI GSRXMRYIH % [IMKLXIH IUYEP XS HF % :MFVEXMSR ;&: 8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW Q W :MFVEXMSR ,%: 8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW PIWW XLER Q W 8LI YRGIXEMRX] SJ QIEWYVIQIRX MW Q W 7SQI MXIQW WLS[R QE] FI STXMSREP IUYMTQIRX

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

13()0 7,9880)v 6<: 8=4) )0)'86-' 4)67322)0 '%66-)6 13()0 =)%6 4EVX 2S +

463(9'8 74)'-*-'%8-32 '32*-+96%8-32 ,-+,0-+,87 4VSKVEQQEFPI %' (VMZI 7]WXIQ *EGXSV] TVSKVEQQEFPI XS ETTPMGEXMSR 7SPMH 7XEXI ZEVMEFPI JVIUYIRG] %' WTIIH GSRXVSPPIV (VMZI F] [MVI IPIGXVSRMG XLVSXXPI GSRXVSP (EWL QSYRXIH HMVIGXMSR WIPIGXSV W[MXGL *SV[EVH 2IYXVEP 6IZIVWI (IWGIRX WTIIH GSRXVSP ERH EYXSQEXMG LMPP LSPH *YPP XMQI VIKIRIVEXMZI FVEOMRK 1SXSV &EXXIV] 'LEVKIV )PIGXVMGEP 7]WXIQ (VMZI 8VEMR 8VERWE\PI &VEOIW &SH] 4VSXIGXMSR

%QT %' 'SRXVSPPIV *YPP XSVUYI VIHYGIH WTIIH VIZIVWI 7IEPIH ,EPP IJJIGX XLVSXXPI WIRWSV *YPP HMEKRSWXMG GETEFMPMX] ,ERH LIPH HMEKRSWXMG YRMX 7M\ JMIPH WIPIGXEFPI WTIIHW [MXL LERH LIPH HMEKRSWXMG YRMX

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} TS[HIV GSEX +IEV 7IPIGXMSR (EWL 1SYRXIH *SV[EVH 2IYXVEP 6IZIVWI &SH] *MRMWL -RNIGXMSR QSPHIH 843 6IEV %\PI 6EXMS

7XERHEVH 'SPSV *SVIWX +VIIR ') 2SMWI :MFVEXMSR ,EVWLRIWW 2SMWI 7SYRH TVIWWYVI GSRXMRYIH % [IMKLXIH IUYEP XS HF % :MFVEXMSR ;&: 8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW Q W :MFVEXMSR ,%: 8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW PIWW XLER Q W 8LI YRGIXEMRX] SJ QIEWYVIQIRX MW Q W 7SQI MXIQW WLS[R QE] FI STXMSREP IUYMTQIRX

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

13()0 7,9880)v 6<: ,MKL 7TIIH )PIG 8=4) )0)'86-' 4)67322)0 '%66-)6 13()0 =)%6 4EVX 2S +

463(9'8 74)'-*-'%8-32 '32*-+96%8-32 ,-+,0-+,87 4VSKVEQQEFPI %' (VMZI 7]WXIQ *EGXSV] TVSKVEQQEFPI XS ETTPMGEXMSR 7SPMH 7XEXI ZEVMEFPI JVIUYIRG] %' WTIIH GSRXVSPPIV (VMZI F] [MVI IPIGXVSRMG XLVSXXPI GSRXVSP (EWL QSYRXIH HMVIGXMSR WIPIGXSV W[MXGL *SV[EVH 2IYXVEP 6IZIVWI (IWGIRX WTIIH GSRXVSP ERH EYXSQEXMG LMPP LSPH *YPP XMQI VIKIRIVEXMZI FVEOMRK 1SXSV &EXXIV] 'LEVKIV )PIGXVMGEP 7]WXIQ (VMZI 8VEMR XVERWE\PI &VEOIW &SH] 4VSXIGXMSR

%QT %' 'SRXVSPPIV *YPP XSVUYI VIHYGIH WTIIH VIZIVWI 7IEPIH ,EPP IJJIGX XLVSXXPI WIRWSV *YPP HMEKRSWXMG GETEFMPMX] ,ERH LIPH HMEKRSWXMG YRMX 7M\ JMIPH WIPIGXEFPI WTIIHW [MXL LERH LIPH HMEKRSWXMG YRMX

:SPX %' MRHYGXMSR QSXSV WSPMH GSTTIV [MRHMRKW LT O; 'SRXMRYSYW %' W]WXIQ VIEHW QSXSV WTIIH JSV EGGYVEXI WTIIH GSRXVSP MR EPP GSRHMXMSRW 6IKIRIVEXMZI FVEOMRK JSV QE\MQYQ IGSRSQ] 7' : 'LEVKIV 90 '7% :SPX (' JSYV ZSPX HIIT G]GPI WXSVEKI FEXXIVMIW FEXXIVMIW QMRYXI QMRMQYQ EQT LSYV $ LV HMWGLEVKI VEXI (MVIGX QSXSV WLEJX GSRRIGXIH XS XVERWE\PI TMRMSR WLEJX HMJJIVIRXMEP [MXL VIZIVWI LIPMGEP KIEVW -RHYGXMSR QSXSV )PIGXVS QEKRIXMG TEVOMRK FVEOI MW ETTPMIH EYXSQEXMGEPP] IRIVK] XVERWJIV FYQTIVW QE\MQM^I ZILMGPI TVSXIGXMSR JVSQ QMRSV MQTEGX

