EZGO TERRAIN 1000 Repair & Service Manual - PDF DOWNLOAD

TERRAIN 1000 TECHNICIAN’S REPAIR AND SERVICE MANUAL 72V Electric Powered Utility Vehicle

640757 ISSUED SEP 2014

REVISED FEB 2015

SAFETY

NOTICES, CAUTIONS, WARNINGS AND DANGERS GERS;

NOTICES, CAUTIONS, WARNINGS,

DAN-

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Address practices not related to personal injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

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

REPAIR AND SERVICE MANUAL 72V ELECTRIC UTILITY VEHICLE

TERRAIN 1000

STARTING MODEL YEAR 2014 CALIFORNIA Proposition 65 Warning WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead and lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes, and particulates, all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.

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. E-Z-GO Division of Textron Inc. prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

E-Z-GO Division of Textron Inc. 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 E-Z-GO, and therefore is subject to change without notice.

E-Z-GO 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: E-Z-GO Division of Textron Inc. 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 at 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, sand or earth and 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.

SAFETY INFORMATION SAFETY INFORMATION

GENERAL

use the chassis or body as a ground connection.

Never

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

Such modifications can result in serious personal injury or death.

GENERAL OPERATION ALWAYS:

SAFETY INFORMATION MAINTENANCE ALWAYS:

VENTILATION ALWAYS:

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:

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

SERVICING THE ELECTRIC VEHICLE

To prevent severe injury or death, resulting from improper servicing techniques, observe the following warnings:

TRANSPORTING VEHICLE Towing

This vehicle is not designed to be towed.

Hauling

To reduce the possibility of severe injury or death while transporting vehicle: Secure the vehicle and contents.

Never ride on vehicle being transported.

Always remove windshield before transporting.

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

Do not attempt any type of servicing operations before reading and understanding all notices, cautions and warnings in this manual.

Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with both drive wheels raised.

Wear eye protection when working on vehicle. In particular, use care when working around batte ries , or us ing so lven ts o r c ompressed air.

To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the batteries before removing any heavy gauge battery wires.

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.

REAR AXLE INITIAL SERVICE CHART Item

Service Operation

BRAKES

ROUTINE MAINTENANCE

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

To prevent severe injury or death resulting from operating a vehicle with improperly operating brake system, the braking system must be properly maintained. All driving brake tests must be done in a safe location with regard for the safety of all personnel.

TIRES /MRK 4MR

/MRK 4MR

Recommended Tire Pressures E-Z-GO P/N 6EGO &EPP .SMRX

TIRE SIZE

RECOMMENDED PSI

6EGO &EPP .SMRX

:MI[ JVSQ 9RHIVWMHI SJ :ILMGPI

Fig. 1 Lubrication Points

Do not use more than three pumps of grease for each grease fitting at any one time. Excess grease may cause grease seals to fail or grease to migrate into areas that could damage grease seals and cause premature bearing failure.

LIGHT BULB REPLACEMENT

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.

VEHICLE CLEANING AND CARE

When pressure washing exterior of vehicle, do not use pressure in excess of 700 psi (4826 kPa) and maintain a 12-in. minumum distance from spray nozzle to painted surgace. To reduce the possibility of cosmetic damage, do not use any abrasive or reactive solvents to clean plastic parts.

Multi-Purpose Hand Cleaner (P/N 607636)

Battery Maintenance Kit (P/N 25587G01)

Plexus Plastic Cleaner and Polish (P/N 606314)

SUN TOP AND WINDSHIELD

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

The windshield provides only minimal protection from tree limbs or flying objects.

VEHICLE CARE PRODUCTS

Touch-Up Paint (P/N 28140G** and 28432G**)

Multi-Purpose Battery Protectant (P/N 606312)

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.

HARDWARE

%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->)

+VEHI

+VEHI

+VEHI

&308 7->)

1

1

1

1

1

1

1

'PEWW

+VEHI

'PEWW

+VEHI

'PEWW

+VEHI

Fig. 2 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 DANGERS;

NOTICES, CAUTIONS, WARNINGS,

Addresses practices not related to personal injury.

MODIFICATIONS TO VEHICLE

To prevent personal injury or death to the operator or passenger, do not make changes to the weight distribution or the center of gravity which could make the vehicle unstable or prone to roll over.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

GENERAL MAINTENANCE Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Do not attempt any type of servicing operations before reading and understanding all notices, cautions and warnings in this manual.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

IMPORTANT SAFETY WARNING

entire

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

BEFORE SERVICING THE VEHICLE

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

Be sure that no loose clothing or hair can become caught in the moving parts of the powertrain.

Use care not to contact hot objects.

Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with drive wheels raised.

Wear OSHA approved clothing and eye protection when working on anything that could expose the body or eyes to potential injury. In particular, use care when working with or around batteries, compressed air or solvents.

Always turn the key switch to ‘OFF’ and remove key before disconnecting a live circuit.

When connecting battery cables, pay particular attention to the polarity of the battery terminals. Never confuse the positive and negative cables.

The park brake should always be set, except for cases where the powertrain must be allowed to rotate or service is being performed on the brake system.

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

Additional Warnings Specific to Electrical System

To prevent battery explosion that could result in severe personal injury or death, keep all

smoking materials, open flame or sparks away from the batteries.

Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air exchanges per hour is considered the minimum requirement.

Be sure that the key switch is off and all electrical accessories are turned off before starting work on vehicle.

Remove batteries before performing any services or repairs that could generate sparks.

Never disconnect a circuit under load at a battery terminal.

Since batteries are heavy, use proper lifting techniques when moving them.

Always lift battery with a commercially available battery lifting device.

Use care not to tip batteries when removing or installing; spilled electrolyte 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. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.

Wear eye protection when working on the vehicle. In particular, use care 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.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’ a battery, which could result in an explosion and severe personal injury or death.

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

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

Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle.

Expelled electrolyte may cause damage to the vehicle and storage facility.

BATTERY REMOVAL AND INSTALLATION Tool List

Qty.

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

Connect the positive (+) battery cable first connect the negative (-) cable last

Before any electrical service is performed, the RunTow/Maintenance switch must be placed in the ‘Tow/Maintenance’ position.

*VSRX SJ :ILMGPI

If a power wire (battery, motor or controller) is disconnected for any reason, the Run-Tow/Maintenance switch must be left in the ‘Tow/Maintenance’ position for at least 30 seconds after the circuit is restored.

*VSRX &EXXIV] 8IQT 7IRWSV ;,8 JVSQ ;,8 JVSQ 'LEVKIV 6IGITXEGPI

Fig. 1 Battery Connections

2IKEXMZI

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

LIFTING THE VEHICLE Tool List

Qty.

'IRXIV SJ *VSRX %\PI

Be aware that the vehicle is extremely unstable during the lifting process and use caution accordingly.

*PEX 4SVXMSR SJ *VEQI

To prevent possible injury or death resulting from a vehicle falling from a jack, be sure the vehicle is on a firm and level surface when the lifting process begins.

Never get under a vehicle while it is supported by a jack.

Use jack stands and test the stability of the vehicle on the stands.

Always place chocks in front and behind the wheels not being raised.

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

3YXWMHI )RH SJ 6IEV %\PI :MI[ JVSQ 9RHIVWMHI SJ :ILMGPI

Fig. 2 Lifting 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.

BODY (VMPP SYX VMZIX LIEH SRP]

4ST 6MZIX

In the following text, there are references to removing/ installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in original positions unless otherwise specified. Non-specified torques are as shown in Fig. 2 on page 4.

GENERAL

Fig. 1 Drill Out Metal Rivet

To prevent possible injury or death from battery explosion, batteries should always be removed before any servicing that will generate sparks.

It is important to use a sharp drill bit when removing the rivets on the side of the vehicle.

Use extreme care when drilling out the rivets located in the front of the body and the bottom side of the body. Excessive pressure could result in the drill bit being forced through the body panel and penetrating an internal component. It is recommended that a protective piece of sheet metal be placed between the battery and the rivet as extra protection. Use of a drill depth stop will also provide additional protection.

4YWL TMR [MXL WGVI[HVMZIV JVSQ VIEV WMHI 36 (VMZI TMR XLVSYKL [MXL TYRGL JVSQ JVSRX

Fig. 2 Drive Rivet Removal

6EXGLIX *EWXIRIV

slightly

sharp

6IQSZI JEWXIRIV [MXL TV] FEV

BODY COMPONENT REPLACEMENT

Fig. 3 Remove Ratchet Fastener

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

*VSRX SJ :ILMGPI

Fig. 4 Front Body Components

Instrument Panel Replacement Tool List

Qty.

To prevent personal injury, disconnect negative (-) battery cables before servicing vehicle.

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

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

Center Compartment Replacement Tool List

Qty.

The center compartment may be removed without removing the instrument panel.

