EZGO TEXTRON ELECTRIC POWERED CARGO AND PERSONNEL CARRIERS REPAIR AND SERVICE MANUAL

ELECTRIC POWERED CARGO AND PERSONNEL CARRIERS TECHNICIAN'S REPAIR AND SERVICE MANUAL

MODEL YEAR: 1995 - 1998

MANUAL: 28184-G01

ISSUED: 01/01/95

REVISED: 08/10/95

SAFETY Read and understand all labels located on the vehicle. For questions on any of the information, contact an E-Z-GO rep­ resentative for clarification.

Always replace any damaged or missing labels.

On steep hills it is possible for the vehicle to coast at greater than normal speeds encountered on a flat surface. To pre­ vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. (See vehicle specification.) Limit speed by applying the service brake.

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

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

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

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NOTES, CAUTIONS AND WARNINGS Throughout this manual, !Rll@'ii�, CAUTION and WARN­ ING will be used. Please observe these !Rll@'ii�@. CAU­ TIONS and WARNINGS; be aware that servicing a vehicle requires mechanical skill and a regard for condi­ tions that could be hazardous.

A note indicates a condition that should be observed.

CAU.TION A CAUTION INDICAT ES A CONDITION THAT MAY RESULT IN DAMAGE T O THE VEHICLE .

A

WARNING

A

A WARNING INDICATES A CONDITION THAT MAY BE HAZARDOUS TO THE MECHANIC OR OTHER PERSONNEL AND MAY RESULT IN DAMAGE TO THE VEHICLE.

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

A WARNING A

WHEN VEHICLE IS TO BE LEFT UNATTENDED, MOVE DIRECTION SELECTOR TO FORWARD (F) POSITION, TURN KEY TO 'OFF' POSITION, REMOVE KEY AND ENGAGE PARKING BRAKE. DRIVE VEHICLE ONLY AS FAST AS TERRAIN AND SAFETY CONSIDERATIONS ALLOW. CONSIDER THE TERRAIN AND EXISTING TRAFFIC CONDITIONS. ENVIRONMENTAL CONSIDER FACTORS WHICH EFFECT THE TERRAIN AND YOUR ABILITY TO CONTROL THE VEHICLE. USE EXTRA CARE AND REDUCED SPEED WHEN DRIVING ON POOR SURFACES, SUCH AS LOOSE DIRT, WET GRASS, GRAVEL, ETC.

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

TECHNICIAN'S REPAIR AND SERVICE MANUAL ELECTRIC POWERED PERSONNEL AND CARGO CARRIERS

PERSONNEL CARRIERS PCX-952 PCX-954 PCX-955 PCX-956 PCX-957

BEVERAGE CARRIER BCX-960

CARGO/PERSONNEL CARRIERS Xl-875 Xl-875P Xl-881

E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEOR GIA 30903-0388

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Repair and Service Manual

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"L-1 _______

L_IM_ I_TE_D_W_�R_R_A_N_ T_Y_____,____,____,_ _

__,.,..._.1

TO OBTAIN A COPY OF THE LIMITED WARRANTY THAT IS AP P LICABLE TO THE VEHICLE, CALL OR WRITE A LOCAL DISTRIBUTOR, E-Z-GO BRANCH OR E-Z-GO WARRANTY DEPARTMENT WITH VEHICLE SERIAL NUMBER AND MANUFACTURER CODE THE USE OF NON E-Z-GO PARTS MAY VOID THE WARRANTY OVERFILLING BATTERIES MAY VOID THE WARRANTY

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Repair and Service Manual

·1....---------TA_B_L_E_O_F_c_o_N_ T_ E-,,-N _T _s__-_______, PAGE

TITLE

Safety ........................................................................................................................... Inside Covers Limited Warranty ............................................................................................................................... ii Table of Contents ............................................................................................................................. iii Introduction....................................................................................................................................... iv

SECTION

TITLE

General.............................................................................................................................................A Safety ............................................................................................................................................... 8 Body .................................................................................................................................................C Wheels and Tires.............................................................................................................................. D Brakes, Mechanical .......................................................................................................................... E Brakes, Hydraulic ............................................................................................................................. F Electronic Speed Control................................................................................................................. G Front Suspension and Steering ........................................................................................................ H Motor ................................................................................................................................................ J Batteries and Charging..................................................................................................................... K Horn andAccessory Wiring .............................................................................................................. N Rear Suspension.............................................................................................................................. P RearAxle .......................................................................................................................................... R Paint ....................... :.··················································································:·······················..············· S Troubleshooting ................................................................................................................................. T Lightning Protection and Grounding ................................................................................................. U General Specifications ..................................................................................................................... V

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INTRODUCTION The Technician's Repair and Service Manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by E-Z-GO. Adherence to these procedures and trouble shooting tips will ensure the best possi­ ble service from the product.

Certain illustrations and text may describe options or features some vehicles are not equipped with; disregard these areas.

Throughout this manual, [l(!]@'[F�®, CAUTIONS and WARNINGS will be used. For the protection of all personnel and the vehicle, please observe the following:

� A note indicates a condition that should be observed. ,;j

CAUTION

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

_A WARNING _A A WARNING INDICATES A CONDIT ION THAT MAY BE HA ZARDOUS TO THE MECHANIC OR OTHER PERSONNEL AND MAY RESULT IN DAMAGE TO , THE VEHICLE.

To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Proper service, repair and maintenance are important to the safety of the service technician and the safe, reliable oper­ ation of all vehicles. If part replacement is necessary, use a specified replacement component.

Note: The use of non E-Z-GO parts may void the warranty. Do not use a replacement part of lesser quality.

The procedures recommended·and described in this manual are effective methods of performing service, repair and maintenance. Some of these procedures require the use of tools specially designed for the purpose.

Accordingly, if a service procedure or tool not recommended by the vehicle manufacturer is to be used, it must first be determined that neither personal safety, nor the safe operation of the vehicle will be jeopardized by use of the service procedure or tool selected.

It is important to note that this manual contains various [1(!]@1F�®, CAUTIONS and WARNINGS that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe.

To facilitate ordering parts, a Service Parts Manual (35112-G01) is available from a local Distributor, an E-Z-GO Branch or the E-Z-GO Service Parts Department.

Only QUALIFIE D personnel should be permitted to service E-Z-GO vehicles.

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Repair and Service Manual

GENERAL

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

PAGE NO. A-1

A-1 CONTROLS Key Switch ............................................................................................................................. A-1 Direction Selector .................................................................................................................. A-1 Accelerator Pedal .................................................................................................................. A-1 Service Brake ........................................................................................................................ A-2 Parking Brake ........................................................................................................................ A-2 BEFORE ENTERING VEHICLE

A-2

BEFORE STARTING

A-2

STARTING THE ELECTRIC VEHICLE

A-3

COASTING

A-3

TOWING

A-3

SERVICING THE ELECTRIC VEHICLE

A-3

A-3 SEATS Preparation of Seats for Service ..................................................•........................................ A-3 ROUTINE MAINTENANCE

A-4

REAR AXLE A-4 Checking the Lubricant Level ................................................................................................A-4 A-4 GENERAL PREVENTATIVE MAINTENANCE Daily Check List..................................................................................................................... A-4 Owner/Operator ..................................................................................................................... A- 5 Mechanic ...............................................................................................................................A- 5 TIRES

A -5

CARE AND CLEANING OF THE VEHICLE

A- 5

WINDSHIELD (IF EQUIPPED) A- 6 Cleaning ................................................................................................................................ A- 6 Trailering ................................................................................................................................ A -6 TORQUE SPECIFICATIONS FOR UNSPECIFIED HARDWARE

A-7

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

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Serial No. Plate Location ................................................................................................... A-1 Controls ............................................................................................................................. A-1 Accelerator and Brake Controls ......................................................................................... A-2 Rear Axle Lubricant Check/Fill .......................................................................................... A -4 Torque Specifications ........................................................................................................ A- 7 Bolt Grades ........................................................................................................................ A- 7 Lubrication Points .............................................................................................................. A- 8 Periodic Service Schedule .................................................................................................A- 9 Periodic Service Schedule (Continued) ........................................................................... A-10

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GENERAL Notes: ______________________________

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Repair and Service Manual

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GENERAL

Section

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

The model, serial and manufacturing numbers are stamped on a plate on the driver's side of the vehicle.

Always provide these numbers to the dealer when order­ ing parts for the vehicle.

The key switch has an additional position to select the lights. In the 'OFF' or 'ON' position, the lights will not operate.

For added security when the vehicle is left unattended, the key may be removed from the 'OFF' position prevent­ ing inadvertent operation of the vehicle.

0

0

LKEYSWITCH

\Ji

DIRECTION

SELECTOR

Fig. A-1 Serial No. Plate Location

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Fig. A-2 Controls

CONTROLS

Direction Selector

(See Fig. A-2 "Controls" on page A-1) (See Fig. A-3 "Accelerator and Brake Controls" on page A-2) _

:he controls of the vehicle·consist of a key switch, direc­ tion selector lever, accelerator pedal, service brake and parking brake.

Key Switch

(See Fig. A-2 "Controls" on page A-1)

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

(See Fig. A-2 "Controls" on page A-1)

Located on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key.

Located on the seat support panel, this lever permits the selection of either forward or reverse. It should be left in neutral when the vehicle is unattended.

Accelerator Pedal (See Fig. A-3 "Accelerator and Brake Controls" on page A-2)

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

Depressing the accelerator pedal starts the motor. Each time the pedal is released, the motor will stop. To stop the vehicle, press the service brake.

Repair and Service Manual

Page A-1

GENERAL Service Brake

CAUTION

(See Fig. A-3 "Accelerator and Brake Controls" on page A-2)

Depressing the foot operated brake pedal activates the wheel brakes.

Parking Brake (See Fig. A-3 "Accelerator and Brake Controls" on page A-2)

The hand operated parking brake is located between the two front seats. The brake is engaged when the handle is vertical and is disengaged when the handle is parallel to the seat bottom.

IMPROPER USE OR OPERATION OF THE VEHICLE OR THE LACK OF PROPER MAINTENANCE MAY RESULT IN DECREASED PERFORMANCE OR DAMAGE TO THE VEHICLE. BEFORE INITIAL USE, REMOVE CLEAR PLASTIC SEAT COVERINGS. (SEE SEATS, PG. A-4)

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

A

SERVICE BRAKE

PARKING BRAKE

ACCELERATOR PEDAL

I

WHEN VEHICLE IS TO BE LEFT UNATTENDED, TURN KEY TO THE 'OFF' POSITION, REMOVE THE KEY AND ENGAGE THE PARKING BRAKE, PLACE THE DIRECTION SELECTOR IN THE NEUTRAL POSITION.

DO NOT ALLOW VEHICLE TO COAST.

D

Fig. A-3 Accelerator and t:Jrake Controls

BEFORE ENTERING VEHICLE 1. Check for correct tire inflation.

2. Inspect for fluid leaks.

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

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

Page A-2

A

DRIVE THE VEHICLE ONLY AS FAST AS TERRAIN AND ALLOW. SAFETY CONSIDERATIONS CONSIDER THE TERRAIN AND EXISTING TRAFFIC CONDITIONS. CONSIDER THE ENVIRONMENTAL FACTORS WHICH EFFECT THE TERRAIN AND YOUR ABILITY TO CONTROL THE VEHICLE.

� I

WARNING

AVOID DRIVING FAST DOWN HILL. A SUDDEN STOP OR CHANGE OF DIRECTION MAY RESULT IN LOSS OF CONTROL. USE BRAKE TO CONTROL SPEED WHEN TRAVELING 'DOWN AN INCLINE. KEEP FEET, LEGS, HANDS AND ARMS INSIDE THE VEHICLE AT ALL TIMES. USE EXTRA CARE AND REDUCED SPEED WHEN DRIVING ON POOR SURFACES, SUCH AS LOOSE DIRT, WET GRASS, GRAVEL, ETC. ALL TRAVEL SHOULD BE DIRECTLY UP OR DOWN HILLS. USE EXTRA CARE WHEN DRIVING THE VEHICLE ACROSS ANY INCLINE. CHECK AREA BEHIND THE VEHICLE BEFORE OPERATING IN REVERSE.

Repair and Service Manual

GENERAL

A

WARNING

A

STAY IN DESIGNATED AREAS AND AVOID STEEP SLOPES. USE THE PARKING BRAKE WHENEVER THE VEHICLE IS PARKED.

T he motor stops when the accelerator pedal is released.

To stop the vehicle more quickly, depress the service brake pedal.

W hen leaving the vehicle unattended, engage the park­ ing brake by pulling the parking brake lever to the vertical position. P lace the direction selector in the neutral posi­ tion, turn the key switch off and remove key.

AVOID EXTREMELY ROUGH TERRAIN. MAKE SURE THE DIRECTION SELECTOR IS IN CORRECT POSITION BEFORE ATTEMPTING TO START VEHICLE. SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. ALWAYS BRING THE VEHICLE TO A COMPLETE STOP BEFORE SHIFTING DIRECTION SELECTOR. ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION. THE STANDARD CARGO CARRIERS (WITH FRONT SEAT ONLY) ARE LIMITED TO TWO OCCUPANTS, WHILE STANDARD PERSONEL CARRIERS ARE LIMITED TO THE NUMBER OF OCCUPANTS SPECIFIED ON THE SERIAL NUMBER PLATE LOCATED ON THE SEAT SUPPORT PANEL. BEFORE ATTEMPTING ANY TYPE OF SERVICING OPERATIONS, READ AND UNDERSTAND ALL NOTES, CAUTIONS AND WARNINGS IN THIS MANUAL. WEAR EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE THE EYES TO POTENTIAL INJURY. IN PARTICULAR, USE CARE WHEN WORKING AROUND THE BATTERIES, WHEN USING SOLVENTS OR COMPRESSED AIR.

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

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

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

COASTING O n steep hills, it is possible for the vehicle to coast at faster than normal speeds encountered on a flat surface.

To prevent loss of vehicle control, speeds should be lim­ ited to no more than the maximum speed on level ground (see vehicle specification). L imit speed by applying ser­ vice brake. S evere damage to the drive train components due to excessive speed may result from driving the vehi­ cle above specified speed. D amage caused by excessive speed may cause a loss of control, is costly, is consid­ ered abuse and will not be covered under warranty.

TOWING

CAUTION MAXIMUM TOWING SPEED IS 12 M.P .H. TOWING VEHICLES ABOVE THE RECOMMENDED SPEED MAY RESULT IN DAMAGE TO THE VEHICLE AND OTHER PROPERTY.

SERVICING THE ELECTRIC VEHICLE

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

Repair and Service Manual

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GENERAL

r

Checking the Lubricant Level

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

(See Fig. A-4 "Rear Axle Lubricant Check/Fill" on page A-4)

Clean the area around the check/fill plug. The check/fill plug should be removed using a 13mm wrench; the cor­ rect lubricant level is just below the bottom of the threaded hole. If lubricant is to be added, remove the check/fill plug and add lubricant using a funnel. Add lubri­ cant slowly until lubricant starts to seep from the plug.

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

INITIAL SERVICE CHART

.•i

i i

ITEM

SERVICE OPERATION

Batteries

Check charge condition

Seats

Remove protective plastic covering

Brakes

Check operation and adjust if necessary

Tires

Check pressure

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..

,, ..,

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

CHECK/FILL PLUG

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

Fig. A-4 Rear Axle Lubricant Check/Fill

GENERAL PREVENTATIVE MAINTENANCE WEEKLY, QUARTERLY, SEMI-ANNUAL AND ANNUAL service requirements are detaUed in the 'Periodic Service Schedule'.

Some maintenance items (service requirements detailed in the Periodic Service Schedule at the end of this section) must be serviced more frequently on vehicles used under severe driving conditions.

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

REAR AXLE (See Fig. A-4 "Rear Axle Lubricant Check/Fill" on page A-4)

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

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

Page A-4

I i

Some maintenance ;ts��;; serviced more frequently on vehicles used under severe driving conditions.