463(9'8 3:)6:-); (MQIRWMSRW 3ZIVEPP 0IRKXL 3ZIVEPP ;MHXL 3ZIVEPP ,IMKLX 2S 'ERST] 3ZIVEPP ,IMKLX ;MXL 'ERST] ;LIIP &EWI *VSRX ;LIIP 8VEGO 6IEV ;LIIP 8VEGO +RH 'PIEVERGI $ (MJJIVIRXMEP :ILMGPI 4S[IV 4S[IV 7SYVGI 1SXSV 8]TI ,SVWITS[IV O; )PIGXVMGEP 7]WXIQ &EXXIVMIW 5X] 8]TI /I] SV 4IHEP 7XEVX 7TIIH 'SRXVSPPIV (VMZI 8VEMR 8VERWE\PI +IEV 7IPIGXMSR 6IEV %\PI 6EXMS

MR GQ MR GQ MR GQ MR GQ MR GQ MR GQ MR GQ MR GQ :SPXW (' :SPX %' LT O; 'SRXMRYSYW :SPX *SYV :SPX (IIT ']GPI 4IHEP %QT %' 'SRXVSPPIV 1SXSV 7LEJX (MVIGX (VMZI 0MQMXIH 7PMT (MJJIVIRXMEP (EWL 1SYRXIH *SV[EVH 2IYXVEP 6IZIVWI

4IVJSVQERGI 7IEXMRK 'ETEGMX] (V] ;IMKLX 'YVF ;IMKLX :ILMGPI PSEH GETEGMX] 3YXWMHI 'PIEVERGI 'MVGPI -RXIVWIGXMRK %MWPI 'PIEVERGI 7TIIH 0IZIP +VSYRH 8S[MRK 'ETEGMX] 7XIIVMRK 7YWTIRWMSR 7XIIVMRK *VSRX 7YWTIRWMSR 6IEV 7YWTIRWMSR 7IVZMGI &VEOI 4EVOMRK &VEOI *VSRX 8MVIW 6IEV 8MVIW &SH] 'LEWWMW *VEQI &SH] *MRMWL 7XERHEVH 'SPSV

4IVWSR PF OK ;MXLSYX &EXXIVMIW PF OK PF OK JX Q 2 % QTL OTL 4VSKVEQQEFPI 2 % (SYFPI )RHIH 6EGO 4MRMSR -RHITIRHIRX % %VQ 'SMP 3ZIV 7LSGO 1SRS 0IEJ 7TVMRK ;MXL ,]HVEYPMG 7LSGOW -RHYGXMSR 1SXSV %YXSQEXMG )PIGXVS 1EKRIXMG \ 4P] 6EXIH \ 4P] 6EXIH ;IPHIH 7XIIP [MXL (YVE7LMIPH} TS[HIV GSEX -RNIGXMSR QSPHIH 843 *SVIWX +VIIR

') 2SMWI :MFVEXMSR ,EVWLRIWW 2SMWI

7SYRH TVIWWYVI GSRXMRYIH % [IMKLXIH IUYEP XS HF %

:MFVEXMSR ;&:

8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW Q W

:MFVEXMSR ,%:

8LI LMKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW PIWW XLER Q W 8LI YRGIXEMRX] SJ QIEWYVIQIRX MW Q W 7SQI -XIQW WLS[R QE] FI STXMSREP IUYMTQIRX

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

APPROXIMATE VEHICLE DIMENSIONS

r

GQ r

GQ

r

GQ r

GQ

r

GQ r

GQ

r

GQ

Fig. 1 Fleet and Freedom Vehicle Dimensions

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

r

GQ r

GQ

r

GQ r

GQ

r

GQ r

GQ

r

GQ

Fig. 2 Shuttle 2 + 2 Vehicle Dimensions

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TURNING DIAMETER AND INCLINE INFORMATION

6)'311)2()( 1%< 7-() 8-08 7-() 8-08 +6%() 36 1%< 1%<

6)'311)2()( 1%< 6%14 +6%() 36 1%<

Fig. 3 Vehicle Incline Specifications and Turning Diameter

GENERAL SPECIFICATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE C

C&A

REMARKS

CL

R

PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

LIGHTNING PROTECTION AND GROUNDING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

LIGHTNING PROTECTION AND GROUNDING

LIGHTNING PROTECTION AND GROUNDING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

LIGHTNING PROTECTION AND GROUNDING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

LIGHTNING PROTECTION AND GROUNDING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Read the following information and warnings before operating vehicle:

To prevent personal injury or death, observe the following: When vehicle is to be left unattended, engage parking brake, move direction selector to neutral, turn key to OFF position and remove from key switch.

Drive vehicle only as fast as terrain and safety considerations allow. Consider environmental factors which effect the terrain and the ability to control the vehicle.

Avoid driving fast down hill. Sudden stops or change of direction may result in 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 if ever forced to drive across an incline.

Stay in designated areas and avoid steep slopes. Activate the parking brake when 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 direction selector is in correct position before starting the vehicle.

Slow down before and during turns.

Al l t u r n s s h o u l d b e e x e c u t e d a t reduced speed.

Always bring vehicle to a complete stop before shifting direction selector.

See GENERAL SPECIFICATIONS for vehicle load and seating capacity.

Before working on vehicle, remove all jewelry (rings, watches, necklaces, etc.).

Be sure no loose clothing or hair can contact moving parts.

Do not touch hot objects.

Raise rear of vehicle and support on jack stands before running or adjusting powertrain.

Wear eye protection when working on or around the vehicle. In particular, use care when working around batteries, using solvents, or compressed air.

Hydrogen gas forms when charging batteries.

Do not charge batteries without adequate ventilation.

Do no permit open flame or smokers in an area being used for charging batteries. A concentration of 4% hydrogen gas or more is explosive.

Textron Specialized Vehicles