Brush Guard Replacement Tool List

Qty.

To prevent personal injury, disconnect negative (-) battery cables before servicing vehicle.

Item

Torque Specification

Cowl Replacement Tool List

Qty.

Fig. 5 Brush Guard

Cowl can also be removed along with the front fenders.

Item

To prevent personal injury, disconnect negative (-) battery cables before servicing vehicle.

Torque Specification

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

Rocker Panel Replacement Tool List

Qty.

Item

Torque Specification

Fig. 6 Rocker Panel Item

Fig. 7 Side Panel

Torque Specification

Rear Fender Replacement Tool List

Side Panel Replacement Tool List

Qty.

Qty.

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

Rear Body Panel Replacement Tool List

Item

Qty.

Torque Specification

Fig. 8 Rear Fender Replacement

Fig. 9 Rear Body Panel Replacement

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

PAINTING

Larger Scratches

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

Wear eye protection and respirator, following manufacturer’s instructions, 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:

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.

To prevent injury caused by a broken socket, use only sockets designed for impact wrench use. Never use a conventional socket.

Tire Repair A tire explosion can cause severe injury or death. Never exceed inflation pressure rating on tire sidewall.

To prevent tire explosion, pressurize tire with small amount of air applied intermittently to seat beads. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face and eyes from escaping air when removing valve core.

Use caution when inflating tires. Due to the low volume of these small tires, overinflation can occur in a matter of seconds. Overinflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause personal injury.

Do not use low inflation pressure tires on any E-Z-GO vehicle. Do not use any tire which has a recommended inflation pressure less than the inflation pressure recommended in Owner’s Guide.

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.

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

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

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

It is important to follow the ‘cross sequence’ pattern when installing lug nuts to ensure even seating of the wheel against the hub.

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:

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

;EZI ;EWLIV

&IEVMRK 3YXIV 7RET 6MRK -RRIV 7RET 6MRK -RXIVQIHMEXI 7LEJX [MXL 9 .SMRXW

6EGO 4MRMSR 9RMX 6EGO )\XIRWMSR

6EGO &EPP .SMRX

7TEGIV

8LVYWX ;EWLIV

/MRK 4MR 8YFI

*VSRX %\PI

4EVX SJ *VEQI

7TMRHPI /MRK 4MR &YWLMRK

Fig. 1 Axle Mounted Steering and Front Suspension Components

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

MAINTENANCE

In the following text, there are references to removing/ installing bolts etc. Additional hardware (nuts, washers etc.) that is removed must always be installed in its original position unless otherwise specified. Non-specified torque specifications are as shown in the GENERAL INFORMATION & ROUTINE MAINTENANCE section.

Do not use more than three pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components.

Wheel Bearing and King Pin Bushing Inspection

To prevent possible injury or death resulting from a vehicle falling from a jack, follow the lifting procedure in SAFETY section of this manual. Be sure vehicle is on a firm and level surface.

Lubrication Tool List

Qty.

*VSRX SJ :ILMGPI

Fig. 2 Lubrication Points

Never get under a vehicle while it is supported by a jack. Use jack stands and test stability of vehicle on stands before starting any repair procedure. Always place chocks in front and behind wheels not being raised. Use extreme care since the vehicle is extremely unstable during the lifting process.

Some minor rocking movement of tire is normal.

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

Wheel Bearing Packing Tool List

Qty.

*VSRX SJ :ILMGPI

Fig. 3 Bearing Adjustment

Once hub is placed onto spindle and before outer wheel bearing is installed, fill the area between the inner and outer wheel bearings about 1/2 - 3/4 full with grease.

Wheel Bearing Adjustment Tool List

Qty.

loosened

closest available

Wheel Alignment 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.

< 6IEV

Item

*VSRX SJ :ILMGPI

QQ <

QQ *VSRX :MI[ JVSQ 9RHIVWMHI SJ :ILMGPI

Fig. 4 Wheel Alignment

To hold threaded tube while loosening jam nut, use a wrench on the center, flat section of tube. with

without

-RXIVQIHMEXI 7LEJX

Fig. 5 Disconnect Intermediate Shaft to Center Steering Wheel

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.

FRONT SUSPENSION

4EVX SJ *VEQI

4EVX SJ *VEQI

238) 8MI 6SH 2SX 7LS[R JSV 'PEVMX]

Fig. 6 Front Suspension Components

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 Shock Absorber Replacement Tool List

Qty. The intermediate shaft is assembled with the universal joints set 90° out of phase with each other.

Front Axle Replacement Tool List

Qty.

To prevent stress and possible damage to the rack and pinion unit, the driver side spring must be mounted to the axle with the hardware (20 - 23) installed in its original location (Ref. Fig. 6).

Item

To prevent possible injury from falling steering components, secure rack and pinion unit (16) to front springs with wire. This will prevent the intermediate shaft connecting the rack and pinion unit to the steering column from pulling apart due to the weight of the steering system.

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.

Front Spring Replacement Tool List

Qty.

Failure of a single spring will result in overstressing the other spring; therefore, replace front springs as a set.

After the springs are replaced, the axle will need to be aligned to the frame. Unless the axle has been replaced, wheel alignment will not be affected; however, it is always good practice to check wheel alignment any time the front-end components are replaced or adjusted.

Item

Torque Specification

:MI[ JVSQ 9RHIVWMHI SJ :ILMGPI

)UYEP (MWXERGI

To prevent stress and possible damage to the rack and pinion unit, the driver side spring must be mounted to the axle with the hardware (20 - 23) installed in its original location (Ref. Fig. 6).

Fig. 7 Front Axle Alignment

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

Hub Replacement Tool List

Qty.

% -RWXEPP XLMW WMHI SJ WIEP MRXS LSYWMRK & 0YFVMGEXI PMT SJ WIEP

&

%

Fig. 9 Seal Installation

Wheel Bearing and Race Replacement Tool List

Qty.

If pitting or blue coloration is present in the rollers, the bearing must be replaced

*VSRX SJ :ILMGPI

Fig. 8 Hub Replacement

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

*VSRX SJ :ILMGPI

Fig. 10 Wheel Bearing Replacement

STEERING

*VSRX SJ :ILMGPI

*PEX 7IGXMSR

Fig. 11 Steering Components

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

Rack Ball Joint Replacement Tool List

Qty. After replacing or servicing steering components, always verify that an 1/8" gap exists between large hex of rack extension and rack and pinion unit when steering is turned fully to the right forcing passenger spindle arm against front axle (Ref. Fig. 20).

Tie Rod Inspection/Replacement Tool List

Qty.

1IEWYVI I\TSWIH XLVIEH PIRKXL ERH YWI PIRKXL XS TSWMXMSR RI[ FEPP NSMRX EX WEQI PSGEXMSR

Fig. 12 Rack Ball Joint Installation

*PEX WIGXMSR XS[EVHW IRH MHIRXMJMIW IRH [MXL PIJX LERH XLVIEHW

1IEWYVI XLVIEHW WLS[MRK JSV PIRKXL XS TSWMXMSR RI[ FEPP NSMRX EX WEQI PSGEXMSR

Item

Torque Specification

Fig. 13 Tie Rod Replacement

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

The tie rod has different threads on each end. The end with the flat area on the threaded tube has left hand threads (clockwise to loosen) while the end without the flat has conventional right hand threads (counter-clockwise to loosen) (Ref. Fig. 13).

The distance to center of tie rod ball joint from jam nut on both ends of threaded tube should be the same.

minimum

+VSSZIW

Fig. 14 Bellows Replacement

Item

After replacing or servicing steering components, always verify that an 1/8" gap exists between large hex of rack extension and rack and pinion unit when steering is turned fully to the right forcing passenger spindle arm against front axle.

Torque Specification

Bellows Replacement Tool List

Qty.

Item

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.

Pinion Seal Replacement Tool List

Qty.

Spindle Replacement Tool List

Qty.

Secure rack and pinion unit in vice by the mounting gears only. The rack and pinion unit is made of aluminum and can be damaged if held otherwise.

The spindle bearings are designed to be used “dry”.

Lubrication attracts dirt and will ruin the bearings.

Do not apply grease to the spindle bearings.

0MT SJ 7IEP

Fig. 15 Pinion Seal Replacement

Wipe bore clean and lubricate pinion and lip of seal with grease.

The bore has a positive stop to correctly locate the seal during installation.

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

The rack and pinion gears are not serviceable items. If they are found to be damaged or excessively worn, a new rack and pinion unit must be installed.

Secure rack and pinion unit in vice by the mounting ears only. The rack and pinion unit is made of aluminum and can be damaged if held otherwise.

Fig. 16 Spindle Replacement

The thrust washer (9) is located on top of spindle between spindle and front axle.