Repair and Service Manual

GENERAL 1. Perform the DAILY BRAKING PERFORMANCE TEST. (See Sections 'E' and 'F' for test procedure.)

To determine the adequacy of the vehicles brake system, the following test should be performed daily:

.A

WARNING

.A

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

•

Mechanical damage.

•

Torn seats.

3. CLEAN THE VEHICLE • Wipe seats.

•

Clean floormats.

•

Remove trash from dash tray.

•

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

•

Wash accumulated dirt from motor compartment and underbody.

Owner/Operator

TIRES

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

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

Mechanic The mechanic should perform a 'panic' stop on the sus­ pect vehicle(s) by applying maximum force and travel to the brake pedal while traveling at full speed. He should observe if either of the rear wheels fail to 'lock up'. If one wheel fails to lock, it is reasonable to expect that a prob­ lem exists with the service brake system and the SIX MONTH BRAKE MAINTENANCE as described in the Repair and Service Manual, must be performed in its entirety. If both wheels lock, the parking brake must be adjusted and the vehicle re-tested per the DAILY BRAK­ ING PERFORMANCE TEST. If the vehicle is to be used commercially we suggest that you also follow lists 2 and 3.

2. INSPECT THE FOLLOWING: • Check the tires for cuts, wear and proper air pres­ sure.

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

• Ensure that all switches are operating normally.

•

•

Listen for unusual noises, such as rattles due to loose hardware, scraping sounds such as brakes dragging, unusual motor noises and be sensitive to abnormal performance.

Damaged or missing equipment.

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

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

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

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

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

The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water is the best method of pre­ serving those painted surface.

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

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

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Page A-5

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

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

WINDSHIELD (IF EQUIPPED) Cleaning

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

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

Clean with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish.

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Repair and Service Manual

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GENERAL TORQUE SPECIFICATIONS FOR UNSPECIFIED HARDWARE

ALL (WET) TORQUE FIGURES ARE IN FT. LBS. (NM)

Unless otherwise noted in the text, tighten all hardware in accordance with this chart

BOLT SIZE

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

5/8"

3/4"

7/8"

1"

Grade2

4 (5)

8 (11)

15 (20)

24 (33)

35 (47)

55 (75)

75 (102)

130 (176)

125 (169)

190 (258)

Grade5

6 (8)

13 (18)

23 (31)

35 (47)

55 (75)

80 (108)

110 (149)

100 (271)

320 (434)

480 (651)

Fig. A-5 Torque Specifications In general two grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hexagonal head. Unmarked hardware is Grade2 .

ow Grade2

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

Grade 5

Fig. A-6 Bolt Grades

Repair and Service Manual

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GENERAL

FRONT OF VEHICLE

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STEERING BOX AND IDLER

2KING PINS

4 WHEEL BEARINGS "PACK"

5 BALL JOINTS

REAR AXLE CHECK AND FILL

Fig. A-7 Lubrication Points

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Repair and Service Manual

GENERAL SYSTEM

DAILY

WEEKLY

MONTH 20 HRS.

3 MONTH 50 HRS.

SEMI-ANNUAL ANNUAL 125 HRS. 250-300 HRS.

BRAKES Pedal ..................•.••••....•. • Check for smooth operation and correct free travel Service Brake ............, ...., • Check brake performance and adjust if required Parking Brake ................. • Check brake performance and adjust if required REVERSE WARNING DEVICE ........, ••..., ............... • Check operation when direction selector is in reverse TIRES ••.....�..., .............. ,...... • Examine for inflation, cuts and excessive wear WHEELS............................. • Check for bent rims, missing/loose lug nuts BATTERIE:S .................u..•.. • Recharge to full charge state after each day's use CHARGER/RECEPTACLE. • Inspect connector system at each charge BATTERIES;................................................................... • Inspect and clean as required • Check electrolyte level - correct if required ACCELERATOR ..; .......................................................... • Check for smooth movement CHARGER/RECEPTACLE..,.............................,,... , .•..... • Check and tighten wire connections as required. Keep receptacles free of dirt and foreign matter DIRECTION SELECTOR ASSEMBLY......•...••....•.....••.... + Check attachment, adjust as required - Lubricate linkage with light oil STEERING ASSEMBLY ................................;................. • Check for abnormal play, tightness of all hardware TIE RODS/LINKAGES,.................................................... • Check for excessive play, bent components or loose connections TIRES •.....•.••.•;••...,......... ,.......................,.;.. , .•••.........••.... • Check pressure, see specifications WIRING ....................,.••..,;....•.•..•,............................., ..••. • Check all wiring for loose connections and broken/missing insulation FRONTAXLE .................; ..... ,.....•.••...••...••..•..•�.................................•..

FRONT SPRINGS ....................................................,..........................

FRONT WHEEL ALIGNMENT.................................0 •••••••••••••••••••••••••• PARKING BRAKE...........,......, ............................,................................

• Check for damage to axle and loose or missing hardware • Check for loose hardware, cracks at attachment points • Check if tire wear is unusual, align per Service Manual • Check for bent/binding linkage rod and damage or wear + Lubricate, use light oil - DO NOT LUBRICATE CABLES CHARGER AND RECEPTACLE............,...........o................................ + Spray with P/N 27934-002 REAR SHOCK ABSORBERS .................................,. ....., ..................... • Check for oil leakage, loose mounting hardware BODY........,....; •••••......••..•••••.........••..•..... ; ...................................................................... + Clean body components and wax all painted surfaces DIRECTION SELECTOR ASSEMBLY.......................................,.................................. + Check for wear and smooth movement (lubricate shafts and ball joints if required) KING PINS;.................�... ,;�......................................................................... ,;................ • Check for excessive play and tightness of retaining nuts · · , · + Lubricate, use Shell Alvania® EP-2 SERVICE BRAKES .•....•..;., ................�............................. , ............................., ............. + Clean and adjust per Service Manual STEERING ASSEMBLY ............................................................................................... + Lubricate linkage, use Shell Alvania® EP-2 TIE RODS/ LINKAGES ...................................................................,.......................... ,. + Lubricate, use Shell Alvania® EP-2

• Check

+Clean, Adjust etc.

• Replace

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

Fig. A-8 Periodic Service Schedule

Repair and Service Ma,nual

PageA-9

GENERAL SYSTEM

DAILY

WEEKLY

MONTH 20HRS

3MONTH 50HRS

SEMI-ANNUAL ANNUAL 125HRS 250-300HRS

FRONT WHEEL BEARINGS ...••.. .'•••......•••••.••.••..•.•••••..•••.•:.•.,.................�..••...•.•...•••.•...•....•.•..•...•.••.....•... + Adjust, see Service Manual + Pack, use Shell Alvania® EP-2 • Check

+Clean, Adjust etc.

.& Replace

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

Fig. A-9 Periodic Service Schedule (Continued)

Page A-10

Repair and Service Manual

SAFETY

Section TABLE OF CONTENTS FOR SECTION 'B' SECTION TITLE GENERAL MAINTENANCE

PAGE NO. B-1

B-1 IMPORTANT SAFETY WARNING NOTES, CAUTIONS and WARNINGS ..................................................................................B - 1 B-1 BEFORE SERVICING THE VEHICLE Battery Removal .................................................................................................................... B - 2 Battery lnstallation ................................................................................................................. B - 3

LIFTING THE VEHICLE

B-3

LIST OF ILLUSTRATIONS Fig. B-1 Battery Connections ..........................................................................................................8 - 3 Fig. B-2 Lifting the Vehicle .............................................................................................................. 8 - 4

Repair and Service Manual

Page B-i

SAFETY Notes: _______________________________

Page B-ii

Repair and Service Manual

SAFETY

Section

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

Always read and observe all of the IR!l@'ii'l§@, CAUTIONS and WARNINGS that are detailed in this manual.

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

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

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

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

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

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

NOTES, CAUTIONS and WARNINGS

CAUTION

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

A_ WARNING A_

A WARNING INDICATES A CONDITION THAT MAY BE HAZARDOUS TO THE MECHANIC OR OTHER PERSONS AND MAY RESULT IN DAMAGE TO THE VEHICLE.

BEFORE SERVICING THE VEHICLE

[R!]@vrn

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

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

A_ WARNING A_ SET PARKING BRAKE BEFORE PERFORMING ANY WORK ON THE VEHICLE. HYDROGEN GAS IS FORMED WHEN CHARGING BATTERIES. DO NOT CHARGE BATTERIES WITHOUT ADEQUATE 4% VENTILLATION. ARE HYDROGEN OF CONCENTRATIONS EXPLOSIVE 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.

Throughout this manual, the following IR!l@'ii'l§@, CAU· TIONS and WARNINGS are used. For the protection of all personnel and the vehicle, be aware of and observe the following:

A note indicates a condition that should be observed.

EmGDii=f:ti;t•J:I

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

Repair and Service Ma.nual

Page B-1

SAFETY

A

WARNING

A

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

A

WARNING

A

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

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

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

Battery Removal Tool List

Qty. Required

Wrench, open end, insulated, 9/16"............................. 1 Wrench, open end, insulated, 1/2"............................... 1 Socket, 1/2", 3/8" drive ................................................ 1 Extension, 12", 3/8" drive ............................................ 1 Ratchet, 3/8" drive ....................................................... 1 Carrier, battery ............................................................. 1 Page B-2

Repair and Service Manual

EaliDii=t:ii;{•l:I

SAFETY Using an insulated wrench, remove all wires from the vehicle batteries. Remove the battery hold downs by removing the hardware and lifting the retainer from the batteries.

Remove the batteries using a commercial battery carrier.

LIFTING THE VEHICLE (See Fig. B-2 "Lifting the Vehicle" on page B-4)

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

CAUTION

Battery Installation (See Fig. B-1 "Battery Connections" on page B-3)

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

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

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

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

•

I

FRONT OF VEHICLE

CR-

BL-

I

I

CL+ BLU

BL+

WHT

I

TERMINAL BLOCK

Fig. B-1 Battery Con nections

WHEN LIFTING THE VEHICLE, POSITION JACKS AND JACK STANDS ONLY ON THE AREAS INDICATED. Qty. Required Tool List Jack, hydraulic, trolley ................................................. 1 Jack stands ................................................................. 4 Chocks ........................................................................ 4

A

WARNING

A

WHEN SERVICING THE POWERTRAIN WITH THE MOTOR RUNNING, BOTH REAR WHEELS MUST BE RAISED. BE SURE THE VEHICLE IS ON A FIRM AND LEVEL SURFACE. NEVER GET UNDER A VEHICLE WHILE IT IS SUPPORTED BY A JACK. USE SAFETY STANDS AND TEST THE STABILITY OF THE VEHICLE ON THE STANDS. ALWAYS PLACE CHOCKS IN FRONT AND BEHIND THE WHEELS THAT ARE NOT TO BE RAISED. USE EXTREME CARE SINCE THE VEHICLE IS EXTREMELY UNSTABLE DURING THE LIFTING PROCESS. Position a jack directly in front of the rear spring, on the rectangular portion of the vehicles frame. Carefully raise the vehicle with a jack and place a safety stand at the end of the frame rail tube as indicated. (See Fig. B-2) Slowly lower the jack and test the stability of the car.

Repeat this same procedure to place a safety stand in the corresponding position on the opposite side of the vehicle.

To jack the front of the vehicle, position the jack directly in the center of the front axle, as indicated. (See Fig. B-2) Carefully raise the front of the vehicle with the jack and place a safety stand on each of the outer most areas of the front axle tube. Slowly lower the jack and check that the vehicle is securely supported by the four safety stands before proceeding.

Lower the vehicle by reversing the lifting sequence.

Repair and Service Manual

Page B-3

SAFETY

FRONT OF VEHICLE

/l A

Fig. B-2 Lifting the Vehicle

Page B-4

Repair and Service Manual

BODY

Section TABLE OF CONTENTS FOR SECTION 'C' SECTION TITLE

PAGE NO.

C- 1 METAL BODY VEHICLES General................................................................................................................................. C - 1 Front Cowl Removal ............................................................................................................. C - 1 Side Panel Removal ............................................................................................................. C - 1 Rear Panel Removal ............................................................................................................ C - 1 Seat Back Removal.............................................................................................................. C - 2 Lower Shield Removal ......................................................................................................... C - 2 BODY PANEL INSTALLATION

C- 2

FIBERGLASS BODY VEHICLES C- 2 General ................................................................................................................................. C - 2 Fiberglass Body Removal .................................................................................................... C - 3 Bumper Removal.................................................................................................................. C -3 Cowl Assembly Removal ...................................................................................................... C - 3 Four Cup Console ...................................................•..................•......................................... C - 4 Sun Top Removal (BCX-960 only) ..................................•.................................................... C - 4 BODY PANEL INSTALLATION

C-4

LIST OF ILLUSTRATIONS Fig. C-1 Remove Front Cowl.......................................................................................................... C - 1 Fig. C-2 Remove Side Panel.......................................................................................................... C - 1 Fig. C-3 Remove the Rear Panel ................................................................................................... C - 2 Fig. C-4 Remove Seat Back........................................................................................................... C - 2 Fig. C-5 Remove the Lower Shield ................................................................................................ C - 2 Fig. C-6 Drill Out Metal Rivet.......................................................................................................... C - 2 Fig. C- 7 Body Mount Components ................................................................................................. C - 3 Fig. C-8 Remove the Bumper......................................................................................................... C -3 Fig. C-9 Remove the Cowl Assembly............................................................................................. C -3 Fig. C-1O Remove the Four Cup Console ...................................................................................... C -4 Fig. C-11 Remove the Sun Top ..................................................................................................... C -4

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Repair and Service Manual

Page C-i

e

[

BODY

Notes: _______________________________

Page C-ii

Repair and Service Manual

-BO-DY--------------e l S-ec-t-i o· _n_' Side Panel Removal

(See Fig. C-2 "Remove Side Panel" on page C-1)

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

METAL BODY VEHICLES For further detailed information on the metal body vehi­ cles, refer to the Service Parts Manual available from the E-Z-GO Service Parts Department. For electric vehicles, order P/N 35112-G01.

[R!]@u[g

The side panels are secured with threaded studs welded to the panels. If the panels are to be repaired and reused, use caution during removal process not to break the welded studs from the panels. The use of a penetrating oil may be necessary to free the nut from the stud.

Remove the lock nuts (item 4) from the welded threaded studs and remove the side panels (item 5).

SIDE PANELS SECURED TO VEHICLE FRAME

General None of the metal body panels need to be removed to perform any servicing operations, however, all body pan­ els are removable should one be damaged and need repair or replacement.

Front Cowl Removal (See Fig. C-1 "Remove Front Cowl" on page C-1)

Remove the bolts (item 2) and lock nuts (item 3) securing the front cowl (item 1) to the floor pan and remove cowl.

Fig. C-2 Remove Side Panel

Rear Panel Removal (See Fig. C-3 "Remove the Rear Fender Panel" on page C-1)

[R!]@u[g

The rear panel is secured with threaded studs welded to the panel. If the panel is to be repaired and reused, use caution during removal process not to break the welded studs from the panel. The use of a penetrating oil may be necessary to free the nut from the stud. ·.

Fig. C-1 Remove Front Cowl

Remove the lock nuts (item 6) securing the rear panel (item 7) to the frame of the vehicle. Remove the bolts (item 8), and nuts (item 9) securing the panel to the splash guards (one place each side}. Remove the rear panel (item 7).

Repair and Service Ma.nual

Page C-1

I BODY FRONT FRAME

Fig. C-5 Remove the Lower Shield Fig. C-3 Remove the Rear Panel

Seat Back Removal

BODY PANEL INSTALLATION Installation of all body panels and assemblies are in the reverse order of disassembly.

(See Fig. C-4 "Remove Seat Back" on page C-2)

Remove the four bolts (item 10) and nuts (item 11) secur­ ing the seat back (item 12) to the frame. Remove the bolts (item 13) and lock nuts (item14) securing the side of the seat back to the frame and remove the seat back.