Item

Torque Specification

must be

Tool List

Rack and Pinion Unit Disassembly and Inspection

Qty.

Fig. 17 Rack and Pinion Unit Disassembly

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

Do not

Item

Torque Specification

Item

Torque Specification

After replacing or servicing steering components, always verify that an 1/8" gap exists between large hex of rack extension and rack and pinion unit when steering is turned fully to the right forcing passenger spindle arm against front axle.

After replacing or servicing steering components, always verify that an 1/8" gap exists between large hex of rack extension and rack and pinion unit when steering is turned fully to the right forcing passenger spindle arm against front axle.

Rack and Pinion Unit Replacement Tool List

Qty.

Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance Tool List

against

Qty.

must rest

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 Wheel Replacement Tool List

Qty.

*VSRX SJ :ILMGPI

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

6EGO &EPP .SMRX

4EWWIRKIV 7MHI 7TMRHPI %VQ 6IWXMRK %KEMRWX *VSRX %\PI

Fig. 18 Spindle Contact with Front Axle

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

%TTVS\MQEXIP] 8LMGO ;EWLIV

+ET

Fig. 19 Checking Gap

7XIT

7XIT

Fig. 20 Clipboard Removal

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

7XIIVMRK 7LEJX

Fig. 21 Steering Wheel Replacement

Do not strike steering nut or end of steering shaft directly with ball peen hammer. Internal damage to rack and pinion unit can result.

Do not force

Item

Torque Specification

Steering Shaft and Column Replacement Tool List

Qty.

Fig. 22 Steering Shaft and Column

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

-RWXEPP [MXL EVGL YT EW WLS[R 7XIIVMRK 7LEJX &IEVMRK

Torque Specification

7QEPP 6IXEMRMRK 6MRK +VSSZI

Fig. 23 Small Retaining Ring Orientation

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:

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 SPEED SENSOR

7TIIH 7IRWSV

CONTROLLER REPLACEMENT Tool List

Qty.

Fig. 1 Speed Sensor

CONTROLLER

'SRXVSPPIV

*VSRX SJ :ILMGPI

Fig. 2 Controller

To prevent electrical shock, the BL- wire must be removed before discharging the controller by shorting the B+ and B- terminals of the controller with a large screwdriver. Be sure to hold screwdriver by the insulated portion.

Note the location of the wiring before disconnecting from controller.

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

Item

Torque Specification

8S 1SXSV q9r

Qty.

To prevent electrical shock, the BL- wire must be removed before discharging the controller by shorting the B+ and B- terminals of the controller with a large screwdriver. Be sure to hold screwdriver by the insulated portion.

Note the location of the wiring before disconnecting from solenoid

8S 1SXSV q:r

Item

8S *YWI

Torque Specification

8S 1SXSV q;r

8S &EXXIV]

8S &EXXIV]

8S GLEVKIV VIGITXEGPI

Fig. 3 Controller Replacement Fig. 4 Solenoid Replacement

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:

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

MOTOR GENERAL

Do not hold vehicle on a hill using the accelerator, which is known as a “stalled” condition. Leaving motor in a stalled condition for more than 3-4 seconds can cause permanent damage to the motor.

Motor Replacement

To prevent shorting motor wires and causing an explosion, disconnect the negative (-) battery cable with an insulated wrench before attempting to remove wires from the motor (see procedures in SAFETY section of this manual).

Tool List

Qty.

2IKEXMZI 'EFPI

*VSQ &EXXIV] 8IQT 7IRWSV ;,8 JVSQ 'LEVKIV

;,8 JVSQ 6IGITXEGPI

*VSRX SJ :ILMGPI

Fig. 1 Disconnect Battery Cable

Fig. 2 Mark Axle and Motor

Be careful not to damage the splines when removing and reassembling the motor to the rear axle housing.

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

Item

Motor Tests

Torque Specification

1SXSV 8IVQMREP

;MVI 1EVOIV

*VSQ 'SRXVSPPIV

9

9

9

:

:

:

;

;

;

Fig. 3 Motor Wiring

'PIER QSXSV GSYTPIV [MXL GSQTVIWWIH EMV

'6377 7)59)2')

Fig. 4 Motor Components

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:

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

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

To prevent battery explosion that could result in severe personal injury or death, keep all smoking materials, open flames or sparks away from the batteries.

Hydrogen gas is formed when charging batteries; do not charge batteries without adequate ventilation. A 4% concentration of hydrogen gas is explosive.

Ensure the key switch is off and all electrical accessories are turned off before starting work on vehicle.

Never disconnect a circuit under load at a battery terminal.

Batteries are heavy; use proper lifting techniques when moving them. Always lift the battery with a commercially available battery lifting device.

Use care not to tip batteries when removing or installing them; spilled electrolyte can cause burns and damage.

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

Always wear a safety shield or approved safety goggles when adding water or charging batteries.

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.

Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle. Expelled electrolyte may cause damage to the vehicle and storage facility.

Aerosol containers of battery terminal protectant must be used with caution. Insulate metal container to prevent can from contacting battery terminals, which could result in an explosion.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’ a battery, which could result in an explosion.

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

Qty. Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage.

:IRX 'ET

At Each Charging Cycle

+EW :IRX

To reduce the possibility of fire, never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle.

Overcharging could cause damage to the vehicle batteries and result in extreme overheating. The charger should be checked after 24 hours and disconnected after the charge cycle is complete.

)\TERWMSR 7TEGI

r XS r

QQ XS QQ

:IRX

r

QQ

4PEXIW

)PIGXVSP]XI PIZIP WLSYPH FI EX PIEWX r QQ EFSZI TPEXIW ERH r XS r XS QQ FIPS[ ZIRX

Monthly

Electrolyte Level and Water

Fig. 1 Correct Electrolyte Level

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

Fig. 2 Water Purity Table

To prevent battery damage, be sure that all battery caps are tightly installed.

2SR 1IXEPMG ;ERH 'YT 10 &EOMRK 7SHE

Fig. 3 Automatic Watering Gun

+EP 0 ;EXIV

+EP 0 +EVHIR 7TVE]IV

+EP 0 &EOMRK 7SHE 7SPYXMSR

Fig. 4 Preparing Acid Neutralizing Solution The watering device should only be used if the electrolyte level is less than 1/2" (13 mm) above top of plates.

Cleaning Batteries

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

Battery Replacement

2IKEXMZI

Before any electrical service is performed, the RunTow/Maintenance switch must be placed in the ‘Tow/ Maintenance’ position.

*VSRX &EXXIV] 8IQT 7IRWSV ;,8 JVSQ ;,8 JVSQ 'LEVKIV 6IGITXEGPI

*VSRX SJ :ILMGPI

Fig. 5 Battery Connections

Prolonged Storage

Disconnect battery charger, controller and other electronic devices since they will contribute to the premature discharge of batteries.

To prevent battery explosion that could result in severe personal injury or death, extreme care must be used with aerosol containers of battery terminal protectant.

Insulate the aerosol container to prevent the metal can from contacting battery terminals, which could result in an explosion.

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

3 * ) 0 ) ' 8 6 3 0 = 8 )

8 ) 1 4 ) 6 % 8 9 6 )

3

'

In some portable chargers, there will be a rattle present in the body of the charger DC plug. This rattle is caused by an internal magnet contained within the charger plug.

The magnet is part of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the vehicle charging receptacle.

AC Voltage

74)'-*-' +6%:-8= )0)'8630=8) *6))>-2+ 43-28

Fig. 6 Freezing Point of Electrolyte

Battery Charging

Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage.

FAULT DIAGNOSIS

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

Hydrometer

Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte.

To prevent battery explosion that could result in severe personal injury or death, never insert a metal thermometer into a battery. Use a hydrometer with a built in thermometer that is designed for testing batteries. ']PMRHIV

Using A Hydrometer

&YPF *PSEX

%HH XS *PSEX 6IEHMRK

7YFXVEGX JVSQ *PSEX 6IEHMRK

add

subtract

;IMKLX 8LIVQSQIXIV

Fig. 7 Hydrometer

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

)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]

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

GSVVIGXIH WTIGMJMG KVEZMX]

Fig. 8 Hydrometer Temperature Correction

BATTERIES AND CHARGING 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

Fig. 1 Wiring Diagram

640757

Repair and Service Manual

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

Fig. 2 Wiring Diagram

Repair and Service Manual

640757

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

&0/

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Fig. 3 On Board Charger Electrical Schematic (CE)

640757

362

9

&0/

Repair and Service Manual

=)0 *

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

6)')48%'0) 3** &3%6( &0/

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Fig.

Electrical Schematic (CE)

Repair and Service Manual

640757

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

&%88)6= 8)14 7)2736

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;,8

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*SV :ILMGPIW 1ERYJEGXYVIH &IJSVI 1%6',

Fig. 5 Wiring Diagram (On Board Charger)

640757

Repair and Service Manual

&

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

7276 &%88 8)14 7)2736 497, 32 '328630 ,%62)77 8) 8%& %;+ 497, 32 '328630 ,%62)77 8) 6)'4 %;+

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4YWL SR ERH GSRRIGXIH XS XLI ,): JYWI EW TEVX SJ XLI LEVRIWW EWWIQFP] *SV :ILMGPIW 1ERYJEGXYVIH *VSQ 1%6',

Fig. 6 Wiring Diagram (On Board Charger)

Repair and Service Manual

640757

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

AWG TO METRIC CONVERSIONS AWG

METRIC (MM2)

MAIN HARNESS Power Supply Tool List

Qty.

Bare wires may cause a short circuit.

VOLTAGE TEST FOR BATTERIES

Hydrogen gas formed during battery charging is explosive and can cause personal injury or death. Prevent electrical spark or open flame near battery.

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 must be replaced.

See “Faulty Wire Replacement”.

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 battery.

640757

Repair and Service Manual

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

2IKEXMZI 'EFPI

*VSQ &EXXIV] 8IQT 7IRWSV ;,8 JVSQ 'LEVKIV

*VSRX SJ :ILMGPI ;,8 JVSQ 6IGITXEGPI

Fig. 7 72V Battery Set Connections

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

Use of incorrect fuse rating can damage electrical components.

The power wire supplies power to the entire fuse block.

Fig. 8 Fuse Block

Repair and Service Manual

640757

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

Accessory Wiring Following procedure is applicable for vehicles with LED headlights.

Tool List

Faulty Wire Replacement

Headlight Replacement

Following procedure is applicable for vehicles with halogen headlights.

640757

Repair and Service Manual

Qty.

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

Fig. 9 Headlights

Taillight Replacement

6YFFIV &I^IP

Fig. 10 Taillights

Repair and Service Manual

640757

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

FAULT DIAGNOSIS

Testing Battery Voltage

General

Example 1:

Example 2:

Continuity Check

To prevent possible injury or death resulting from a battery explosion, use an insulated wrench and remove the BL- wire from the battery to disconnect electrical power to vehicle.

640757

Repair and Service Manual

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

Testing a Switch for Continuity

4VIWW XS EGXMZEXI W[MXGL

Testing a Solenoid for Continuity

Fig. 12 Continuity Check of Solenoid

Fig. 11 Continuity Check of Switch

Repair and Service Manual

640757

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

Notes:

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

Notes:

Repair and Service Manual

640757

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

BRAKES 4EVO &VEOI 4IHEP

8SVWMSR 7TVMRKW 4YWL 2YX

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7IPJ %HNYWXMRK ;LIIP &VEOI

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Fig. 1 Mechanical Brake System

BRAKE SYSTEM OVERVIEW General Description

How the Service Brake Works

238) &SXXSQ TYPP FVEOI HVYQ WLS[R WSQI QSHIPW EVI XST TYPP 8LI] EVI JYRGXMSREPP] XLI WEQI

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

Equalizer Link 4IHEP 0EXGL %VQ

Automatic Adjuster Mechanism

Never manually adjust the brakes at the star wheel.

Doing so will cause permanent damage to the adjuster assembly and result in a gradual loss of brakes.

4IHEP 0EXGL %VQ %GGIPIVEXSV 4IHEP

'EXGL &VEGOIX 4IHEP &YQTIV

/MGO 3JJ 'EQ

Fig. 2 Park Brake and Kick-Off Mechanism

How the Park Brake Works

Kick-Off Actuating Linkage

Compensator Assembly

7TVMRK

7XST 8YFI

Fig. 3 Compensator Assembly

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

FAULT DIAGNOSIS FLOWCHART

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6ITPEGI 7II 6IEV %\PI 7IGXMSR MR 1ERYEP

+SSH

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=IW

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=IW

'SQTIRWEXSV 'PIZMW 4MR %HNYWXQIRX &IRX 6SH 0SSWI 7TLIVMGEP 2YX ERH 0SGO 2YX 7IVZMGI &VEOI 4IHEP 4MZSX 8SVWMSR 7TVMRK (EQEKI 'SVVSWMSR 4IHEP 4EH

%HNYWX 'SVVIGX 6ITPEGI

&EH

:MWYEP )\XIVREP -RWTIGXMSR -RGPYHIW

:MWYEPP] 'LIGO 'SRHMXMSR SJ

;LIIP &VEOI 'PIZMW 4MRW 8MKLX#

2S

6IXYVR 8S 7IVZMGI

=IW +S XS

4VSZMHMRK JVII XVEZIP MW GSVVIGXP] EHNYWXIH XLI GPIZMW TMRW [MPP RSX FI YRHIV XIRWMSR F] XLI FVEOI GEFPIW

Fig. 4 Fault Diagnosis Flowchart

'LIGO %HNYWXIV *YRGXMSR F] ,SPHMRK *VSRX &VEOI 7LSI 3TIVEXI &VEOI 0IZIV

+S XS

6ITPEGI ;LIIP &VEOI %WWIQFP]

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

%HNYWXIV 8VMIW XS 1SZI 7XEV ;LIIP# 7XEV ;LIIP 6SXEXIW# *VII 1SZIQIRX SJ 7PMHMRK %RGLSV#

2S

(MWEWWIQFPI &VEOI 'PIER 0YFI 6ITPEGI %HNYWXIV &SXL 7MHIW

=IW

=IW

6ITPEGI &SXL 7MHIW

2S

=IW

4&48

*EMP

:MWYEPP] -RWTIGX &VEOI 7LSIW

(MWEWWIQFPI 'PIER ERH 0YFI &SWWIW

2S 'EVIJYPP] 6IWIX %HNYWXIV

6ITIEX ;LIIP &VEOI ;SVO XS 3XLIV 7MHI *VSQ 7XIT XS

-RWXEPP -RRIV &VEOI (VYQ ;EWLIVW ERH %TTP] %RXM WIM^I GSQTSYRH XS 7TPMRIW

;LIIP &VEOI 'PIZMW 4MRW 8MKLX#

6I %HNYWX *VII 8VEZIP

(EQEKIH =IW ;SVR SV PIWW +PE^IH#

(]REQMG %HNYWX &VEOIW ERH 4IHEP *VII 8VEZIP

2S

-RWXEPP ;LIIP ERH 8MVI 'LIGO 8MVI 4VIWWYVI 8SVUYI 0YK 2YXW

:MWYEPP] -RWTIGX &VEOI 7TVMRKW

7TVMRKW &IRX &VSOIR SV 1MWWMRK#

-RWXEPP &VEOI (VYQ ERH 8SVUYI

-RWXEPP 2I[ 7LSIW ERH 7TVMRKW

%KKVIWWMZI &VEOI 8IWX

XMQIW

;LIIP &VEOI 'PIZMW 4MRW 8MKLX#

=IW

+S XS JMVWX -J XMKLX EJXIV WIGSRH XMQI KS XS

2S

6IXYVR XS 7IVZMGI

(]REQMG %HNYWX QIERW XS JYPP] ETTP] ERH VIPIEWI XLI FVEOIW SR E

ZILMGPI [LMPI MX MW VSPPMRK (S XLMW F] JMVWX ZIVMJ]MRK XLEX WSQI FVEOMRK JYRGXMSR I\MWXW 8LIR HVMZI ZILMGPI EX WPS[ WTIIH ERH ETTP] XLI FVEOIW EKKVIWWMZIP] %W XLI FVEOIW EHNYWX ERH WXST XLI ZILMGPI QSVI IJJIGXMZIP] WXEVX HVMZMRK EX QE\MQYQ WTIIH ERH FVEOI EKKVIWWMZIP] XMQIW %X XLI WTLIVMGEP RYX VIEHNYWX XLI JVII XVEZIP (VMZI ERH FVEOI EKKVIWWMZIP] QSVI XMQIW 6ITIEX YRXMP XLI TIHEP JVII XVEZIP WXEFMPM^IW [MXLMR XLI WTIGMJMIH VERKI

Fig. 5 Fault Diagnosis Flowchart

4EWW

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

FAULT DIAGNOSIS TABLE

Condition

Possible Cause

Fails Brake Performance Test by stopping in a longer distance than normal

In excess of 1-1/8" (2.9 cm) free pedal travel (Soft Pedal)

Less than 7/8" (2.2 cm) free pedal travel (Hard Pedal)

Neither wheel locks when park brake is latched. (Note: At full speed the wheels may not lock, but should brake aggressively).