FIBERGLASS BODY VEHICLES For further detailed information on the metal body vehi­ cles, refer to the Service Parts Manual available from the E-Z-GO Service Parts Department. For electric vehicles, order P/N 35112-G01.

General (See Fig. C-6 "Drill Out Metal River on page C-2)

Most body components are held in place with conven­ tional removable hardware (nuts, bolts, washers and screws). Some components are mounted with metal riv­ ets that can be removed by drilling into the head with a drill bit that is slightly larger than the shank of the rivet.

Care must be exercised when drilling to prevent the drill from being forced through and damaging components located directly behind the rivet. The best way to prevent this from occurring is to use a sharp drill bit requiring very little pressure to cut successfully and to place a piece of protective sheet metal between the surface being drilled and components directly behind it.

POP RIVET

Fig. C-4 Remove Seat Back

Lower Shield Removal

;,:,,/

\;

DRILL OUT RIVET HEAD ONLY

I

(See Fig. C-5 "Remove the Lower Shieldn on page C-2)

Remove the screws (item 15) and remove the lower shield (item 16).

Page C-2

Repair and Service Manual

Fig. C-6 Drill Out Metal Rivet

Ei2HiDii:i:U;MII

BODY Fiberglass Body Removal (See Fig. C-7 "Body Components" on page C-3)

If the fiberglass body is damaged, it may be repaired with a fiberglass repair kit. Carefully follow manufacturer's instructions for repair procedure. Be sure to observe all manufacturer's cautions and warnings.

"

If the body needs to be removed from the vehicle for repair or replacement, remove the hardware securing the fiberglass body to the frame. Lift the body from vehicle frame. Note sequence of hardware removal for installa­ tion.

FRAME

(1/) FLOOR MAT� FIBERGLASS BODY

..-

5 REAR BUMPER REAR MOUNT FRAME

(0

4

/@_@l

/�

DECK SUPPORT 5

(1/)- FENDER BOLT

T

� = _,..;;;;.-,, -= (8

FIBERGLASS BODY

Fig. C-8 Remove the Bumper

FENDERWASHER FRAME

WASHER @-L°.C NUT � �--

Fig. C-7 Body Mount Components

Bumper Removal (See Fig. C-8 "Remove the Bumper" on page C-3)

Remove the carriage bolt (item 1 ), spacer (item 2), washer (item 3) and lock nut (item 4) securing the bumper (item 5) to the vehicle. Note there is no spacer used at the rear mounts of the rear bumper.

Cowl Assembly Removal (See Fig. C-9 "Remove the Cowl Assembly" on page C-3)

Remove the fiberglass cowl (item 1) by removing the bolts (item 2), washers (item 3) and lock nuts (item 4).

Eia13Dii:f:ti.!•l:I

Fig. C-9 Remove the Cowl Assembly

Repair and Service M.anual

Page C-3

BODY Four Cup Console (See Fig. C-10 "Remove the Four Cup Console" on page C-3)

FRONT DRIVER'S SIDE

The four cup console (item 1) can be removed by remov­ ing the screws (item 2) and nuts (item 3) from each side of the four cup console. Remove the console brackets (item 4) by removing the hardware (item 5) as shown.

FRONT STRUT

_,...,..---COWL

REAR DRIVER'S SIDE

DECK FRAME

Fig. C-11 Remove the Sun Top

Fig. C-10 Remove the Four Cup Console

Sun Top Removal (BCX-960 only)

BODY PANEL INSTALLATION Installation of all body panels and assemblies are in the reverse order of disassembly.

(See Fig. C-11 "Remove the Sun Top" on page C-3)

The fabric canopy may be removed by unhooking the bungee ropes and removing the drawstring fastening it to the canopy frame.

�@u�

Removing the sun top from the vehicle may require the assis­ tance of an addiitional person.

Remove the hardware securing the front strut to the cowl. Remove the hardware securing the rear strut to the deck frame at the rear of the vehicle.

�@u�

When installing the sun top, firmly tighten all hardware, but do not over tighten the hardware to the point of crushing the tubing.

Page C-4

Repair and Service Manual

EaliClii#:ti;t•l:I

_ _ _ _ _ _ _ _ _ _ - _ _ __________ _e_ct_i_on-1�>1 W H E E L S A N D T IR E S S TABLE OF CONTENTS FOR SECTION 'D' SECTION TITLE

PAGE NO.

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

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

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Repair and Service Manual

Page D-i

D

,,.. �

_______________ _ _ _ _ _ _ _ _ _ _ _ _ _ _, W H E E L S A N D T I RE S

Notes: ____________________________

Page D-ii

Repair and Service Manual

.---W_H_ E_E_L_S_A_N_D_T_I_R_E _S___________ _e_c_tt-.o-n-DI

S

WHEEL AND TIRE SERVICE Tool List

CAUTION

Qty. Required

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

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

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

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

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

..

.· ·

·•

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

.

... ·

.•

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

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

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

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

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

Wheel Installation

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

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

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

Install wheel on vehicle as shown.

Repair and Service Manual

Page D-1

. )· · D · · . r-------

· · ·•·. ··... .. I

WHEELS AND TIRES

TIGHTEN 5 TAPERED LUG NUTS TO 50 - 60 FT. LBS. TORQUE

TIRE STYLE MAY VARY PER VEHICLE

\i-

VALVE STEM IS ALWAYS TO OUTSIDE OF WHEEL

Fig. D-1 Wheels and Tires

Page D-2

Repair and Service Manual

EiZGt:u f•:U;MII

J

.·I.-- _ _ A_ _ _ _, _ _ _C- A- - C_A _ ________ _e_ct-io-n-,I.; BR K E S M E H N I L S TABLE OF CONTENTS FOR SECTION 'E' SECTION TITLE

PAGE NO.

DAILY BRAKE PERFORMANCE TEST E -1 General .................................................................................................................................. E -1 Test Method .......................................................................................................................... E -1 SIX MONTH BRAKE SYSTEM MAINTENANCE

E- 1

INSPECTION OF BRAKE SHOES

E-2

E-2 HOW THE BRAKE SYSTEM WORKS How the Adjuster Works ....................................................................................................... E - 3 ADJUSTING THE BRAKE PEDAL

E -4

BRAKE DRUM AND SHOE REMOVAL E- 4 Drum Removal. ...................................................................................................................... E -4 Cleaning ................................................................................................................................ E- 4 Shoe Removal ....................................................................................................................... E- 5 BRAKE REMOVAL

E -5

RECOMMENDED BRAKE ADJUSTMENT PROCEDURE

E- 6

MAINTENANCE TIP

E -7

PARKING BRAKE ADJUSTMENT

E -7

LIST OF ILLUSTRATIONS Fig. E-1 Brake Wear........................................................................................................................ E -2 Fig. E2 Lubrication Areas............................................................................................................... E-2 Fig. E-3 Brake at Rest ..................................................................................................................... E -2 Fig. E-4 Brake Operation ................................................................................................................ E - 3 Fig. E-5 Adjusting Screw ................................................................................................................. E - 3 Fig. E-6 Brake Adjustments ............................................................................................................ E - 3 Fig. E-7 Tightened Adjuster ............................................................................................................ E -4 Fig. E-8 Wheel Brake Components ................................................................................................. E- 5 Fig. E-9 Removing Screw Boot ....................................................................................................... E- 6 Fig. E-10 Parking Brake Adjustment ............................................................................................... E -7

Repair and Service Manual

Page E-i

E----. [ .• ,es BRAKES, MECHANICAL

Notes: ____________________________

Page E-ii

Repair and Service Manual

_ _ _A_ -E _,_ _E_ _ _A_ _ _AL ___________ _e_c_tt-.0-n-,�1.-�] S B R K S M C H N IC

To assure correct braking performance, all periodic mainte­ nance, inspections and procedures must be performed as indicated in the Periodic Service Schedule in Section �' of this manual. It is most important that a Daily Brake Perfor­ mance Test be performed and the entire brake system be serviced in accordance with the Periodic Service Sched­ ule.

1

If any brake system component is replaced, the entire brake system must be �A:.-�•�"'

DAILY BRAKE PERFORMANCE TEST To determine the adequacy of the vehicles brake system, a brake performance test should be performed daily.

_A WARNING _A

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

General Since weather conditions and terrain frequently vary, no specific braking distance can be specified. The test is intended to compare similar vehicles by applying the parking brake (to eliminate different pedal pressures) at a common point to determine if any vehicle shows signifi­ cantly different braking characteristics from other vehi­ cles being tested.

Since loss of braking performance can deteriorate over a prolonged period, brake performance characteristics should also be compared to the performance of a new vehicle.

Test Method The recommended way of performing the daily brake test and determining any vehicles that have unacceptable braking performance is to have personnel handling the vehicles engage the parking brake at a common point on a paved surface while traveling at maximum speed.

The vehicle stopping location must be observed and vehicles that stop in a significantly greater distance than other acceptable vehicles should immediately be removed from service and inspected by a qualified mechanic.

The mechanic should perform a 'panic' stop on the sus­ pect vehicle(s) by applying maximum force and travel to the brake pedal while traveling at full speed. He should

E�l3CliiUii!0):1

observe if either of the rear wheels fails to 'lock up'. If one wheel fails to lock, it is reasonable to expect that a prob­ lem exists with the service brake system and the Six Month Brake System Maintenance must be performed in its entirety. If both wheels lock, the parking brake must be adjusted and the vehicle re-tested per the Daily Brake Performance Test.

SIX MONTH BRAKE SYSTEM MAINTENANCE Raise the entire vehicle (as specified in section B Safety).

Rotate each rear wheel by hand. Feel for a dragging brake shoe that prevents smooth movement of the wheel and brake drum.

Remove the clevis pin from both cables where they attach to the wheel brake levers.

Again rotate each wheel by hand and feel for a dragging brake shoe that prevents smooth movement of the wheel and brake drum. If the wheel rotates more smoothly than with the brake cables attached, a worn or damaged brake cable is indicated and MUST be replaced.

Inspect the cables for abrasion to the cable housing. A kinked cable or a cable housing that has worn to the point of exposing the metal jacket will result in the cable dragging. Any worn or kinked cables MUST be replaced.

Operate the brake pedal and observe the movement of the cables. Both should move the same amount and return fully when the brake pedal is released. If the brake pedal does not return to the full upright position, excess pedal bushing friction is indicated or a cable is defective.

The bushing must be_ removed and lubricated or replaced. Observe the equalizer bar to see if it pivots dur­ ing operation of the brake pedal. A pivoting equalizer bar, uneven movement or failure of the brake cables to return fully indicates a dragging brake cable which MUST be replaced.

Remove each brake drum and shoes according to proce­ dures indicated in BRAKE DRUM AND SHOE REMOVAL section. Clean and inspect all brake parts.

If there is evidence of rust or if the lever slide mechanism does not move smoothly in the backing plate, the sur­ faces must be cleaned and smoothed using an emery cloth. The backing plate MUST be replaced if excessive wear such as gouges or galling are in evidence on the backing plate.

Repair and Service Manual

Page E-1

I BRAKES, MECHANICAL INSPECTION OF BRAKE S HOES

Clean before lubricating. After lubricating the backing plate and lever slide mechanism at the lubrication points (See Fig. E-2), reassemble and adjust the complete brake system according to the procedures outlined later in this section.

(See Fig. E-1 "Brake Wear" on page E-2) (See Fig. E-2 "Lubrication Areas" on page E-2)

The pattern of normal brake shoe wear is shown in quad­ rants A, B, C and D with quadrant 'I( showing the most wear, 'B' will show the second most wear. Quandrants B and C will always be to the rear of the vehicle.

BACKING PLATE

B

D

- - DRIVER'S SIDE BRAKE I

A

I

LUBRICATE BOTH FRONT AND BACK SURFACES AROUND THIS SLOT

C

Fig. E-2 Lubrication Areas Retest according to DAILY BRAKING PERFORMANCE TEST.

D

HOWTHE BRAKE SYSTEM WORKS (See Fig. E-3 "Brake at Rest" on page E-2) (See Fig. E-4 "Brake Operation" on page E-3)

A

C

BACKING PLATE

Fig. E-1 Brake Wear Inspect brake shoes. Brake shoes MUST be replaced as a set when either shoe has a lining thickness less than .040 in. thick AT ANY POINT on the shoe.

Page E-2

Repair and Service Manual

I'&?-.�

ACTUATING LEVER

PIVOT ASSEMBLY

BRAKE CABLE

Fig. E-3 Brake at Rest

BRAKES, MECHANICAL The brakes are the "servo acting" type.

(See Fig. E-6 "Brake Adjustments" on page E-3)

Depressing the brake pedal causes the brake cable to pull the brake actuating lever forward which in turn pushes the rear brake shoe against the brake drum. Con­ tinued movement of the brake actuating lever causes the lever slide mechanism to move which pushes the front shoe against the drum. As the shoes contact the drum "servo action" takes place. If the vehicle is moving for­ ward, the rear brake shoe moves upwards applying pres­ sure against the upper rear portion of the brake drum.

The front shoe moves downwards applying pressure against the lower front portion of the brake drum.

(See Fig. E-7 "Tightened Adjuster" on page E-4) (See Fig. E-9 "Removing Screw Boof' on page E-6)

Qty. Required

Tool List

Hydraulic trolley jack ................................................... 1 Jack stands ................................................................. 2 Chocks ........................................................................ 2 Wrench, open end, 7 mm ............................................ 1 The brake adjusting screw (anchor) has a conical shape with six flats at one end. (Ref. Fig. E-5)

SIZED FOR A 7mmWRENCH

REAR BRAKE SHOE CONTACTS DRUM (QUADRANT'C' FIG. D-1)

Fig. E-5 Adjusting Screw

0

FRONT BRAKE SHOE CONTACTS DRUM (QUADRANT'A' FIG. E-1)

An extension spring holds the front and rear brake shoes against two anchor pistons that ride on the conical end of the adjusting screw (Ref. Fig. E-6). A ratcheting or index­ ing effect is encountered when turning the adjusting screw as the two anchor pistons are forced outward by the crowns and pulled back into the flats by the spring.

NOTE: ACTUATING LEVER POSITIONS ARE EXAGGERATED FOR CLARITY

ADJUSTING SCREW

ANCHOR PISTONS

Fig. E-4 Brake Operation

The action reverses when the brakes are applied with the vehicle operating in reverse.

It is very important to the function of the brake assembly and to proper wear of the brake lining that the brake be adjusted properly. If the brakes are adjusted by the brake linkage rod (attached to the brake pivot) only, the geome­ try of the brake mechanism is compromised resulting in rapid and abnormal wear of the brake linings. This also results in a high braking effort at the brake pedal.

How the Adjuster Works (See Fig. E-5 "Adjusting Screw" on page E-3)

E.ZGPii½:ii;t•):I

EXTENSION SPRING

Fig. E-6 Brake Adjustments

Before tightening the adjusting screw: Raise the rear of vehicle and install jack stands (see section B - Safety).

Remove the wheel and tire assembly. Leave the brake

Repair and Service Manual

Page E-3

BRAKES, MECHANICAL drum on and face the brake assembly from the side of the vehicle. Reach over the top of the brake and remove the adjusting screw boot (Ref. Fig. E-9).With a wrench, tum the adjusting screw counterclockwise until it will no longer tum.

BRAKE DRUM AND SHOE REMOVAL Tool List

Qty. Required

Jack, hydraulic trolley .................................................. 1 Hammer, plastic tipped ................................................ 1 Jack stands .................................................................. 4

CAUTION FORCING OF THE SCREW TO TURN IN A COUNTERCLOCKWISE DIRECTION CAN CAUSE INTERNAL DAMAGE TO THE ADJUSTING MECHANISM.

Notice the screw will now turn clockwise easily but will not tum counterclockwise when you are facing the wheel.