Fig. 6 Fault Diagnosis Table

Correction

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

Condition

Possible Cause

Unequal braking (one wheel locks while other rotates)

Correction not

Neither wheel locks

Grabbing brakes (oversensitive)

Park brake hard to latch

Park brake will not stay latched Fig. 6 Fault Diagnosis Table

FAULT DIAGNOSIS AND INSPECTION New Vehicle

Fault Diagnosis and Inspection Procedures

Satisfactory brake performance does not eliminate the need for routine brake testing and inspection as indicated in the Periodic Service Schedule in Section A. Continued proper brake operation depends on periodic maintenance.

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

Brake Pedal and Linkage Inspection

Check the brake pedal free travel.

Inspect brake pedal return bumper.

1IEWYVIH EQSYRX SJ JVII XVEZIP

QQ HMEQIXIV HVMPP SV FSPX QYWX TEWW %HNYWX EX FYQTIV MJ RIIHIH XLVSYKL XET

Fig. 7 Brake Pedal Bumper Inspection *PSSVFSEVH

Check brake pedal return.

Fig. 9 Check Free Travel

&VEOI 4IHEP %VQ

4EVX SJ *VEQI

4MZSX &SPX

0SSWIR .EQ 2YX

&VEOI 4IHEP &YWLMRK 8SVWMSR 7TVMRK

Fig. 8 Brake Pedal Inspection

7TLIVMGEP 2YX

Fig. 10 Checking Park Brake Latching Pressure

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

2SX XS I\GIIH

QQ MR IMXLIV HMVIGXMSR

Inspect the brake cables.

*VSRX

2SVQEP 4SWMXMSR

Check the clevis pins.

7TLIVMGEP 2YX

0SGO 2YX

:MI[ *VSQ &IPS[ 238) 8LMW HMQIRWMSR MW JEGXSV] TVI WIX [MXL XLI TEVOMRK FVEOI HMWIRKEKIH ERH WLSYPH RSX FI GLERKIH 238) &SXXSQ TYPP FVEOI HVYQ WLS[R WSQI QSHIPW EVI XST TYPP 8LI] EVI JYRGXMSREPP] XLI WEQI

.EQ 2YX

GQ

%HNYWXMRK 2YX

7TVMRK

Fig. 12 Equalizer and Compensator 'LIGO JSV PSSWI GPIZMW TMR

8SVWMSR 7TVMRKW

,MRKI 4MR

Fig. 11 Check Clevis Pins Inspect the brake cable equalizer linkage.

4YWL 2YX

Inspect the compensator assembly.

Fig. 13 Park Brake Pedal Hinge Inspection Check the condition and operation of the park brake latching mechanism.

Inspect park brake pedal hinge.

To prevent serious injury or death from the use of worn park brake components, do not attempt to re-new worn parts. The park brake latch arm, kick-off cam and catch bracket are hardened parts. Do not grind or file them, as doing so will cause the parts to lose hardness characteristics. New parts must be used.

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

Inspect catch bracket and latch arm.

Inspect the park brake kick-off cam.

Inspect kick-off cam linkage and bushings.

4IHEP 0EXGL %VQ

'EQ QYWX FI EKEMRWX PEXGL EVQ EX XLMW TSMRX [MXL RS KET 'EXGL &VEGOIX 7IXWGVI[ /MGO 3JJ 'EQ

Fig. 14 Kick-Off Cam Inspection

%GGIPIVEXI XS QE\MQYQ WTIIH

Periodic Brake Performance Test (PBPT)

To prevent severe injury or death resulting from operating a vehicle with improperly functioning brake system, the brake system must be properly maintained. All driving brake tests must be done in a safe location with regard for the safety of all personnel.

Fig. 15 Periodic Brake Performance Test

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

A subtle loss of performance may take place over time; therefore, it is important to establish the standard with a new vehicle.

The brake adjuster mechanism must expand and release fully to function. Under light usage this may not occur, even though the vehicle stops acceptably. The adjuster functions most consistently with aggressive braking.

Fig. 16 Evenly Loaded Vehicle

Wheel Brake Inspection

Aggressive Stop Test

Wear a dust mask and eye protection working on wheel brakes.

Do not use pressurized air to blow dust from brake assemblies.

To prevent serious injury or death, all brake tests must be done in a safe location with regard for the safety of all personnel.

Replace both brake shoes on both wheels if one or more shoes are worn below .06” (1.5 mm) thickness at any point.

Do NOT touch any of the wheel brake mechanism except as instructed.

Do NOT use a commercial brake cleaner unless the entire brake has been disassembled.

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

fails to rotate it

The drum must not be turned to “true” a worn friction surface. Turning will make the drum too thin and cause drum failure and a loss of brake functionality, which could cause severe injury or death. ;LIIP &VEOI 0IZIV

&VEOI %HNYWXIV %VQ

%HNYWXMRK 7GVI[

7XEV ;LIIP

Fig. 17 Adjuster Mechanism

If one wheel brake assembly is replaced, the second must also be replaced.

Use care when handling the adjuster arm. Too much force will damage the adjuster and require that both wheel brake assemblies be replaced.

engages and turns fails to engage

A backing plate assembly that shows any indication of galling or gouging is not repairable and must be replaced with a new wheel brake assembly. Always replace wheel brake assemblies in pairs.

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

238) 8ST TYPP FVEOI HVYQ WLS[R WSQI QSHIPW EVI FSXXSQ TYPP 8LI] EVI JYRGXMSREPP] XLI WEQI

,IEZ] 7LSI 7TVMRK

8LI TEXXIVR SJ RSVQEP FVEOI WLSI [IEV MW WLS[R MR UYEHVERX s%t s&t s't s(t [MXL UYEHVERX s%t WLS[MRK XLI QSWX [IEV 5YEHVERX s&t [MPP WLS[ XLI WIGSRH QSWX [IEV 4%77)2+)6 7-()

*SV[EVH (VYQ 6SXEXMSR

0MKLX 7LSI 7TVMRK

Fig. 19 Orientation of Brake Shoe Springs

&

' MAINTENANCE AND REPAIRS Tool List

(

% *SV[EVH (VYQ 6SXEXMSR

(6-:)6 7-()

'

&

%

(

Fig. 18 Brake Shoe Wear (Top Pull)

Qty.

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

Adjusting Brake Pedal Free Travel

Brake pedal free travel must be checked and adjusted any time the brake system is serviced, or when parts are replaced.

The purpose of this procedure is to adjust the brakes and seat brake system components.

The brake system may not be effective for the first few presses to the brake pedal.

XS XS GQ

All brake tests must be done in a safe location with regard for the safety of all personnel.

238) &SXXSQ TYPP FVEOI HVYQ WLS[R WSQI QSHIPW EVI XST TYPP 8LI] EVI JYRGXMSREPP] XLI WEQI

'LIGO JSV PSSWI GPIZMW TMR

Fig. 21 Check Clevis Pins

.EQ 2YX

7TLIVMGEP 2YX

Fig. 20 Free Travel Adjustment

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

Use care when raising the adjuster arm. Excessive force will damage the adjuster and necessitate both wheel brake assemblies be replaced.

just above

0SSWIR .EQ 2YX

7TLIVMGEP 2YX

Fig. 22 Checking Park Brake Latching Pressure

Brake Drum Removal and Installation

Pay particular attention to location of inner brake drum washer (6) inside brake drum. It may be on the axle shaft or attached to the rear of the drum hub. This washer must be reinstalled when brake is reassembled.

*VSRX SJ :ILMGPI

238) &SXXSQ TYPP FVEOI HVYQ WLS[R WSQI QSHIPW EVI XST TYPP 8LI] EVI JYRGXMSREPP] XLI WEQI

Do not back off nut to install cotter pin.

Fig. 23 Brake Assembly

Do not apply the brake when removing the nut as the shoes may not fully retract, preventing removal of the brake drum.

Wheel Brake Service

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

Wear eye protection and a mask when cleaning brake components.

Do not use compressed air to remove brake dust from brake assembly.

&EGOMRK 4PEXI

0YFVMGEXI

FSWWIW IEGL WMHI

0YFVMGEXI

FSWWIW IEGL WMHI

Do NOT use a commercial brake cleaner unless the entire brake has been disassembled.

0YFVMGEXI MR ERH EVSYRH WYVJEGIW

0YFVMGEXI

0YFVMGEXI

&VEOI %HNYWXIV %VQ

It is important that friction areas between backing plate and brake shoes be lubricated. Be careful not to allow lubricant to contact braking portion of brake shoes or friction surface of brake drum. Use only recommended lubricants.

Fig. 24 Wheel Brake Lubrication Points

Backing Plate/Entire Wheel Brake Assembly Removal and Installation

Ensure the adjusting screw is screwed into the star wheel nut until only 1 - 2 threads are exposed.

If brake shoes are replaced, replace brake springs and adjuster components.

238) &SXXSQ TYPP FVEOI HVYQ WLS[R WSQI QSHIPW EVI XST TYPP 8LI] EVI JYRGXMSREPP] XLI WEQI

Fig. 25 Backing Plate Removal and Installation

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

Brake Shoe Removal

It is recommended when brake shoes are replaced, adjusters and springs also be replaced. Do one side at a time, using the other side for reference.