This means that the brake shoes have expanded against the drum and that the crowns of the adjusting screw can­ not expand the brake shoes any more. (Ref. Fig. E-7) Tum the adjusting screw clockwise to the last flat that was encountered during tightening. Starting at this flat, tum the adjusting screw clockwise three more flats (or notches). Replace the adjusting screw boot.

Socket, 3/4" ................................................................. 1 Ratchet, drive, 1/2" ...................................................... 1 Socket, 1 1/16" ............................................................ 1

Drum Removal Loosen lug nuts on rear wheels 1/8 to 1/4 tum. Raise the rear of the vehicle and support on jack stands (see sec­ tion B - Safety). Remove the wheel(s). Remove the dust cap (1), cotter pin (2) and axle nut (3). Tap the brake drum (8) lightly with a plastic faced hammer to loosen the drum. If the drum does not come off, it will be necessary to back off the brake adjusting screw. Remove the brake drum. Remove slight scores by polishing with a fine emery cloth. An extensively scored drum will cause excessive brake lining wear and must be replaced with a new drum. An out-of-round drum makes accurate brake adjustment impossible due to its eccentric action.A drum that is more than .01O inch out-of-round on the inside diameter should be replaced with a new drum.

_A WARNING _A

DO NOT MACHINE DRUMS IN ORDER TO TRUE UP THE BRAKING SURFACE.

Fig. E-7 Tightene� Adjuster

Cleaning

ADJUSTING THE BRAKE· PEDAL After adjusting the wheel brakes, the brake pedal travel should be checked. In most cases, no adjustment is required; however, if free play at pedal exceeds 1", adjust the brake actuating rod by screwing the rod in the adjustable yokes.

Free travel is the movement at the pedal that takes place before the brake levers are moved. The brake pedal adjusting yoke should ONLY be used to establish the correct free pedal travel AFTER the brakes are ro erly adjusted.

Page E-4

_A WARNING _A

WEAR PROTECTIVE GOGGLES AND MASK WHEN CLEANING BRAKE COMPONENTS. LUBRICATE AREAS INDICATED (Ref. Fig. E-2) WITH COMMERCIALLY AVAILABLE BRAKE COMPONENT LUBRICANT AVAILABLE AT ANY AUTO PARTS STORE. It is recommended that suitable greaseless type solvent be used to clean the braking surface of brake drums

Repair and Service Manual

EiZGCH i:S:ji;M:I

BRAKES, MECHANICAL BRAKE REMOVAL

before they are placed in service to assure the cleanest possible surface.

(See Fig. E-8 "Wheel Brake Components" on page E-5)

CAUTION

Chocks ........................................................................ 2

GASOLINE OR KEROSENE SHOULD NOT BE USED AS THERE IS DANGER THAT A PORTION OF THE DILUTED OILY SUBSTANCE MAY BE LEFT ON THE BRAKING SURFACE.

Socket, 1/2" ................................................................. 1 Ratchet, drive, 1/2" ...................................................... 1 Jack stands ................................................................. 2

Shoe Removal

Retaining ring pliers ..................................................... 1

(See Fig. E-8 "Wheel Brake Components" on page E-5)

Tool List

Qty. Required

Tool List

CAUTION

Qty. Required

Pliers ........................................................................... 1 Remove dust cap (1 ), cotter pin (2) and axle nut (3).

Using a pair of pliers, compress the brake shoe spring retainer (4) at the open end of spring. While holding the tension pin (5) with the pliers, turn the spring retainer 1/4 turn to align the slot in the spring retainer with the flats on the tension pin.

Remove the brake shoe retainer springs. Grasp the brake shoes (6) in the center and tilt them outward and away from the back mounting plate. This will release the tension on the brake springs (7). Remove the brake springs and remove the brake shoes.

f

DO NOT TURN THE PINS AS THEIR SEALS MAY BE BROKEN. For axle or seal replacement, the brake must be removed. Raise the vehicle and support on jack stands (see section B - Safety). Remove the wheel and brake drum. Remove the retaining ring (9) from the inside of the axle tube and pull the axle and bearing assembly out­ wards.

Remove the cotter pin and clevis pin attaching the brake cable to the brake lever. Using 1/2" socket wrench,

Fig. E-8 Wheel Brake Components

Emlit:iiiUi;!•):I

Repair and Service Manual

Page E-5

BRAKES, MECHANICAL remove the four bolts and nuts attaching the brake assembly to the axle and remove the brake assembly.

Reinstall brake in the reverse order of disassembly.

Tighten the brake mounting bolts to 23-35 ft. lbs. torque, and the axle nut to 70 ft. lbs. minimum.

If the slot in the axle nut and the hole in the axle are not in alignment, continue to tighten the axle nut until the alignment is achieved.

the�!�.,

5. Turn the adjusting screw clockwise until it indexes on the last flat surface encountered when tightening.

6. Starting at this flat, turn the adjusting screw clockwise three more flats (or notches).

7. Replace the rubber boot, and wheel and tire assembly.

8. Repeat steps 1 - 7 for the opposite side.

; Mimmum torque on 70 ft lbs. Torque read­ $ inas up to 140 ff. lbs. are satisfactory.

Clean the axle shaft to remove grease, dirt and all foreign matter. Apply small amount of lubricant (anti-seize com­ pound) to the spline. Install the axle and bearing assem­ bly and reinstall retaining ring.

CAUTION USE CARE TO PREVENT DAMAGE TO SEAL.

RECOMMENDED BRAKE ADJUSTMENT PROCEDURE (See Fig. E-9 "Removing Screw Boot" on page E-6)

9. Lower the vehicle (see section B - Safety).

10. After adjusting the brake with the brake adjusting screw, check the free pedal travel. If it is in excess of 1" or less than 3/4", adjust as follows: a). Loosen the nuts on both sides of the brake pedal adjusting yoke. b). Tighten the brake pedal adjusting yoke nut until ALL free play is removed from the pedal. c). Loosen the brake pedal adjusting yoke nut until 3/ 4" - 1" of the free pedal travel is obtained. d). Tighten the jam nuts on the brake pedal adjusting yoke.

If there is any doubt whether or not the brakes have been adjusted properly in the past, then it is recommended that before any adjustment is made at the brake adjusting screw that the brake pedal linkage rod be loosened to allow plenty of slack in the cable system. This will allow the brake lever to return to its ro r position. Then proceed with ste 1.

1. Lift the vehicle so that the rear tires are off the ground and support on jack stands (see section B - Safety).

2. Remove the wheel and tire assembly.

3. Face the brake assembly from the side of the vehicle, reach over the top of the brake and remove the brake adjusting screw boot (Ref. Fig. E-9).

4. While holding the drum in place, turn the adjusting screw counterclockwise until the adjusting screw will no longer turn. DO NOT FORCE. Page E-6

Repair and Service Manual

Fig. E-9 Removing Screw Boot

rE

BRAKES, MECHANICAL

MAINTENANCE TIP

The brake manufacturer recommends that the surfaces of the brake lever slide mechanism be lubricated with grease every three to four months of normal operating conditions.

CAUTION

'.!�',

t

i IF FREE MOVEMENT CANNOT BE OBTAINED WITH

If adjustment cannot be made at the brake adjusting knob (1), the knob should be turned to its minimum adjustment. The adjustment may be made at the point that the actuating rod (2) enters the brake bellcrank (3).

Adjust the nut (4) on the actuating rod until it contacts the bellcrank. Loosen the nut four complete turns to lock the adjustment. Reinspect the bellcrank to ensure that it is in the fully released position. The adjusting knob may now be used to make any additional adjustment.

'"' LUBRICATION, THE ENTIRE BACK PLATE Yi ASSEMBLY MUST BE REPLACED. NO DISASSEMBLY OF SLIDE LEVER MECHANISM lf MAY BE ACCOMPLISHED. �,:

f

PARKING BRAKE ADJUSTMENT (See Fig. E-10 "Parking Brake Adjustment" on page E-7)

The parking brake engagement and holding force should be properly adjusted after the brakes have been adjusted per the "Recommended Brake Adjustment Procedure".

The parking brake may be adjusted by rotating the brake adjusting knob (1) on the end of the parking brake lever.

Be sure that the wheel brake levers are fully released when the brake is in the disen a ed osition.

Eil!laDii:f:ti;{•]:I

Fig. E-10 Parking Brake Adjustment

Repair and Service Manual

Page E-7

BRAKES, MECHANICAL Notes: ____________________________

Page E-8

Repair and Service Manual

EiZliDlifaii!-1:1

�.:·,;.I�',• -------------------------------------.......

BRAKES, HYDRAULIC Section -!L_·--� TABLE OF CONTENTS FOR SECTION 'F' SECTION TITLE

PAGE NO.

DAILY BRAKING PERFORMANCE TEST

F -1

HOW THE BRAKE SYSTEM WORKS

F-1

BRAKE MASTER CYLINDER FLUID

F-1

MASTER CYLINDER SERVICING

F-1

BRAKE ADJUSTMENT- REAR

F- 1

BRAKE ADJUSTMENT - F RONT (IF EQUIPPED)

F- 3

SHOE REPLACEMENT - FRONT

F-4

BRAKE SYSTEM INSPECTION

F -4

BLEEDING BRAKES

F- 4

LIST OF ILLUSTRATIONS F ig. F-1 Fig. F-2 Fig. F-3 Fig. F-4

Rear Brake Components ................................................................................................... F - 2 Brake Shoe Adjustment ..................................................................................................... F - 2 Front Brake Components ................................................................................................... F- 3 Sequence for Bleeding Valves ........................................................................................... F- 6

Repair and Service Manual

Page F-i

BRAKES, HYDRAULIC Notes: _____________________________

Page F-ii

Repair and Service Manual

E2:liDiit:ii;t•J:I

,---1 ,

4 -BR_ A_K_E_S_,_H_Y_D_R _A _U_L_IC _________ _e_ct-io_n_-J, S

To assure proper braking performance, all periodic mainte­ nance inspections and procedures should be performed. (as specified in section A) i.e. Daily, Weekly, Monthly, Semiannu­ ally, and Annually.

A complete brake system adjustment procedure must be performed whenever any part of the brake system has been replaced.

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

A

WARNING

A

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

The recommended way of performing the daily brake test and determining any vehicles that have unacceptable braking performance is to have personnel handling the vehicle engage the parking brake at a common point on a paved surface while traveling at maximum speed. The vehicle stopping location must be observed and vehicles that stop in a significantly greater distance than other acceptable vehicles should immediately be removed from service and inspected by a qualified mechanic.

The mechanic should perform a 'panic' stop on the sus­ pect vehicle(s) by applyi_ng maximum force and travel to the brake pedal while traveling at full speed. He should observe if either of the rear wheels fails to 'lock up'. If one wheel fails to lock, it is reasonable to expect that a prob­ lem exists with the service brake system. If both wheels lock, the parking brake must be adjusted and the vehicle re-tested per the Daily Brake Performance Test

HOW THE BRAKE SYSTEM WORKS Hydraulic systems are used to actuate the brakes. The system transports the power required to force the fric­ tional surfaces of the braking system together from the pedal to the individual brake units at each wheel. A hydraulic system is used for two reasons. First, fluid under pressure can be carried to all parts of a vehicle by

I

small hoses without taking up a significant amount of space or posing routing problems. Second, a great mechanical advantage can be given to the brake pedal end of the system, and the foot pressure required to actuate the brakes can be reduced.

The hydraulic system operates as follows: When at rest, the entire system is full of brake fluid. Upon application of the brake pedal, fluid trapped in front of the master cylinder piston is forced through the lines to the wheel cylinders. Here, it forces the pistons outwards.

Upon release of the brake pedal, a spring located inside the master cylinder immediately returns the piston to the normal position. As the return springs force the brake shoes into the released position, the excess fluid flows back .to the reservoir.

Hydraulic brake systems must be totally flushed if the fluid becomes contaminated with water, dirt or other corrosive chemicals. To flush, simply bleed the entire system until all brake fluid has been replaced with DOT 3 standard automo­ tive brake fluid.

BRAKE MASTER CYLINDER FLUID It is important to maintain proper fluid levels in the brake master cylinder. The fill cap for the cylinder is located under the drivers seat. When checking the fluid, wipe off any dirt from the fill cap, before removing. Fluid level should be maintained at 1/8 inch below the top of the housing. Use DOT 3 standard automotive brake fluid.

MASTER CYLINDER SERVICING Just like any other brake parts, master cylinders require periodic service. The usual reason for a master cylinder failure is that the cups don't seal anymore. Fluid leaks past cups internally and sometimes shows up as an external leak as well. A common symptom is a "spongy'' brake pedal that goes all the way to the floor when all the other brake components are in good condition. The rub­ ber parts wear with usage or may deteriorate with age of fluid contamination. Corrosion or deposits formed in the bore due to moisture or dirt in the hydraulic system may result in wear of the cylinder bore or the parts therein.

Also, the fluid level in the reservoir should be checked periodically. Whenever needed, clean brake fluid should be added to maintain the fluid level 1/8" from the top of the reservoir.

Repair and Service Manual

Page F-1

BRAKES, HYDRAULIC

Fig. F-1 Rear Brake Components

BRAKE ADJUSTMENT - REAR (See Fig. F-2 "Brake Shoe Adjustmenf' on page F-2)

The vehicle is equipped with an automotive brake drum and shoe system on the rear wheels. Should the braking be inadequate, adjustment should be made at the wheel drums. Use the following adjustment procedure:

A

WARNING

A

b). Rotate the star wheel adjuster one full turn at a time through opening in drum. c). Loosen star wheel 3 'clicks'. If any drag is encoun­ tered, the star wheel may be loosened one addi­ tional "click''. If the wheel still binds, repeat the adjustment procedure. If the drum continues to bind, the drum should be checked for a warped condition.

PLACE CHOCKS BOTH,. IN FRONT OF AND BEHIND THE FRONT WHEELS TO PREVENT THE VEHICLE FROM ROLLING. ,J;

1. At the brake to be adjusted, loosen the wheel nuts 1/2 turn.

2. Raise the rear of the vehicle (see section B - Safety) enough so that the wheel turns freely. Remove the lug nuts and the wheel.

ADJUSTER

3. Remove the brake drum and inspect the brake shoes for excessive wear. a). If shoe replacement is not required, the shoes must be adjusted. Note that the slot in drum must be in line with adjuster.

Page F-2

Fig. F-2 Brake Shoe Adjustment

Brake failure usually occurs as either a gradual decrease in braking effect from the shoe material being worn away, or as a loss of braking at one wheel or a sudden and

Repair and Service Manual

[r

��

BRAKES, HYDRAULIC

complete failure with no brakes working except the park­ ing brake.

The shoes should be replaced whenever the braking effect has diminished or the brakes start squeaking and proper adjustment does not remedy the problem. Use the following procedure for shoe replacement:

BRAKE ADJUSTMENT - FRONT (IF EQUIPPED) Tool List

Qty. Required

Jack, hydraulic, trolley ................................................. 1 Chocks......................................................................... 2 Jack stands.................................................................. 2

A_ WARNING A_ NEVER WORK ON A VEHICLE SUPPORTED BY A JACK ALONE.

1. Support the vehicle with jack stands (as specified in section B - Lifting and Jacking).

2. Remove wheel and brake drum.

3. To remove the shoes, remove the springs from the hole in each brake shoe. With these springs removed, the brake shoes can be removed.

4. Reassemble in the reverse order of assembly. Note that the slot in drum must be in line with adjuster.

5. After assembly, the brakes should be adjusted as pre­ viously detailed.

Pliers, needle nose ...................................................... 1 Socket, 3/4" ................................................................. 1 Ratchet wrench, 3/8" drive .......................................... 1

A_ WARNING A_ NEVER WORK ON A VEHICLE SUPPORTED BY A JACK ALONE. SUPPORT THE VEHICLE WITH JACK STANDS (SEE SECTION B - SAFETY).