8ST TYPP FVEOI HVYQ WLS[R WSQI QSHIPW EVI FSXXSQ TYPP 8LI] EVI JYRGXMSREPP] XLI WEQI

Wear a dust mask and eye protection working on wheel brakes. Do not use pressurized air to blow dust from brake assemblies.

834 4900

Fig. 26 Brake Shoes and Springs

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

Brake Shoe Installation

8

0

Fig. 28 Brake Shoe ’17T’

Fig. 27 Brake Shoe ’17L’

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

Brake Cable and Equalizer Assembly Removal and Installation

Brake Pedal Removal and Installation

The brake cables and equalizer are only serviceable as a complete assembly.

'PIZMW 4MR

'SXXIV 4MR

'SQTIRWEXSV 7TLIVMGEP %WWIQFP] )UYEPM^IV 2YX &VEGOIX .EQ 0SGO 2YX &VEOI 'EFPIW 'SQTIRWEXSV 6SH

3PHIV 1SHIPW

Fig. 29 Brake Cable, Equalizer and Compensator

Compensator Assembly, Removal and Installation

ERH 0EXIV

4IHEP 0EXGL

Fig. 30 Brake Pedal Removal and Installation

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

Park Brake Pedal Removal and Installation

Park Brake Catch Bracket Removal and Installation

To prevent serious injury death resulting from the use of worn park brake components, do not attempt to re-new worn components. The catch bracket is a hardened part. Do not grind or file it, as doing so will cause the part to lose its hardness characteristics. A new part must be used.

To prevent serious injury or death resulting from the use of worn park brake components, do not attempt to re-new worn components.

The park brake arm latch is a hardened part.

Do not grind or file it, as doing so will cause the part to lose its hardness characteristics. A new part must be used.

Pedal Bumper Adjustment

4IHEP 0EXGL %VQ

QQ QE\ KET EJXIV EHNYWXQIRX SJ GEQ 'EQ QYWX FI EKEMRWX PEXGL EVQ EX XLMW TSMRX [MXL RS KET

'EXGL &VEGOIX

QQ QE\ KET EX XLMW TSMRX

Fig. 31 Catch Bracket and Latch Arm

QQ HMEQIXIV HVMPP SV FSPX QYWX TEWW %HNYWX EX FYQTIV MJ RIIHIH XLVSYKL XET

Fig. 32 Pedal Bumper Adjustment

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

Park Brake Release Linkage Removal and Replacement

%GGIPIVEXSV 4IHEP

Fig. 33 Park Brake Release Linkage and Kick-Off Cam Removal and Installation

Park Brake Kick-Off Cam Removal, Replacement and Installation

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:

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

BATTERY CHARGER CHARGER DESCRIPTION

Use charger only on 72 volt battery systems.

Other usage may cause personal injury and damage.

4VSZMHI 4VSXIGXMSR *VSQ )PIQIRXW

To reduce risk of electrical shock, connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances.

A grounded outlet is required to reduce risk of electric shock – do not use ground adapters or modify plug.

(S 2SX &PSGO 0SYZIVIH %MV[E]W 2)1% 6 +VSYRHIH %' 6IGITXEGPI :%' (IHMGEXIH %14 'MVGYMX 0SGEXMSRW SYXWMHI XLI 97 ERH 'EREHE 6IJIVIRGI ETTVSTVMEXI PSGEP IPIGXVMGEP GSHI ERH GLEVKIV QERY JEGXYVIV VIGSQQIRHEXMSRW JSV %' TS[IV VIUYMVIQIRXW

Fig. 1 Charger

Do not touch uninsulated portion of output connector or uninsulated battery terminal.

Disconnect the DC supply before making or breaking the connections to the battery while charging.

Do not open or disassemble charger.

Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way – refer all repair work to qualified personnel.

Not for use by children.

Looping the DC cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging. The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away.

An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution.

BATTERY CHARGER 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 REAR SUSPENSION

In the following text, there are references to removing/ installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in original positions unless otherwise specified. Non-specified torques are as shown in GENERAL INFORMATION & ROUTINE MAINTENANCE section.

Shock Absorber Installation

General Tool List

Qty.

Rear Spring Removal

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 front wheels and check stability of vehicle on jack stands before starting any repair procedure. Never work on a vehicle that is supported by a jack alone.

Shock Absorber Removal

If both springs are to be replaced, but the rear axle is not being removed from the vehicle, it is important to replace one spring at a time so that the rear axle is supported at all times.

Springs must be replaced in sets; never replace only one.

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 front wheels and check stability of vehicle on jack stands before starting any repair procedure. Never work on a vehicle that is supported by a jack alone.

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

Rear Spring Installation

*VSRX &EXXIV] 8IQT 7IRWSV

2IKEXMZI

;,8 JVSQ ;,8 JVSQ 'LEVKIV 6IGITXEGPI

*VSRX SJ :ILMGPI

Fig. 1 Battery Connections

Rear Axle Assembly Removal

The motor is part of the rear axle assembly.

The position of the motor causes the rear axle to be top heavy and it will rotate when it is disengaged from the vehicle if not supported adequately. To reduce the possibility of personal injury while removing the leaf springs, the use of an overhead hoist to support the motor is recommended. If a hoist is unavailable, the motor may be held in position by a second person until the springs are removed and the axle can be removed from underneath the vehicle.

Disable the vehicle electrical system before attemping to remove wires from motor. Possible shorting of motor wires could cause an explosion.

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 Axle Assembly Installation

1SXSV 8IVQMREP

;MVI 1EVOIV

*VSQ 'SRXVSPPIV

9

9

9

:

:

:

;

;

;

Fig. 2 Motor Wire Connections

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

6IEV %\PI

Fig. 3 Rear Suspension

REAR SUSPENSION 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 REAR AXLE DISASSEMBLY

REAR AXLE MAINTENANCE

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.

Item

Lubricant Capacity

Checking the Lubricant Level

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

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

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.

Axle Shaft Removal and Disassembly Tool List

'LIGO *MPP 4PYK

Fig. 1 Add, Check and Drain Rear Axle Lubricant

Qty.

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

&IEVMRK 7ITEVEXSV

Fig. 4 Pressing Bearing from Axle Shaft Fig. 2 Removing/Installing Outer Snap Ring

Axle Shaft Seal Removal and Replacement Tools List

Qty.

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

Fig. 3 Removing/Installing Axle Shaft

Fig. 5 Removing/Installing Inner Snap Ring

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

Axle Shaft Replacement

Item

Fig. 6 Removing Seal

Torque Specification

Tighten the castellated axle nut to 70 ft. lbs. (95 Nm) torque minimum, 140 ft. lbs. (190 Nm) torque maximum.

Continue to tighten until the slot in the nut aligns with the cotter pin hole.

8LMR 8LVYWX -RRIV 7RET ;EWLIV 6MRK 7TPMRI 8LMGO 8LVYWX ;EWLIV

'SXXIV 4MR

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

%\PI 2YX &IEVMRK &VEOI (VYQ

3YXIV 7RET 6MRK

Fig. 8 Cut Away of Outer Bearing and Brake Drum Item

Fig. 7 Installing Seal

Lubricant Capacity

REAR AXLE 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 SUN TOP AND WINDSHIELD Rear Support Installation The sun top does not provide protection from roll over or falling objects.

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

Front Struts Transporting Vehicle

Refer to “TRANSPORTING VEHICLE” on page 1 in the GENERAL INFORMATION AND ROUTINE MAINENANCE section of this manual for complete information on vehicle transport.

Sun Top

Always remove windshield (if equipped) before transporting vehicle on a trailer.

Maximum transport speed with sun top installed is 50 mph (80 kph).

SUN TOP Tool List

Qty.

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

*VSRX SJ :ILMGPI

(

( ' %

'

%

7IEX &EGO 7YTTSVX

&YQTIV

*VSRX SJ :ILMGPI

*VSRX SJ :ILMGPI

Fig. 1 Sun Top

7IEX

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

SPLIT WINDSHIELD Tool List

Qty.

Do not over-tighten or

squeeze grommet

7XVYX

;MRHWLMIPH

()8%-0 (

()8%-0 &

6YFFIV 0EXGL 7XVYX

*VSRX SJ :ILMGPI

()8%-0 %

;MRHWLMIPH

7XVYX

*VSRX SJ :ILMGPI ;MRHWLMIPH 6IXEMRIV

()8%-0 '

Fig. 2 Split Windshield

It may be necessary on early production sun tops to drill a 9/32" hole in front face of both sides of front strut approximately 7" down from top of strut.

Take care not to warp windshield when raising and lowering the top section of windshield.