PLACE CHOCKS BOTH IN THE FRONT AND BEHIND THE REAR WHEELS TO PREVENT THE VEHICLE FROM ROLLING.

c:,

Fig. F-3 Front Brake Components

Repair and Service Manual

Page F-3

FJ ,

BRAKES, HYDRAULIC

The procedure for front brake adjustment should be made with the wheel secured to the drum.

Available only as an option, the vehicle can be equipped with front hydraulic brakes. At 50 hours (or if braking is inadequate) adjust the brakes using the following proce­ dure: 1. Lift the front of the vehicle (as specified in section B Safety) enough for the tires to clear the ground.

2. Tighten the adjusting nut just enough for the wheel to rotate with a small amount of resistance when turned by hand.

A

WARNING

A

the pedal sinks very slowly to the floor, the system has a leak. This is not to be confused with a springy or spongy feel due to the compression of air within the lines.

Care should be taken to prevent brake fluid from coming into contact with the brake shoes. If the brake shoes should become wet, remove the brake drum and wipe the brake shoes and drum until they are dry.

Check for leaks along all lines and at wheel cylinders. If no external leaks are apparent, the problem is inside the master cylinder.

CAUTION DO NOT ALLOW BRAKE FLUID TO CONTACT PAINTED SURFACES. WIPE OFF IMMEDIATELY.

DO NOT ATTEMPT TO REPAIR DAMAGED BRAKE LINES, REPLACE WITH NEW ITEMS.

SHOE REPLACEMENT - FRONT Shoe replacement should be in accord with standard automotive practice.

It is recommended that ALL brake shoes be changed at the same time. If proper adjustment has been main­ tained, all the shoes should wear at approximately the same rate.

After making any repairs to the hydraulic line, the brakes must be bled to remove any entrapped air. A small valve is provided on the top of each wheel cylinder for this pur­ pose.

BRAKE SYSTEM INSPECTION

(See Fig. F-4 "Sequence for Bleeding Valves" on page F-6)

Should the brakes at one wheel become ineffective while the brakes at the other wheel function properly, remove the wheel and drum. Inspect the brakes for a leaking or inoperative wheel cylinder assembly.

Complete brake failure usually indicates a loss of hydrau­ lic fluid pressure. First check the f4uid level at the master cylinder. If the cylinder is full, inspect the master cylinder for a defective piston seal which will allow the fluid to escape around the piston. A master cylinder repair kit is available through our Service Parts Department (E-Z-GO P/N 32825-G1). Pipe joints and the wheel cylinder seals are possible locations which should be checked for leaks. If the inspection does not reveal a leak, fill the master cylinder with brake fluid. While you observe the vehicle, have an assistant depress the brake pedal. The brake fluid will be forced out of the defect, making the leaking point readily apparent.

The hydraulic system may be checked for leaks by applying pressure to the pedal gradually and steadily. If Page F-4

BLEEDING BRAKES The hydraulic brake system must be free of air to operate properly. Air can enter the system when hydraulic parts are disconnected for servicing or replacement, or when the fluid level in the master cylinder reservoir is very low.

Air in the system will give the brake pedal a spongy feel­ ing upon application.

Use a clean cloth to wipe off the master cylinder reservoir and bleeder screw. Clean each fitting before opening to prevent contaminating the system. Open the master cyl­ inder reservoir and top off with DOT 3 standard automo­ tive brake fluid. Attach a short length of clear hose to the bleed fitting and insert the other end into a suitable clean container containing fresh brake fluid. Check the fluid level in the master cylinder frequently during this opera­ tion to prevent air from entering the lines.

Repair and Service Manual

rP

BRAKES, HYDRAULIC

Starting with the passenger side rear brake then the driver's side rear brake, bleed the brakes using the fol­ lowing procedure: Open the fitting and have an assistant depress brake pedal gently until fluid flows into container with no bubbles evident. Close the bleed fitting and have the assistant slowly release the brake pedal. Repeat the process until no bubbles can be seen leaving the bleed fitting. Close the fitting and move to the next brake.

Bleed fitting must be closed prior to lifting brake pedal and end of hose must be immersed in brake fluid in container.

CAUTION THE BLEED VALVE AT THE WHEEL CYLINDER MUST BE CLOSED AT THE END OF EACH STROKE AND BEFORE THE BRAKE PEDAL IS RELEASED TO INSURE THAT AIR CANNOT ENTER THE SYSTEM. IT IS ALSO IMPORTANT THAT THE BRAKE PEDAL BE RETURNED TO FULL "UP" POSITION.

_A WARNING _A NEVER REUSE ANY EXCESS FLUID RETURN TO THE ORIGINAL CONTAINER.

Ei!H:it:nii:,i;t•m

Repair and Service Manual

OR

Page F-5

.::p.

rl

BRAKES, HYDRAULIC

3

4

i-------,...++=-----'-,-,._----=++-,--r--� - - [ I STEPS 3 AND 4 SHOULD ONLY BE PERFORMED IF THE VEHICLE IS EQUIPPED WITH FRONT HYDRAULIC BRAKES

1

2

Fig. F-4 Sequence for Bleeding Valves Page F-6

Repair and Service Manual

E2HiCHi,S:ji;M:I

ELECTRONIC SPEED CONTROL

Section

TABLE OF CONTENTS FOR SECTION 'G' SECTION TITLE GENERAL

PAGE NO. G-1

CONTROL CIRCUIT G -1 Forward Operation ............................................................................................................... G -1 Reverse Warning Operation ................................................................................................. G-1 POWER CIRCUIT

G -1

TROUBLESHOOTING VEHICLE WIRING

G -1

TROUBLESHOOTING SOLID STATE SPEED CONTROLLER

G-4

GENERAL

G- 4

TROUBLE SHOOTING

G- 6

REVERSE WARNING DEVICE

G-7

POWER CIRCUIT

G-9

CHECKING FOR CONTINUITY

G-10

TESTING THE MOTOR

G-11

G-11 DIRECTION SELECTOR SWITCH Switch Lubrication .............................................................................................................. G-11 Direction Selector Switch Inspection and Repair ............................................................... G -12 Direction Selector Switch Removal and Disassembly ........................................................ G -12

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

Accelerator Positions........................................................................................................ G -1 Wiring Diagram (Onboard Charger) ................................................................................. G -2 Wiring Diagram (Portable Charger) .................................................................................. G- 3 Charging Receptacle (Viewed from Front) ....................................................................... G - 4 Direction Selector Micro Switches and Reverse Warning Device.................................... G- 5 Accelerator Adjustments .................................................................................................. G- 6 Trouble Shooting Diagram ............................................................................................... G - 8 Direction Selector Switch Assembly............................................................................... G -1 3

Repair and Service M,mual

Page G-i

[

ELECTRONIC SPEED CONTROL Notes: ___________________________

Page G-ii

Repair and Service Manual

E.Zl:iiDii:f:ti;t•J:I

·.1

ELECTRONIC SPEED CONTROL

GENERAL

There are two distinct circuits used in the operation of an electric vehicle. These circuits are the CONTROL and the POWER circuits.

CONTROL CIRCUIT

The control circuit may be identified by the light gauge wire used. The control circuit components consist of the key switch, the solenoid, a reverse warning device and two micro switches. Micro switch 2 (MS-2) is actuated by the direction selector switch and micro switch 3 (MS-3) is actuated by movement of the potentiometer lever which is moved by the accelerator linkage.

Forward Operation

With the key switch in the 'ON' position and the direction selector switch in the 'FORWARD' (F) position, micro switch 2 (MS-2) is closed which provides an electrical path to accelerator micro switch. Depressing the acceler­ ator pedal moves the lever of the potentiometer from the 'OFF' position and also activates micro switch 3 (MS-3).

The closure of micro switch 3 (MS-3) completes the con­ trol circuit and activates the coils of the solenoid. This causes the solenoid contacts to close which in tum acti­ vates the power circuit.

Reverse Warning Operation

The reverse operation is identical to forward operation except that a reverse warning device is activated by the direction selector switch that is placed in the 'REVERSE' (R) position which activates micro switch MS-1. This warning device is in continuous operation while the direc­ tion selector switch is in the 'REVERSE' (R) position.

POWER CIRCUIT

DO OHMS PRE-TRAVEL (AT LEAST 1/2")

� 0 - 6000 OHMS (OPERATING RANGE IN � FORWARD) PEDAL OVER TRAVEL (FULL SPEED TO PEDAL STOP) 1 ART HM v - � F8��fRD g� :EHJ��iifi ���PJc�1D WITH THE PEDAL IN THIS POSITION - THE LOWER LIMIT MAY VARY DEPENDING ON TOLERANCE OF MOTOR AND CONTROLLER)

1111

Fig. G-1 Accelerator Positions Tool List

(See Fig. G-1 "Accelerator Positionsn on page G-1)

With the control circuit ,activated, the solenoid contacts are closed. Power is applied to the power circuit.

Depressing the accelerator pedal moves the lever of the potentiometer which increases the resistance from O 6000 ohms. The control module uses solid state circuitry to supply the appropriate power required through the direction selector switch which directs this power through the field windings of the motor to control the speed of the vehicle.

TROUBLESHOOTING VEHICLE WIRING (See Fig. G-2 "Wiring Diagram (Onboard Charger)" on page G-2) (See Fig. G-3 "Wiring Diagram (Portable Charger)" on page G-3)

(See Fig. G-4 "Charging Receptacle (Viewed from Front)" on page G-4) (See Fig. G-5 "Direction Selector Micro Switches and Reverse Warning Devicen on page G-5)

E�litliifai;!-):1

- ACCELERATOR PEDAL AT REST

Qty. Required

VOM ............................................................................ 1 If the vehicle fails to operate or operates poorly, the fol­ lowing test sequence should be followed.

A

WARNING

A

TO PREVENT VEHICLE FROM INADVERTENTLY ACCELERATING, WHICH COULD CAUSE BODILY INJURY, THE VEHICLE MUST BE LIFTED TO RAISE BOTH DRIVE WHEELS ABOVE THE GROUND. Raise the vehicle (as specified in section B - Safety) before proceeding

Repair and Service Manual

Page G-1

ELECTRONIC SPEED CONTROL

CHARGER NO TOGGLE SWITCH .---1--1--0_...n-RED MS-1 MS-3 :_,-;: 0----0----�BLU---f--l---l--------+----O..-;D---RED-----c>I MS-2 '--BLU--ll--+-.,_-+----------------� I

RELAY

(>:;:>

RED

BLK_/\__ �RN CHARGE METER.r-+--------ORN---11---' BLU

SOLENOID BLK

•

0-

I xx I

REVERSE FORWARD WIRE IDENTIFICATION MARKER

CONTROL/SIGNAL WIRE ------ POWER WIRE -- - - -- - ENCLOSURE --------- MECHANICAL ATTACHMENT

POWER WIRING EQUIPPED WITH ONBOARD CHARGER Fig. G-2 Wiring Diagram (Onboard Charger)

Page G-2

Repair and Service Manual

YEL

ELECTRONIC SPEED CONTROL

CHARGING RECEPTACLE NO TOGGLE SWITCH

.----1-......-0--C>-RED

BLU----,

RED

MS-3

BLK_f\__ '---./G'RN CHARGE METER..+----- --ORN----tt---' BLK

YEL

BLU

ORN

SOLENOID BLK

•

c:>

I xx I

REVERSE FORWARD WIRE IDENTIFICATION MARKER

------ CONTROL/SIGNAL WIRE ------ POWER WIRE -- - - - - - ENCLOSURE --------- MECHANICAL ATTACHMENT

POWER WIRING EQUIPPED WITH PORTABLE CHARGER Fig. G-3 Wiring Diagram (Portable Charger)

EmliCnifaiiM:I

Repair and Service Manual

Page G-3

�I

ELECTRONIC SPEED CONTROL

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

To test the control circuit, turn the key switch to the 'ON' position. Set the VOM to the 50 VDC range. Touch the black probe to the negative(-) contact of the vehicle DC receptacle and the red (+) probe to the positive (+) con­ tact of the vehicle DC receptacle.

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

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

With the adequacy of the batteries confirmed, operate vehicle for a minimum of two minutes to remove any sur­ face charge. Use a VOM connected directly to the bat­ tery terminal posts to determine the open voltage of the set. In the following tests, this voltage level will be used as a reference. Some loss due to resistance of wires and connectors may be indicated by readings that may be up to one volt less than the reference voltage. No reading indicates an 'open' condition and the power transmission circuit should be inspected for a broken or disconnected conductor.

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

TROUBLESHOOTING SOLID STATE SPEED CONTROLLER (See Fig. G-2 "Wiring Diagram (Onboard Charger)" on page G-2) (See Fig. G-3 "Wiring Diagram (Portable Charger)" on page G-3) (See Fig. G-5 "Direction Selector Micro Switches and Reverse Warning Device" on page G-5) (See Fig. G-6 "Accelerator Adjustments" on page G-6)

_A WARNING _A

BEFORE ATTEMPTING TO TROUBLESHOOT OR REPAIR THE EQUIPMENT, BE SURE THAT PERSONNEL WORKING ON OR AROUND THE EQUIPMENT CANNOT BE INJURED. REFER TO THE APPROPRIATE PARAGRAPHS IN SECTION 'B' FOR THE CORRECT PROCEDURE FOR RAISING BOTH OF THE VEHICLES DRIVE ALL WHEELS. WARNINGS OBSERVE PERTAINING TO SAFE PRACTICES WHEN WORKING ON AN ELECTRIC VEHICLE. ALWAYS WEAR APPROVED EYE PROTECTION.

GENERAL T he following procedures will assist in the trouble shoot­ ing and repair or adjustment of the E-Z-GO solid state speed controllers in an efficient and timely manner.

No procedure can cover every situation, therefore this procedure should be used in conjunction with good repair practices.

Tool List

Qty. Required

VOM ............................................................................ 1 Wrench, open end, 7/16" ............................................. 1 Wrench, open end, 1 /2" ............................................... 1 Wrench, open end, 3/8" ............................................... 1

Fig. G-4 Charging Receptacle (Viewed from Front) Page G-4

No special tools are required to install, remove or adjust the unit. Good quality tools are required and locking pli­ ers, pliers or adjustable wrenches should not be used.

Repair and Service Manual

ELECTRONIC SPEED CONTROL VIEWED FROM FRONT OF VEHICLE NEUTRAL REVERSE WARNING DEVICE

l1J

RED D <� + \ /BLK­

BLU /� RED \ TOMS-3�-� -­

l)-.l

...._/

...._

MS-1

MS-2

REVERSE WARNING DEVICE

\ "

l)I

RED / -... 'RED

\

o

�

...._

�

/BLK

MS-1

FORWARD

BLU /-:-TOMS-3 o --0 ' \

...._/ MS-2

BLU TOMS-3

/� o --0 ' \

...._/ MS-2

RED/__ �

\

RED

' � � / BLK ...._ MS-1

REVERSE WARNING DEVICE

Fig. G-5 Direction Selector Micro Switches and Reverse Warning Device

Repair and Service Manual

Page G-5

.·•u,

ELECTRONIC SPEED CONTROL The use of a Volt Ohm Meter (VOM) is mandatory to perform trouble shooting on the solid state speed control­ ler. When selecting a VOM, either an analog (needle type) or a digital type is acceptable, although it is easier to determine small voltage and resistance changes with a digital meter. It should be capable of accurately mea­ suring both voltage and resistance. If an analog meter is selected it should have a scale that is large enough to be easily and accurately read. The meter will be reading voltages from 1 to 50 and resistances from O to 10,000 ohms. Look at the the DC voltage selector and select a meter that permits voltage selection that is most applica­ ble to your needs. Remember that reading 6 volts on a 50 volt meter scale would be difficult. The same problem exists when reading resistance (ohms). Select a meter with scales that are appropriate for the readings required.

A VOM that can easily be misinterpreted can cost many hours of wasted time looking for problems that do not exist or overlooking genuine problems. It does not mat­ ter if you choose analog or digital, just be sure that the VOM is reliable and accurate. Most important is to be sure that you know how to use it efficiently.

TROUBLE SHOOTING (See Fig. G-2 Wiring Diagram (Onboard Charger)" on page G-2) (See Fig. G-3 Wiring Diagram (Portable Charger)" on page G-3) (See Fig. G-5 "Direction Selector Micro Switches and Reverse Warning Devicen on page G-5) (See Fig. G-6 "Accelerator Adjustmentsn on page G-6) (See Fig. G-7 '7rouble Shooting Diagramn on page G-8)

Use common sense and the following step by step chart when troubleshooting the entire accelerator and solid state controller system.

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

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

With the adequacy of the batteries confirmed, operate vehicle for a minimum of two minutes to remove any sur­ face charge. Use a VOM connected directly to the bat­ tery terminal posts to determine the open voltage of the set. In the following tests, this voltage level will be used as a reference. Some loss due to resistance of wires and connectors may be indicated by readings that may be up to one volt less than the reference voltage.

1. Verify that adequate battery voltage is present to operate the vehicle. Battery voltage should be referPage G-6

.�. . .·.·.. · ·

POTENTIOMETER LEVER ADJUSTING CLAMP LEVER

BELL CRANK ADJUST ACCELERATOR ROD LENGTH AT THE CLEVIS (FRONT) END TO ALLOW THE LEVER TO REST AGAINST THE SPACER PLACED BETWEEN THE TOP STOP AND THE LEVER

JAM NUT

I

I

ACCELERATOR ROD

Fig. G-6 Accelerator Adjustments ence voltage after the surface charge is removed.

2. Examine all the wiring to assure all wires are without physical damage or corrosion. Check the routing of all wiring and the tightness of each connection.

Repair or replace any suspect wires or connections.

(Ref. Fig. G-5) 3. Inspect the male 'push on' contacts at the control unit and be sure they and the areas around them are free of corrosion. (Ref. Fig. G-2)

�@v�

Use radio and TV tuner cleaner applied with a cotton swab or a small brush. Do not use solvents that could attack the plastic sealant. Mild soap and water applied with a soft brush (tooth brush) rinsed with clear water and thoroughly dried is very effective.

4. Remove the blue wire at 'push on' connection from the control unit (wire from the micro switch to the con-

Repair and Service M,mual

ELECTRONIC SPEED CONTROL trol unit). Place the direction selector switch in the 'FORWARD' (F) position. Turn the key switch to 'ON' and slowly depress the accelerator pedal. The sole­ noid should make an audible 'click'. If there is an audible 'click' go to step 6. If there is no 'click' the fault is in the solenoid coil, micro switch, key switch or wir­ ing.

5. With the VOM adjusted to the correct scale, connect the (B-) probe to the (B-) terminal at the battery set.

Connect the (B+) probe to the female contact of the blue wire that was removed in step 4. With the key switch in the 'ON' position and the accelerator pedal in the fully depressed position, battery voltage should be indicated. If battery reference voltage is not indi­ cated move the (B+) probe to each component work­ ing towards the positive side of the battery until the failed component is found. Example: From wire to accelerator micro switch to key switch to (+) terminal of battery. If battery voltage is present at the female connection of the wire removed in step 4 and the solenoid does not 'click' the fault is in the solenoid coil windings and the solenoid must be replaced.

6. With the VOM adjusted to the correct scale and with the blue 'push on' connector removed, place the direction selector switch in the 'FORWARD' (F) posi­ tion. Connect the (B-) probe to the (B-) terminal at the battery set. Connect the (B+) probe to the large solenoid contact connected to the positive side of the battery set and verify that battery voltage is present.

Move the (B+) probe to the other large contact, the meter should indicate approximately 1 V less than battery reference voltage indicating that the resistor is in good condition. No voltage drop indicates a welded solenoid that must be replaced. A reading of O volts indicates a poor resistor that must be replaced.

Depress the accelerator pedal several times to acti­ vate the solen.oid arid .observe the meter. No meter movement or erratic moyement indicates a poor or failed solenoid which must be replaced. Full battery reference voltage indicates that the system is func­ tioning properly.

7. At the control unit, remove the two wires with female 'push on' connectors coming from the potentiometer.

With the VOM adjusted to the correct ohms scale, attach each probe to the two wires from the potenti­ ometer. With the accelerator pedal in the released position, the meter must indicate less than 50 ohms and continue to indicate less than 50 through at least 1/2" of downward pedal movement. Slowly depress the accelerator pedal and observe the meter. The meter should rise smoothly to a minimum of 4800

E;DlaDiif:ili;!•l:I

ohms and a maximum of 6000 ohms. When the meter indicates the specified range, the pedal should not be fully depressed. (Approximately 1/2" of pedal travel should remain after the reading). If correct readings are not achieved, check the potentiometers activating linkage. With the accelerator in the released position, insert a gauge (dime) between the arm and the top stop. The potentiometer activating lever should just retain the dime. (Ref. Fig. G-6) Should the potenti­ ometer activating lever not properly contact the top stop, remove the connecting linkage and adjust by lengthening or shortening the linkage. (Ref. Fig. G-6) With the accelerator in the released position, the potentiometer activating lever should just contact the upper stop with a gauge (dime) installed.

8. Depress the accelerator pedal. The micro switch attached to the potentiometer should activate as near to the O ohms position as possible. Readings less than 49 ohms are acceptable.

[K{]@v�

If the micro switch activation takes place at 50 ohms or higher, the high pedal protection circuit will be activated which will cause the unit to malfunction.

9. Remove one of the VOM probes and touch to the metal housing of the potentiometer. The meter should read infinity (oo). If it does not, replace the potentiome­ ter.

1 O. Reconnect the wiring. If the vehicle does not operate correctly check the direction selector switch, the motor and use a VOM wired between (B+) and (M-) which should indicate between O and battery refer­ ence voltage when the accelerator pedal is operated.

If all the previous checks indicate the vehicle is in good operating condition, the control module must be replaced with a new one that is known to be good.

REVERSE WARNING DEVICE (See Fig. G-2 "Wiring Diagram (Onboard Chargerr on page G-2) (See Fig. G-3 "Wiring Diagram (Portable Chargerr on page G-3) (See Fig. G-4 "Charging Receptacle (Viewed from Front)" on page G-4) (See Fig. G-5 "Direction Selector Micro Switches and Reverse Warning Device" on page G-5)

The completion of the preceding trouble shooting proce­ dure will have checked all wiring and components in the control circuit.

Repair and Service Manual

Page G-7

ELECTRONIC SPEED CONTROL

VEHICLE WILL NOT RUN OR IS ERRATIC DOES SOLENOID FUNCTION CORRECTLY?

ADEQUATE VOLTAGE? Step 1

Ste 6and7

RECHARGE BATTERIES CHECK CONDITION See Operation and SeNice Manual

WIRING CONDITION AND ROUTING?

IS POTENTIOMETER .-------- IN ADJUSTMENT?

Step2

TROUBLE SHOOT REPAIR

StepB

ADJUST POTENTIOMETER

See wiring diagram

StepB

ARE CONTACTS CLEAN?

IS MICRO SWITCH ADJUSTED?

Step3

StepB

ADJUST MICRO SWITCH

CLEAN CONTACTS Step3 See note

Step9

IS POTENTIOMETER ISOLATED FROM CASE?

DOES SOLENOID CLICK? Step4

TROUBLE SHOOT SOLENOID SWITCHES AND WIRING

Step 10

REPLACE POTENTIOMETER

Fig. G-7 Trouble Shooting Diagram

Page G-8

Repair and Service Manual

ELECTRONIC SPEED CONTROL The reverse warning device does not affect the operation of the vehicle, however, E-Z-GO strongly recommends that its operation be checked and maintained since the correct functioning of this safety device may prevent an accident.

The warning device (Ref. Fig. G-2) should sound when­ ever the direction selector switch is in the 'REVERSE' (R) position. Should the warning device fail to sound, the following procedure should be used to troubleshoot the circuit.

Set the VOM to the 15 VDC range, check that the key switch is 'ON' and the direction selector switch is in the 'REVERSE'(R) position. Locate the black probe(-) in the negative side of the vehicle receptacle (Ref. Fig. G-4) and place the red (+) probe to the terminal on micro switch 2 (MS-2) with the white wire closest to the direc­ tion selector switch. A meter reading of 12 VDC indi­ cates the white wire between the positive(+) terminal of the front right battery and the micro switch 2(MS-2) is in good condition.

Separate the connection in the black wire from the warn­ ing device to the battery. Place the red probe (+) on the terminal of the black wire attached to the battery. A meter reading of 12 volts indicates that the black wire from the battery is in good condition. Rejoin the connection.

Locate the red (+) probe on the other terminal of micro switch 2 (MS-2). A meter reading of 12 VDC will indicate that the micro switch 2 (MS-2) is in good condition and the warning device must be replaced.

POWER CIRCUIT (See Fig. G-2 "Wiring Diagram (Onboard Charger)" on page G-2) (See Fig. G-3 "Wiring Diagram (Portable Charger)" on page G-3)

Tool List

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

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

With the adequacy of the batteries confirmed, operate vehicle for a minimum of two minutes to remove any sur­ face charge. Use a VOM connected directly to the bat­ tery terminal posts to determine the open voltage of the set. In the following tests, this voltage level will be used as a reference. Some loss due to resistance of wires and connectors may be indicated by readings that may be up to one volt less than the reference voltage.

Place the key switch in the 'ON' position and the direc­ tion selector switch to the 'FORWARD'(F) position.

Locate the black(-) probe on the negative (-) post of the battery that has two heavy gauge wires attached to it.

Locate the red(+) probe to the positive side of the sole­ noid. A meter reading of reference voltage indicates that the wire joining(BL+) to solenoid is satisfactory.

A reading of less than reference voltage indicates a bro­ ken wire, a poor connection or corrosion at the battery.

Locate the black(-) probe on the negative (-) post of the battery that has two heavy gauge wires attached to it.

Locate the positive probe on the negative (-) side of the solenoid. A meter reading of approximately 1 volt less than reference voltage indicates that the resistor on the solenoid is satisfactory. A meter reading of approxi­ mately O VDC indicates that the resistor has failed.

[R{]@v�

Qty. Required

VOM ....................•........ :...:.......................................... 1

IF THE VEHICLE DOES NOTRUN:

_A WARNING _A

TO PREVENT VEHICLE FROM INADVERTENTLY ACCELERATING, WHICH COULD CAUSE BODILY INJURY, THE VEHICLE MUST BE LIFTED TO RAISE BOTH DRIVE WHEELS ABOVE THE GROUND. Raise the vehicle (as specified in section B - Safety) before proceeding.

When testing for voltage from the negative side of the sole­ noid a meter reading of 1 volt less than reference voltage indicates a satisfactory condition. Reduced voltage is observed due to the resistor located on the solenoid.

Locate the red (+) probe to the motor terminal A1. A meter reading of 1 volt less than reference voltage indi­ cates continuity between the solenoid and A 1 on motor. A reading of O VDC indicates an 'open' circuit and should be repaired.

Locate the red(+) probe on(B+) terminal on the control­ ler. A reading of 1 volt less than reference voltage indi­ cates the solenoid wire to (B+) on controller is satisfactory. A reading of O VDC indicates an 'open' con­ dition that should be repaired.

Repair and Service Manual

Page G-9

ELECTRONIC SPEED CONTROL Locate the red(+) probe on motor terminal to A2. A read­ ing of 1 volt less than reference voltage indicates the motor armature is satisfactory. A meter reading of O VDC requires repair or replacement of the motor.

Locate the red(+) probe on the A2 lead of the controller.

A reading of 1 volt less than reference voltage indicates the wire between A2 on the motor and the controller is satisfactory. A reading of O VDC indicates an 'open' cir­ cuit and the wire should be repaired or replaced.

Locate the red (+) probe on A contact of the direction selector switch. A reading of 1 volt less than reference voltage indicates the wire between A2 on the controller and A contact on the direction selector switch is satisfac­ tory. A reading of O VDC indicates an 'open' circuit and the wire should be repaired or replaced.

Locate the red (+) probe on B contact of the direction selector switch. A reading of 1 volt less than reference voltage indicates satisfactory connection between A and B terminals of the direction selector switch. A reading of O VDC indicates an 'open' circuit and the direction selector switch should be repaired or replaced.

Locate the red(+) probe to the S1 terminal on the motor.

A meter reading of 1 volt less than reference voltage indi­ cates satisfactory connection between S1 on motor and B on direction selector. A reading of O VDC indicates an 'open' circuit and the wire between B on direction selec­ tor and S1 on motor should be repaired or replaced.

Locate the red (+) probe on S2 terminal on the motor. A meter reading of 1 volt less than reference voltage indi­ cates the field coil is satisfactory. A meter reading of O VDC indicates an 'open' circuit which would require the repair or replacement of the motor.

Locate the red(+) probe on the D contact of the direction selector switch. A meter reading of 1 volt less than refer­ ence voltage indicates the wire between S2 on the motor and D on the directionselector. switch is satisfactory. A meter reading of O VDC indicate§> an 'open' circuit and the wire between S2 on motor and D on direction selec­ tor should be repaired or replaced.

indicates an 'open' circuit and the wire between C termi­ nal on direction selector and M1 on controller should be repaired or replaced.

Locate the red (+) probe on the battery (BL+) terminal.

Locate the black(-) probe on the controller (B-) terminal.

Reference voltage indicates good wire. O voltage indi­ cates an open circuit and the wire should be repaired or replaced.

IF VEHICLE RUNS BUT PERFORMS ERRATICALLY:

A

WARNING

A

TO PREVENT VEHICLE FROM INADVERTENTLY ACCELERATING, WHICH COULD CAUSE BODILY INJURY, THE VEHICLE MUST BE LIFTED TO RAISE BOTH DRIVE WHEELS ABOVE THE GROUND. Raise the vehicle (as specified in section B - Safety) before proceeding.

Place key switch in the 'ON' position and the direction selector switch to the 'FORWARD'(F) position.

Visually inspect all components for burned or broken wires or loose connections. Inspect all terminals for cor­ rosion and clean if required. If a visual inspection fails to yield the cause of the problem, a VOM may be used to perform a 'continuity' test at each component.

CHECKING FOR CONTINUITY The VOM can be very useful in testing for continuity. A wire conductor that is continuous without a break has partically O ohms of resistance. When testing for continu­ ity, be sure the VOM is set to the lowest ohms range.

There are many applications.· Because of the insulated cover, a wire conductor can have an internal break which is not visible, or the wire can have a bad connection at the terminal.

Locate the red (+) probe on C contact of the direction selector switch. A meter reading of 1 volt less than refer­ ence voltage indicates satisfactory connection between D and C terminals of the direction selector switch. A meter reading of O VDC indicates an 'open' circuit and the direction selector switch should be repaired or replaced.

When testing for continuity, check for O ohms between any two points along the conductor. A break in the con­ ducting path is evident from a reading of infinite resis­ tance(oo) showing an open circuit.

Locate the red(+) probe on M1 of the controller. A meter reading of 1 volt less than reference voltage indicates satisfactory connection between C terminal of direction selector switch and M1 on controller. A reading of O VDC

REMOVE THE BATTERY (+) CONNECTIONS BEFORE USING A VOM (AS SPECIFIED IN SECTION 8- SAFETY PROCEDURES).

Page G-10

CAUTION

Repair and Service Manual

ELECTRONIC SPEED CONTROL �@u@

A test light may be substituted for an VOM.

If the vehicle continues to run with the accelerator pedal in the released position, the accelerator linkage is out of adjustment(see Accelerator Adjustment).

TESTING THE MOTOR (See Fig. G-2 "Wiring Diagram (Onboard Chargerr on page G-2) (See Fig. G-3 "Wiring Diagram (Portable Chargerr on page G-3)

Tool List

Qty. Required

VOM ............................................................................ 1

�@u@

This test is valid only after the control and power wiring has been inspected as detailed in the preceding procedures.