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

FULL WINDSHIELD Tool List

Qty. squeeze grommet

Do not over-tighten or

;MRHWLMIPH ()8%-0 &

()8%-0 %

;MRHWLMIPH

7XVYX

7XVYX *VSRX SJ :ILMGPI ()8%-0 '

Fig. 3 Full Windshield

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

GENERAL

Transporting Vehicle

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

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

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

Do not ride on a vehicle being transported.

Remove the windshield before transporting.

Maximum speed with the canopy top installed is 24 mph (39 kph).

%

:ILMGPI WLS[R JSV VIJIVIRGI SRP]

%

Fig. 4 Canopy Top

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

CANOPY TOP Canopy Top Removal Tool List

Qty.

Do not twist windshield when lifting and lowering the top section of windshield.

Do not over tighten or compress the windshield grommets (9) when installing windshield.

SPLIT WINDSHIELD Split Windshield Removal Tool List

Qty.

If the bottom of the split windshield is attached to the upper OPS frame, perform the following procedure to remove the split windshield.

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

% '

%

:ILMGPI WLS[R JSV VIJIVIRGI SRP]

&

*VSRX SJ :ILMGPI

&

Fig. 5 Split Windshield

'

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

FULL WINDSHIELD Full Windshield Removal Do not over tighten or compress the windshield grommets (16) when installing windshield.

%

*VSRX SJ :ILMGPI :ILMGPI WLS[R JSV VIJIVIRGI SRP]

%

Fig. 6 Full Windshield

WEATHER PROTECTION 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.

Notes:

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

ROPS UPPER ROPS Headrest Removal and Installation Tool List

9TTIV 6347

Qty.

*VSRX SJ :ILMGPI

Fig. 2 Grab Handle Removal

Item

Upper ROPS Frame Removal and Installation

Torque Specification

Tool List

Qty.

*VSRX SJ :ILMGPI

The following steps involve lifting heavy and awkward objects. Two people are recommended. Use a personal back support brace and proper lifting technique to prevent personal injury.

Fig. 1 Headrest Removal

Grab Handle Removal and Installation Tool List

Qty.

Item

Torque Specification

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

*VSRX SJ :ILMGPI

0S[IV 347

Fig. 3 Upper ROPS Weldment Removal

LOWER ROPS Lower ROPS Weldment Removal and Installation Tool List

Qty.

Item

Torque Specification

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

*VSRX SJ :ILMGPI

4EVX SJ

*VEQI

*VSRX SJ :ILMGPI

4EVX SJ *VEQI

Fig. 5 Front Seat Belt Removal

Front Seat Belt Buckle Latch Replacement Fig. 4 Lower ROPS Weldment Removal

Tool List

Qty.

Front Seat Belt Removal and Installation Tool List

Qty.

Item

Item

Torque Specification

Torque Specification

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

4EVX SJ 0S[IV 6347

Fig. 6 Front Seat Belt Buckle Latch Removal

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

Notes:

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

Notes:

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

HANDHELD DIAGNOSTICS HOW TO USE THE HANDHELD PROGRAMMER The handheld programmer will not function when the Run-Tow switch is in the Tow position.

The handheld programmer will not function when the battery charger is connected to the vehicle.

(MWTPE] 7GVIIR

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

Primary Connection: 4-Pin Tyco

2EZMKEXMSR /I] &SSOQEVO /I]

4S[IV 'SVH

Fig. 2 Primary Connection

Alternate Connection: 4-Pin Molex Fig. 1 Curtis Handheld Programmer

Fig. 3 Alternate Connection

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

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

Navigation

Main Menu Definitions

94 6-+,8

0)*8 (3;2

DIAGNOSTICS Changing Data Value

Bookmark

)\EQTPI &EXXIV] 9RHIVZSPXEKI GSHI -R XLI *EYPX QIRY SJ XLI TVSKVEQQIV XLI [SVHW 9RHIVZSPXEKI 'YXFEGO [MPP FI HMWTPE]IH XLI VIEP XMQI FEXXIV] ZSPXEKI MW HMWTPE]IH MR XLI 1SRMXSV QIRY r/I]W[MXGL :SPXEKIr 8LI GSRXVSPPIVtW X[S 0)(W [MPP HMWTPE] XLMW VITIEXMRK TEXXIVR 6)(

JMVWX HMKMX

=)003;

6)(

=)003;

WIGSRH HMKMX

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

Summary of LED Display Formats

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

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

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

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

Controller over current

Current sensor Fault

Precharge failed

Controller sever under temp

Controller sever over temp

Severe under voltage

Severe over voltage

Controller over temp cutback

Under voltage cutback

Overvoltage cutback

+5V supply failure

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

Motor temperature hot cutback

Motor temperature sensor fault Coil1 driver open or short - also can be main open or short

Coil2 driver open or short

Coil3 driver open or short

Coil4 driver open or short

PD open or short

Encoder fault

Motor open

Main contactor welded

Main contactor did not close

Throttle wiper high

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

Throttle wiper low

Pot2 wiper high

Pot2 wiper low Pot low over current

EEPROM failure

HPD/Sequencing fault

Parameter change fault Charger interlock

VCL HPD fault

VCL run time error

External supply out of range

OS general

PDO timeout

Stall detected

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

Motor characterization fault

Motor type fault

VCL/OS mismatch

Encoder LOS (limited operating strategy)

Illegal model number

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

Notes:

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

Notes:

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

TROUBLESHOOTING ELECTRICAL SYSTEM Condition

Possible Cause

Basic Electrical Power System Troubleshooting

Basic Electrical Troubleshooting for Accessories

Correction

TROUBLESHOOTING 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

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

Notes:

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

Notes:

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

GENERAL SPECIFICATIONS

13()0 8)66%-2 : 8=4) )0)'86-' : 43;)6)( 869'/ 13()0 =)%6 4EVX 2S

463(9'8 74)'-*-'%8-32 '32*-+96%8-32 ,-+,0-+,87 7SPMH 7XEXI GSRXMRYSYWP] ZEVMEFPI %' WTIIH GSRXVSPPIV 7IEX[VET QSYRXIH HMVIGXMSR WIPIGXSV W[MXGL *SV[EVH 2IYXVEP 6IZIVWI %RXM VSPP FEGO [EPOE[E] FVEOMRK ERH EPEVQ %RXM WXEPP QSXSV TVSXIGXMSR 6IKIRIVEXMZI t4IHEP (S[Rt ERH SV s4IHEP 9Tt FVEOMRK &EXXIV] 'LEVKIV 1SXSV (VMZI 8VEMR )PIGXVMGEP 7]WXIQ 8VERWE\PI &VEOIW 'EVKS &IH

*YPP XSVUYI VIHYGIH WTIIH VIZIVWI -RHYGXMZI XLVSXXPI WIRWSV (MEKRSWXMG MRHMGEXSV *EGXSV] TVSKVEQQEFPI XS ETTPMGEXMSR

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

463(9'8 3:)6:-); (MQIRWMSRW 3ZIVEPP 0IRKXL 3ZIVEPP ;MHXL 3 3ZIVEPP ,IMKLX 2S 'ERST] PP , M LX 2 '

3ZIVEPP ,IMKLX ;MXL 'ERST] ;LIIP &EWI *VSRX ;LIIP 8VEGO 6IEV ;LIIP 8VEGO +VSYRH 'PIEVERGI EX (MJJIVIRXMEP 'EVKS &S\ ;MHXL MRWMHI 'EVKS &S\ 0IRKXL MRWMHI 'EVKS &S\ (ITXL MRWMHI 'EVKS &S\ 'ETEGMX] 'EVKS &S\ QEXIVMEP :ILMGPI 4S[IV 4S[IV 7SYVGI 1SXSV 8]TI ,SVWITS[IV O; )PIGXVMGEP 7]WXIQ &EXXIVMIW 5X] 8]TI /I] SV 4IHEP 7XEVX &EXXIV] 'LEVKIV 7TIIH 'SRXVSPPIV (VMZI 8VEMR 8VERWE\PI +IEV 7IPIGXMSR 6IEV %\PI 6EXMS

MR GQ MR GQ MR GQ 8ST SJ WXIIVMRK [LIIP M

8 J X M L P MR GQ MR GQ MR GQ MR GQ MR GQ MR GQ MR GQ MR GQ GY JX Q 6SXS QSPHIH TSP]IXL]PIRI

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v TS[HIV GSEX -RNIGXMSR 1SPHIH 843 *VSRX &SH] *MRMWL 7XERHEVH 'SPSV ,YRXIV +VIIR 2SMWI :MFVEXMSR 7SYRH TVIWWYVI GSRXMRYIH % [IMKLXIH HF % 2SMWI