A

WARNING

A

TO PREVENT VEHICLE FROM INADVERTENTLY ACCELERATING, WHICH COULD CAUSE BODILY INJURY, THE VEHICLE MUST BE LIFTED TO RAISE BOTH DRIVE WHEELS ABOVE THE GROUND.

Raise the vehicle (as specified in section B - Safety) before proceeding.

�@u@

Use the following test ONLY IF THE MOTOR WILL NOT RUN.

Place key switch in the_ 'ON' position and the direction selector switch to the 'FORWARD'(F) position.

This check is for open circuits in field coils, brushes or brush rigging. To check for a short circuit, refer to the Motor Section.

Set the VOM to the 50 VDC range.

Locate the red (+) probe on the motor terminal A2. A reading other than O VDC indicates the power wiring should be rechecked. Locate the red (+) probe to the motor terminal A1. A meter reading of 1 volt less than reference voltage indicates the brushes, brush holder and all connections are satisfactory. A meter reading of 0 indicates a problem with the brushes, brush holder or connections.

The following tests may be performed with an VOM or test light.

A

WARNING

A

REMOVE THE BATTERY (+) CONNECTIONS BEFORE CONTINUING WITH THIS TEST. SHORTING OF MOTOR WIRES COULD RESULT IN AN EXPLOSION.

Remove wires from motor terminals A1 and S2. Set the VOM to the RX1 scale. Using the VOM, place probes on motor terminals S1 and S2. A meter reading of O indi­ cates a satisfactory condition at the field coils. No needle deflection indicates an 'open' condition that will require the motor to be repaired or replaced.

Place the probes on motor terminals A1 and A2. A meter reading of O indicates a satisfactory condition at the brushes and rigging. No needle deflection indicates a condition that will require the motor to be repaired or replaced.

Check for continuity between each of the motor terminals and the motor shell. Continuity between terminals S1 and S2 to the motor shell indicates a short circuit between the field coils and the case. Continuity between terminals A1 or A2 to the motor shell indicates a short circuit in the armature. Both of the preceding conditions will require the motor to be repaired or replaced.

Tighten all motor terminal connections to 35-40 in. lbs. torque.

DIRECTION SELECTOR SWITCH (See Fig. G-8 "Direction Selector Switch Assembly" on page G-13)

Locate the black (-) probe to the negative (-) contact of the vehicle DC receptacle and the red (+) probe to the motor terminal S2. A meter reading of 1 volt less than reference voltage indicates a good condition. Locate the red(+) probe on the motor terminal S1. A meter reading of 1 volt less than reference voltage indicates the field coils are satisfactory. A meter reading of O indicates the field coils are open and the motor must be repaired or replaced.

The direction selector switch operation is described in Power Circuit at the beginning of this section.

Switch Lubrication During the servicing of the vehicle, the direction selector switch shaft(2) should be removed, cleaned and lubricat­ ed with bearing grease. The contact surfaces may also be lubricated with a thin coat of petroleum jelly to permit smooth operation of the switch.

Repair and Service Mtmual

Page G-11

ELECTRONIC SPEED CONTROL Direction Selector Switch Inspection and Repair

A

WARNING

A

DISCONNECT THE BATTERY LEAD (BL+) FROM THE BATTERY BEFORE ATTEMPTING SERVICE OF THE DIRECTION SELECTOR SWITCH.

Direction Selector Switch Removal and Dis­ assembly (See Fig. G-8 "Direction Selector Switch Assembly" on page G-13)

Tool List

Qty. Required

Wrench, box end combination, 7/16"-1/2" ................... 1 Wrench, box end, 9/16" ............................................... 1 Screwdriver, Phillips .................................................... 1 Remove switch lever (1) from shaft (2).

Periodic inspection of the switch should include the fol­ lowing: 1. Check that all wire connections are tight and free of corrosion.

2. Check the contacts for abnormal wear. The contacts in the movable cam portion of the switch are spring loaded and the cam assembly must be replaced when worn sufficiently to cause a loss of spring pres­ sure.

3. Rotate the switch lever (1) from 'stop to stop' to check for smooth operation. If the switch is excessively hard to operate, inspect for rough contact surfaces and replace if required. If the contact surfaces are good, the stationary contact surfaces may be lubri­ cated, if required, with a very thin coat of petroleum jelly.

If the switch lever (1) is abnormally loose, check the shaft nut (3) and tighten if required. Inspect for abnormally worn spring loaded contacts.

Disconnect all the wiring connections from the rear of the switch. Disconnect the push-on connections and any other connections securing the switch to the vehicle elec­ trical system. Disconnect the wire from the micro switch to the key switch at micro switch 2 (MS-2).

Remove the hardware (4) which secures the switch to the seat wrap and remove the switch assembly.

Remove the nut (3) from the switch shaft (2). Remove the cam (5) complete with the switch shaft (2) from the bushing and remove the switch shaft (2) from the cam assembly (5).

Reassemble the switch in the reverse order of disassem­ bly. Rotate the cam from stop to stop and check the oper­ ation of the micro switch rollers.

Reinstall the direction selector switch in the vehicle and adjust the switch to align with the hole in the seat wrap.

Tighten the hardware that secures the direction selector switch to the vehicle to 10-12 ft. lbs. torque.

Inspect the micro switches for operation and dirt that might inhibit their operation.

Page G-12

Repair and Service Manual

ELECTRONIC SPEED CONTROL

BLACK FROM (BL-)

BLUE -FROM KEY SWITCH

Fig. G-8 Direction Selector Switch Assembly

Repair and Service Manual

Page G-13

I ELECTRONIC SPEED CONTROL Notes: _________________________

Page G-14

Repair and Service M,mual

,.....F_ R_ O_ N_ T_S_U_S_P_E_N _S_IO _N_&_ S_T _E_E_R _IN_G_____ -ec-t-io_n_B S TABLE OF CONTENTS FOR SECTION 'H'

SECTION TITLE

PAGE NO.

FRONT SUSPENSION

H -1

FRONT AXLE REMOVAL

H- 1

FRONT AXLE INSTALLATION

H-1

FRONT SPRING REMOVAL

H- 1

FRONT SPRING INSTALLATION

H -2

TIE ROD AND KING PIN INSPECTION

H -2

TIE ROD REMOVAL

H-2

TIE ROD INSTALLATION

H -3

MAINTENANCE H-3 Lubrication ............................................................................................................................ H - 3 Packing and Adjusting Wheel Bearings ............................................................................... H -3 Bearing Inspection ................................................................................................................ H - 3 Seal Installation .................................................................................................................... H - 4 Bearing Adjustment .............................................................................................................. H - 4 King Pin Bushing Inspection/Replacement .......................................................................... H - 4 STEERING

H-5

GENERAL

H-5

STEERING ASSEMBLY REMOVAL

H-5

STEERING ASSEMBLY INSTALLATION

H-5

STEERING ASSEMBLY DISASSEMBLY H-6 Steering Wheel Removal ...................................................................................................... H -6 Steering Wheel Installation ................................................................................................... H - 6 Steering Shaft Removal ....................................................................................................... H -6 Gear and Rack Removal ...................................................................................................... H - 6 Idler Arm ............................................................................................................................... H - 6 Idler Arm Removal ................................................................................................................ H -6

LIST OF ILLUSTRATIONS Fig. H-1 Front Axle Removal ..................................................... :.................................................... H - 1 Fig. H-2 Front Spring Removal....................................................................................................... H -2 Fig. H-3 Tie Rod Removal.............................................................................................................. H -2 Fig. H-4 Correct Tie Rod and Toe In Adjustment ........................................................................... H - 3 Fig. H-5 Front Spindle and Bearing ................................................................................................ H - 3 Fig. H-6 Seal Installation ................................................................................................................ H - 4 Fig. H-7 King Pin Bushing Replacement ........................................................................................ H - 5 Fig. H-8 Drill Out Metal Rivet.......................................................................................................... H - 5 Fig. H-9 Factory Adjusted Steering Unit......................................................................................... H -6 Fig. H-10 Steering Components ..................................................................................................... H - 8

Repair and Service Ma.nual

Page H-i

ll

FRONT SUSPENSION & STEERING

Notes: ___________________________

Page H-ii

Repair and Service Manual

.-----P ,,::JI FRONT SUSPENSION & STEERING

FRONT SUSPENSION

Remove the nut (item 3) from the king pin (item 2) and remove the king pin and thrust washer (item 4) from the spindle (item 5). Swing the spindle out of the way.

·..

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

Tool List

Qty. Required

Floor jack .................................................................... 1 Jack stands ................................................................. 2 Wheel chocks.............................................................. 4 For all front suspension repairs, raise the front end using the procedures described in Section 'B' (Safety) of this manual and support the vehicle frame on jack stands.

A

WARNING

Section

A

Remove hardware (item 6) and mounting plate (item 7) securing the leaf spring (item 8) to the front axle (item 9).

The front axle can be removed.

FRONT AXLE INSTALLAT ION (See Fig. H-1 "Front Axle Removar on page H-1)

Front axle installation is the reverse order of disassembly.

Tighten the castellated nut (item 3) to 40 ft. lbs. torque.

Continue tightening until a cotter pin can be inserted.

Tighten the leaf spring hardware (item 6) to 23 ft. lbs. torque.

Replace cotter pins (item 1) with new ones.

Check for smooth rotation of the wheel and an absence of play when the wheel is grasped by the outside of the tire.

TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LIFTING PROCEDURE IN SECTION B OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF AND BEHIND THE REAR WHEELS 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.

FRONT AXLE REMOVAL (See Fig. H-1 "Front Axle Removal" on page H-1)

Tool List

Qty. Required

Pliers, needle nose ···············'.····································· 1 Wrench, closed end, 5/16" .......................................... 1 Socket, 5/16", 3/8" drive .............................................. 1 Wrench, closed end, 9/16" .......................................... 1 Socket, 9/16", 3/8" drive.............................................. 1 Ratchet, 3/8" drive ....................................................... 1 Remove the front wheels.

Remove the cotter pin (item 1) from the king pin (item 2).

Loosen the castellated nut (item 3) until the threaded end of the king pin is protected and tap the nut with a plastic faced hammer to loosen the king pin.

E'2Hibii½:tiiM:t

Fig. H-1 Front Axle Removal

FRONT SPRING REMOVAL (See Fig. H-2 "Front Spring Removal" on page H-2)

Tool List

Qty. Required

Wrench, closed end, 9/16" .......................................... 1 Socket, 9/16", 3/8" drive .............................................. 1 Ratchet, 3/8" drive ....................................................... 1 Remove the front wheel on the side of the vehicle that is to have the spring replaced.

Repair and Service Manual

Page H-1

·B . ·.· .·:·

FRONT SUSPENSION & STEERING Support the front frame on the side of the vehicle that is to have the spring replaced with a jack stand. Place an additional jack stand to support the axle.

Remove hardware (item 1) and mounting plate (item 2) securing the spring (item 3) to the axle (item 4).

Remove hardware (item 5) securing the spring to the welded bracket toward the front of the vehicle.

Remove hardware (item 6) and spring shackles (item 7) securing spring to the frame toward the rear of the vehi­ cle.

...... .

TIE ROD AND KING PIN INSPECTION

Qty. Required

Tool List

Floor jack ..................................................................... 1 Jack stands .................................................................. 2 Wheel chocks .............................................................. 1 Lift the front of the vehicle and support on jack stands as shown in Section B. Grasp the tie rod and check for any vertical motion which would indicate a worn condition requiring replacement.

Grasp the top and bottom of the wheel and use a rocking motion to check for king pin movement which would indi­ cate a worn condition.

TIE ROD REMOVAL (See Fig. H-3 '7ie Rod Removal" on page H-2)

Qty. Required

Tool List

Pliers, needle nose ...................................................... 1 Wrench, closed end, 11/16" ......................................... 1 Ball Joint Separator ..................................................... 1 To remove the tie rod (item 1), remove the cotter pin (item 2) from the ball joint (item 3) and remove the castellated nut (item 4). Insert a ball joint separator between the ball joint and the linkage and separate the ball joint from the linkage at both ends of the tie rod.

Fig. H-2 Front Spring Removal

FRONT SPRING INSTALLATION (See Fig. H-2 "Front Spring Removal" on· page H-2)

Tool List

Qty. Required

Torque wrench, ft. lbs., 3/8" drive ................................ 1

�@v�

It is recommended that when a spring is replaced, the spring bushings (item 8) also be replaced with new ones. ..· . .

Install the spring bushings (item 8) into the spring (item 3).

Spring installation is the reverse order of disassembly.

Fig. H-3 Tie Rod Removal

Tighten all hardware to 23 ft. lbs. torque.

Page H-2

3

Repair and Service Manual

E.ZliDii:i:foM:I

FRONT SUSPENSION & STEERING TIE ROD INSTALLATION

Lubrication Tool List

(See Fig. H-3 "Tie Rod Removar on page H-2) (See Fig. H-4 ucorrect T ie Rod and Toe In Adjustment" on page H-3)

Qty. Required

Tool List

Torque wrench, ft. lbs., 1/2" drive ................................ 1 A correctly adjusted tie rod (item 1) should be installed in the reverse order of disassembly (Ref. Fig. H-4). T he castellated nut (item 4) should be tightened to a minimum of 35 ft. lbs. torque and tightened as required to insert a new cotter pin (item 2). Maximum torque is 50 ft. lbs.

��

2 5- 1t 8" RE F· == -= == :::: = - _ _ _ _

�

\

I

I

I

Qty. Required

Floor jack ..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Grease gun.................................................................. 1 Bearing packer ............................................................ 1 Routinely grease the idler bushings, all ball joints and king pin bushings.

Packing and Adjusting Wheel Bearings (See Fig. H-5 "Front Spindle and Bearing" on page H-3)

T he front wheel bearings (item 1) are tapered roller type and must be packed with grease at installation or any time the bearing is removed for inspection. It is recom­ mended that a bearing packer attached to a grease gun be used; however, manual packing is acceptable if done correctly. To pack a bearing manually requires a dab of grease be placed in the palm of the hand and the bearing be dipped in the grease. Force the grease up through and around all of the rollers until the entire bearing is coated in grease. Fill the area between the rollers with grease and apply a light coating to the bearing race (item 2). Install and adjust the bearing.

I

\

0

I--- x -----1 FRONT OF TIRES ,_______ :· X ��

BACK SIDE OF TIRES

Fig. H-4 Correct Tie Rod and Toe In Adjustment Fig. H-5 Front Spindle and Bearing

MAINTENANCE

Bearing Inspection

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

Be sure to use the recommended lubricants. Maintain the correct adjustment of the front bearings and repack them in accordance with the Periodic Service Schedule or if a bearing replacement is required. Routine examination of the tires will provide indications that an alignment is required.

(See Fig. H-5 "Front Spindle and Bearing" on page H-3)

Tool List

Qty. Required

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

Repair and Service Manual

Page H-3

B

___________ & _ N_ _ _ _ _ _ N _ _ _N_S _ _ S_ _S _S r--F_ R_ _N_ IO T EE R I G O T U P E Wrench, closed end, 1 5/8" ......................................... 1

Bearing Adjustment

Pliers, needle nose ...................................................... 1

(See Fig. H-5 "Front Spindle and Bearing" on page H-3)

Punch, non ferrous ...................................................... 1

Rotate the wheel while tightening the castellated nut (item 5). Tighten until the wheel becomes noticeably resistant to being rotated.

Hammer, ball pein ....................................................... 1 Lift the front of the vehicle and support on jack stands as detailed in Section B of this manual. Rotate the front wheel and feel for any roughness. Grasp the outside of the tire and rock it. If any movement is detected, the wheel bearing may require replacement/adjustment.

Remove the dust cap (item 3), cotter pin (item 4), and castellated nut (item 5) and remove the hub assembly (item 6). Remove the inner bearing and seal (item 7) by tapping lightly around the bearing. Clean all bearings, seal, hub and dust cap in solvent and dry thoroughly.