:SPXW (' %' -RHYGXMSR LT O; 4IEO :SPX 2MRI :SPX (IIT ']GPI 4IHEP 7XEVX ;EXX :(' %QT %' 1SXSV 7LEJX (MVIGX (VMZI (MJJIVIRXMEP [MXL LIPMGEP KIEVW :MFVEXMSR ;&: ,MKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW PIWW XLER Q W 7IEX[VET 1SYRXIH *SV[EVH 2IYXVEP 6IZIVWI :MFVEXMSR ,%: ,MKLIWX 617 ZEPYI SJ [IMKLXIH EGGIPIVEXMSR MW PIWW XLER Q W

8LI YRGIVXEMRX] SJ QIEWYVIQIRX MW Q W 1IEWYVIQIRX QIXLSHW [IVI ETTPMIH TIV XLI -73 ERH -73 7SQI MXIQW WLS[R QE] FI STXMSREP IUYMTQIRX WXERHEVHW YRHIV GSRHMXMSRW SJ X]TMGEP ZILMGPI WYVJEGIW 7TIGMJMGEXMSRW EVI WYFNIGX XS GLERKI [MXLSYX RSXMGI *MIPH MRWXEPPIH EGGIWWSVMIW QE] VIUYMVI MRWXEPPEXMSR GLEVKIW

Fig. 1 General Specifications

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

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

7XH 3TX*PH < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < < <

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

7XH 3TX *PH < <

< < < < < < < < < < < < < < < < < < < < < < < < <

:),-'0) '%& 7XIIP 'EF 8ER 7XIIP 'EF ;LMXI *YWI 4ERIP [ W[MXGLIW 'EF 6IUYMVIH &IEGSR %QFIV 'EF 6IUYMVIH (IJVSWXIV *ER 'EF 6IUYMVIH (SQI 0MKLX 'EF 6IUYMVIH (SSVW 7XIIP 8ER 'EF 6IUYMVIH (SSVW 7XIIP ;LMXI 'EF 6IUYMVIH (SSVW :MR]P 8ER 'EF 6IUYMVIH 6IEV :MI[ 1MVVSV 'EF 6IUYMVIH ;MRHWLMIPH ;MTIV 'EF 6IUYMVIH

< 7TIGMJMGEXMSRW EVI WYFNIGX XS GLERKI [MXLSYX RSXMGI *MIPH MRWXEPPIH EGGIWWSVMIW QE] VIUYMVI MRWXEPPEXMSR GLEVKIW

< < < < < < < < < < <

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

VEHICLE DIMENSIONS

MR

GQ

MR

GQ

*VSRX MR GQ

6IEV MR GQ

MR GQ MR GQ

MR

GQ

MR GQ

Fig. 2 Vehicle Dimensions

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

INCLINE AND TURNING CLEARANCE

6)'311)2()( 1%< 7-() 8-08 SV S 1%<

6)'311)2()( 1%< 6%14 +6%() SV S 1%<

8962-2+ '0)%6%2') (-% %TTVS\ JX Q

Fig. 3 Incline Specifications and Turning Clearance Diameter

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

Notes:

GENERAL SPECIFICATIONS 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

CL

R

REMARKS

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

CL

CL

CL

CL

C/A

C/A

C/A

C/A

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

CL

CL

CL

CL

C

C

C

C

C

C

C

C

C

C

C

C

C C

R C

C

C

C

C/A

C/A

C/A

C

C

C 20,000 AMPHrs

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

Notes:

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

APPENDIX A DELTA-Q USER’S GUIDE

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

7%:) 8,)7) -14368%28 7%*)8= -27869'8-327 8LMW QERYEP GSRXEMRW MQTSVXERX WEJIX] ERH STIVEXMRK MRWXVYGXMSRW i VIEH FIJSVI YWMRK GLEVKIV

;EVRMRK 9WI GLEVKIV SRP] [MXL ER EPKSVMXLQ WIPIGXIH XLEX MW ETTVSTVMEXI XS XLI WTIGMJMG FEXXIV] X]TI 3XLIV YWEKI QE] GEYWI TIVWSREP MRNYV] ERH HEQEKI 0IEH EGMH FEXXIVMIW QE] KIRIVEXI I\TPSWMZI L]HVSKIR KEW HYVMRK RSVQEP STIVEXMSR /IIT WTEVOW JPEQIW ERH WQSOMRK QEXIVMEPW E[E] JVSQ FEXXIVMIW 4VSZMHI EHIUYEXI ZIRXMPEXMSR HYVMRK GLEVKMRK 2IZIV GLEVKI E JVS^IR FEXXIV] 7XYH] EPP FEXXIV] QERYJEGXYVIVWt WTIGMJMG TVIGEYXMSRW MI QE\MQYQ GLEVKI VEXIW ERH MJ GIPP GETW WLSYPH FI VIQSZIH [LMPI GLEVKMRK

-2*361%8-327 -14368%28)7 () 7­'96-8­ 'I QERYIP GSRXMIRX HIW MRWXVYGXMSRW MQTSVXERXIW GSRGIVRERX PE WÍGYVMXÍ IX PI JSRGXMSRRIQIRX

%XXIRXMSR 9XMPMWIV PI GLEVKIYV WIYPIQIRX EZIG YR EPKSVMXLQI ETTVSTVMÍ EY X]TI WTÍGMJMUYI HI FEXXIVMI ( EYXVIW X]TIW HI FEXXIVMIW TSYVVEMIRX ÍGPEXIV IX GEYWIV HIW FPIWWYVIW SY HSQQEKIW 0IW FEXXIVMIW TIYZIRX TVSHYMVI HIW KE^ I\TPSWMJW IR WIVZMGI RSVQEP 2I NEQEMW JYQIV TVÌW HI PE FEXXIVMI IX ÍZMXIV XSYXI ÍXMRGIPPI SY JPEQQI RYI Ä TVS\MQMXÍ HIW FEXXIVMIW *SYVRMWWI^ YRI ZIRXMPEXMSR EHÍUYEXI HY GLEVKIQIRX 2I NEQEMW GLEVKIV YRI FEXXIVMI KIPÍI 4VIRHVI GSRREMWWERGI HIW QIWYVIW HI TVÍGEYXMSR WTÍGMJMÍIW TEV PI JEFVMGERX HI PE FEXXIVMI T I\ ZÍVMJMIV W MP JEYX IRPIZIV PIW FSYGLSRW HIW GIPPYPIW PSVW HY GLEVKIQIRX IX PIW XEY\ HI GLEVKIQIRX

(ERKIV 6MWO SJ IPIGXVMG WLSGO 'SRRIGX GLEVKIV TS[IV GSVH XS ER SYXPIX XLEX LEW FIIR TVSTIVP] MRWXEPPIH ERH KVSYRHIH MR EGGSVHERGI [MXL EPP PSGEP GSHIW ERH SVHMRERGIW % KVSYRHIH SYXPIX MW VIUYMVIH XS VIHYGI VMWO SJ IPIGXVMG WLSGO i HS RSX YWI KVSYRH EHETXIVW SV QSHMJ] TPYK (S RSX XSYGL YRMRWYPEXIH TSVXMSR SJ SYXTYX GSRRIGXSV SV YRMRWYPEXIH FEXXIV] XIVQMREPW (MWGSRRIGX XLI %' WYTTP] FIJSVI QEOMRK SV FVIEOMRK XLI GSRRIGXMSRW XS XLI FEXXIV] (S RSX STIR SV HMWEWWIQFPI GLEVKIV (S RSX STIVEXI XLMW GLEVKIV MJ XLI %' WYTTP] GSVH MW HEQEKIH SV MJ XLI GLEVKIV LEW VIGIMZIH E WLEVT FPS[ FIIR HVSTTIH SV SXLIV[MWI HEQEKIH MR ER] [E] i VIJIV EPP VITEMV [SVO XS XLI QERYJEGXYVIV SV UYEPMJMIH TIVWSRRIP 8LMW ETTPMERGI MW RSX MRXIRHIH JSV YWI F] TIVWSRW MRGPYHMRK GLMPHVIR [MXL VIHYGIH TL]WMGEP WIRWSV] SV QIRXEP GETEFMPMXMIW SV PEGO SJ I\TIVMIRGI ERH ORS[PIHKI YRPIWW XLI] LEZI FIIR KMZIR WYTIVZMWMSR SV MRWXVYGXMSR GSRGIVRMRK YWI SJ XLI ETTPMERGI F] E TIVWSR VIWTSRWMFPI JSV XLIMV WEJIX] 'LMPHVIR WLSYPH FI WYTIVZMWIH XS IRWYVI XLEX XLI] HS RSX TPE] [MXL XLI ETTPMERGI

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

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

Notes:

Read the following warnings before operating vehicle:

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 park 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 service 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 park 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 desired 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.

Use care not to 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.

E-Z-GO Division of Textron Inc.