Inspect for signs of damage. Pitting or a blue coloration of the rollers will require replacement of the bearing. If the roller portion of the bearing (item 1) is to be replaced, the race (item 2) must also be replaced. The old race may be tapped out of the hub using a punch inserted through the bore. Tap the punch in a circular pattern to avoid damaging the bore of the hub. Install a new bearing after packing the bearing.

Rotate the wheel 2 - 3 more turns to displace excess grease. If the cotter pin hole in the spindle aligns with a slot in the castellated nut, insert a new cotter pin (item 4).

If the hole does not align, the castellated nut must be

loosened to align with the closest available slot in the nut.

Check for smooth rotation of the wheel and an absence of play when the wheel is grasped by the outside of the tire. Bend the cotter pin (item 4) against the flats of the castellated nut and cut off any excess.

Replace the dust cap (item 3).

King Pin Bushing Inspection/Replacement (See Fig. H-7 "King Pin Bushing Replacement" on page H-5)

Qty. Required

Tool List

Floor jack ..................................................................... 1 Jack stands.................................................................. 2

Seal Installation

Wheel chocks .............................................................. 4

(See Fig. H-6 "Seal Installation" on page H-4)

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

Lubricate the seal surface with a light oil.

Pliers............................................................................ 1 Wrench, box end, 15/16" ............................................. 1 Reamer, sizing, .875"................................................... 1 Socket, 15/16", 1 /2" drive ............................................ 1 Torque wrench, ft. lbs., 1/2" drive ................................ 1 Micrometer, inside, 1" .. 1 Remove the spindle assembly (item 1) and clean the king pin bushings (item 2) with sol­ vent. If the inside diameter of the bushings are worn to .880" or greater, the bushings should be replaced. Press out the old bushings and press new ones into the spindle until flush with the spindle housing.

[Rl]@u�

··. As a result of the press operation, the bushing inside diame­ ter may close slightly. If a reaming operation is required, use .•. an .875" diameter sizing reamer to correctly size the new bushings.

A

A- INSTALL THIS SIDE OF SEAL INTO HOUSING B- LUBRICATE SEAL SURFACE

Fig. H-6 Seal Installation Page H-4

Reinstall the spindle (item 1) and tighten the castellated nut (item 3) to 40 ft. lbs torque. If a cotter pin (item 4) cannot be aligned with the hole in the king pin (item 5), continue tightening the nut (item 3) until a cotter pin (item 4) can be inserted.

Repair and Service Manual

EsZEiDii!:ii;{•l:1

FRONT SUSPENSION & STEERING Remove the cotter pin (item 1) from castellated nut (item 2) and back nut off until it protects ball joint stud threads.

Using a ball joint separator as a lever, apply pressure to ball joint and tap nut with a hammer to release ball stud.

Remove nut and lift stud from arm. (Ref. Fig. H-10) Remove rivets securing the steering cover. The rivets can be removed by drilling into the head with a drill bit that is slightly larger than the shank of the rivet. Care must be exercised when drilling to prevent the drill from being forced through and damaging components that may be directly behind. (Ref. Fig. H-8)

POP RIVET

I

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@)--------

DRILL OUT RIVET HEAD ONLY /

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Fig. H-8 Drill Out Metal Rivet Fig. H-7 King Pin Bushing Replacement

STEERING

Remove three bolts (item 3) and lock washers (item 4) securing steering box to steering channel and lift assem­ bly out of vehicle. (Ref. Fig. H-10)

STEERING ASSEMBLY INSTALLATION

GENERAL The steering unit is a rack and pinion type steering unit.

(See Fig. H-9 "Factory Adjusted Steering Unit" on page H-6)

Tool List

(See Fig. H-10 "Steering Components" on page H-8)

Qty. Required

Screwdriver, Phillips .................................................... 1 Socket, 1/2" drive, 15/16" ............................................ 1

Assemble steering unit to steering channel with hard­ ware (items 3 and 4).

Ratchet, 1/2" drive....................................................... 1

CAUTION

Hammer, ball pein ......... ,. ............................................ 1 Torque wrench, 1/2" drive····�······································ 1 Ball joint separator ...................................................... 1 Pliers ........................................................................... 1 Hammer, rubber faced ................................................ 1 Wrench, closed end, 15/16" ........................................ 1 Wrench, closed end, 11/16" ........................................ 1

STEERING ASSEMBLY REMOVAL (See Fig. H-8 "Drill Out Metal Rivet" on page H-5) (See Fig. H-10 "Steering Components" on page H-8)

Tum the steering wheel full travel to the right to correctly position rack end ball joint.

EiZGDiii=;i:M:1

THE RACK AND ROD ASSEMBLY (ITEM 20) COMES FACTORY ADJUSTED. DO NOT ADJUST THIS ASSEMBLY UNDER ANY CIRCUMSTANCES. ANY ADJUSTMENTS NEEDING TO BE MADE SHOULD BE MADE TO THE TIE ROD ASSEMBLY GOING TO THE STEERING ARM. With the rack and rod end assembly (item 20) already set to pre-determined dimension (Ref. Fig. H-9), secure to upper arm of idler with castellated nut (item 2) and cotter pin (item 1). Tighten castellated nut to 36 ft. lbs. torque.

Continue to tighten the nut until a cotter pin can be inserted. Maximum torque is 44 ft. lbs. Insert new cotter pin.

Repair and Service Manual

Page H-5

.·,•.·..··.iy.·.

B

FRONT SUSPENSION & STEERING

...•., .,

Steering Shaft Removal (See Fig. H-10 "Steering Components• on page H-8)

Remove bolts (item 9) and lock washers (item 10) secur­ ing the column to the gear housing. Remove column (item 11) and gasket (item 12) and slide the shaft (item 13) out through the flanged end of the column.

Gear and Rack Removal (See Fig. H-10 "Steering Components· on page H-8)

Fig. H-9 Factory Adjusted Steering Unit

Remove steering column (item 11) from gear housing.

When removing gears, make note of the position of the spring washers (item 14), one under the pinion (item 15) and one under the reduction gear (item 16). Be sure the washers are properly positioned when reassembling the gears. The flat washer (item 17) is placed on top of the reduction gear (item 16).

Turn steering shaft completely to the left and then to the right bringing the spindle arms against the stops. If the spindle arms do not rest against the stops in both direc­ tions, adjust the tie rod assembly going to the steering arm.

Position the steering cover and secure with metal rivets.

Loosen the clamp (item 1 8) securing the bellows (item 19). Slide the rack and rod end assembly (item 20) out.

Clean all parts with solvent and check for wear. Replace worn or damaged parts with new parts. Repack gear housing with a high quality gear grease. (E-Z-GO recom­ mends Shell Alvania® EP-2 multi-purpose grease.) Apply grease liberally to gear pins (item 21 ), rack and gears before reassembly.

STEERING ASSEMBLY DISASSEMBLY Steering Wheel Removal (See Fig. H-10 "Steering Components• on page H-8)

Remove two screws (item 5) holding the clipboard (item 6) located on the back of the steering wheel (item 7).

Loosen steering wheel retaining nut (item 8) two to three turns. Apply upwards pressure to the steering wheel.

Place a plastic faced hammer against the steering wheel nut (item 8) and strike plastic faced hammer sharply with a ball pein hammer. The combination of upwards pres­ sure and striking the plastic faced hammer will cause the steering wheel to separate from the steering shaft.

CAUTION DO NOT STRIKE THE STEERING NUT OR THE END OF THE STEERING SHAFT DIRECTLY WITH A HAMMER. .···

...·.

..·

Lightly coat the splines of the steering shaft with Nev­ erseize®. Slide steering wheel onto steering shaft splines. Install steering nut and tighten to 10 - 15 ft. lbs. torque. Reinstall clipboard in the reverse order of disas­ sembly. Tighten clipboard screws to 6 in. lbs. torque.

.

'

..

U\:!J@u(g

Pins (item 21) must be lubricated prior to reassembly. .· ·.·

·.

...

..

.

Reassemble all parts in reverse order of disassembly. Be sure all hardware is tightened securely.

Idler Arm If the idler arm assembly (item 22) is worn or has exces­ sive play, the idler arm bushings (item 23) must be replaced.

Idler Arm Removal (See Fig. H-10 "Steering Components• on page H-8)

Tool List

. .. With the wheels in the straight ahead position, center the steering wheel before installing the steering nut and clip­ . board

Page H-6

,

:

(See Fig. H-10 "Steering Components• on page H-8)

Steering Wheel Installation

U\:!J@u[g

U\:!J@u(g

If ball joint or tie rod end is worn or damaged, the rack and rod end assembly must be replaced as a complete unit.

Qty. Required

Pliers ............................................................................ 1 Wrench, open end, 11/16" ........................................... 1 Torque wrench, 3/8" drive ............................................ 1

Repair and Service Manual

FRONT SUSPENSION & STEERING To remove the idler arm (item 22), disconnect the tie rod ball joint (item 25) at the bottom of the idler arm and the steering gear ball joint (item 24) at the top of the idler arm using the procedure outlined under "STEERING ASSEM­ BLY REMOVAL" Lift the front of the vehicle per procedures in Section B of this manual. Remove cotter pin (item 26). Using a pair of pliers or vice grips, rotate idler shaft (item 27) back and forth while pulling downwards until the idler arm shaft is removed. After removal of the idler arm shaft, the idler arm assembly may be removed.

Before reinstalling idler arm assembly, repack with Shell Alvania® EP-2 multi-purpose grease. Reinstall in the reverse order of disassembly. Tighten castellated nuts to 36 ft. lbs. torque and install new cotter pins.

Repair and Service Manual

Page H-7

FRONT SUSPENSION & STEERING

25

24

STEERING CHANNEL

21 13

l I I -------

I

---------------- i --------,

7

Fig. H-10 Steering Components

Page H-8

Repair and Service Manual

EiZGtn i:S:jiiM:•

..--------�I_ MOTOR

Section

U

TABLE OF CONTENTS FOR SECTION 'J' SECTION TITLE

PAGE NO.

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

LIST OF ILLUSTRATIONS Fig. J-1 Brush Wear .......................................................................................................................... J-1 Fig. J-2 Removing the Motor ............................................................................................................. J - 2 Fig. J-3 Motor Components ............................................................................................................... J - 3

Repair and Service Manual

Page J-i

[l--:

---------------- - - _ __, M 0 TO R

Notes: ______________________________

Page J-ii

Repair and Service Manual

Ei2Hatni:£:,i;M:I

.- _O_ _O_ _ _________ ______ _ - - --JJ M T R S ce t io n .

Remove all wires from the motor.

GENERAL

The brush life in the electric motor used in this vehicle is rated at 2,000 hours of use. The brushes have a usable length of .80" and they should be replaced when they have worn to .60". The brushes are a serrated design which promotes rapid seating and long life. Disassembly of the motor is not recommended unless the vehicle has reached the 2,000 hour running time or replacement of a worn or noisy bearing is required.

CAUTION DO NOT HOLD THE VEHICLE ON AN INCLINE WITH THE ACCELERATOR. THIS WILL RAISE THE COMMUTATOR BARS RESULTING IN UNACCEPTABLE NOISE AND ACCELERATED "i BRUSH WEAR. \ The armature is not available as a service item, therefore in the unlikely event of a failure in this component, the entire motor must be replaced.

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

A

WARNING

A

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

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

Remove the three bolts and washers that secure the motor to the axle housing and carefully slide the motor straight out from the axle splines.

CAUTION TAKE CARE NOT TO DAMAGE THE SPLINES WHEN REMOVING AND ASSEMBLING THE MOTOR TO THE REAR AXLE HOUSING.

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

Remove the four vented covers (1). Push the retainer springs (2) back and pull the brushes (3) away from the commutator. Let the springs rest against the sides of the brushes.

Remove the three screws (4) that secure the bearing retainer (5). Set the motor on end and lift the stator (6) and end shield (7) from the armature (8).

Mark both stator (6) and end shield (7) to assist realign­ ment during reassembly of motor.

Remove hardware from S1 and S2 field coil studs.

Remove the two bolts (9) from the end shield and while pushing in on the field coil studs, remove the end shield from the stator.

Brush Replacement (See Fig. J-1 "Brush Wear" on page J-1) (See Fig. J-3 "Motor Components" on page J-3)

Brushes should be measured as shown and replaced when the minimum dimension of .60" is reached.

Qty. Required

Insulated wrench, 9/16" ............................................... 1 Wrench, box end, 1/2" ................................................. 1 Wrench, box end, 7 /16"............................................... 1 Ratchet, 1/4" drive ....................................................... 1 Socket, 1/4", 1/4" drive ................................................ 1 Socket 5/16", 1/4" drive ............................................... 1 Extension, 3", 1/4" drive .............................................. 1 Torque wrench, in. lbs. 1/4" drive ................................ 1 Screwdriver, straight blade .......................................... 1 Puller, bearing ............................................................. 1

E:Zlatn i=f:i i;M:•

Repair and Service Manual

r

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.60"MIN

Fig. J-1 Brush Wear Page J-1

·j�M_ O_T_O _R_________________

2

1

� \J

REMOVE ALL WIRES

MARK MOTOR/AXLE HOUSING

3

4

REMOVE BOLTS AND WASHERS

Fig. J-2 Removing the Motor

Page J-2

Repair and Service Manual

SLIDE MOTOR OUT

-fJ

rJ

MOTOR

'

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\ Fig. J-3 Motor Components

Remove two screws (10) holding the brush holder (11) and brushes (3). Remove the hardware from the A1 and A2. field coil studs. Remove the entire brush holder and brushes from the end shi.eld.

Spline Inspection Inspect spline for wear. Replace the motor if necessary (the armature is not available for replacement).

To replace the brushes, first note the location and orien­ tation of the brush wires. Remove the brushes.

Field Coil Replacement

Replace the brushes with a new set and install the A1 and A2. terminals and hardware. Tighten to 60 in. lbs. torque.

Remove eight bolts (13) holding the field poles (14) to the stator. Lift the field coils (15) from the stator. Install replacement field coils securing with eight bolts to the stator.

Bearing Replacement

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

Motor Assembly

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

The bearing (12) is pressed onto the armature and must be removed with a bearing puller centered on the indent in the armature shaft.

A new bearing must be installed using an arbor press applying force to the inner race of the bearing to avoid damage to the bearing and the armature.

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

Thread two 2" length of threaded rod (a screw with the head removed works well) into the bearing retainer (5) mounting holes.

Align the end shield with the holes in the stator and align the threaded rods in the bearing retainer with the holes in

Repair and Service Manual

Page J-3

�OR ._______ ________l_j J. the end shield. Assemble the bearing retainer, end shield and stator case by installing the two mounting bolts (9) and tighten to 90 in. lbs. torque.

Pull up on the threaded rods to pull the bearing retainer against the end shield. Remove one of the threaded rods and replace it with the bearing retainer mounting screw (4). Remove the other threaded rod and replace it with the second bearing retainer screw. Install third screw.

Tighten all hardware securely.

Motor Tests The armature is not available as an individual part, there­ fore no testing is recommended to determine the specific area of failure. When a test of the power wiring system indicates that the system is operating correctly and the vehicle either does not run or runs poorly, the motor is

Page J-4

the only remaining component, therefore the motor must be replaced.

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

Be sure that a bumper spline is installed between the motor input pinion shaft and splines. Apply a small quan­ tity of molybdenum grease to the male portion of the spline. Carefully mate the motor spline with the input shaft of the rear axle. Align the orientation marks and install the mounting hardware. Tighten to 14 ft. lbs. torque.

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

Repair and Service Manual

BATTERIES AND CHARGING

Section

TABLE OF CONTENTS FOR SECTION 'K' SECTION TITLE

PAGE NO.

SAFETY

K-1

GENERAL

K-2

MAINTENANCE

K-2

ONBOARD CHARGER K-2 At Each Charging Cycle ........................................................................................................ K- 2 Monthly .................................................................................................................................. K- 2 PORTABLE CHARGER K- 2 At Each Charging Cycle ........................................................................................................K- 2 Monthly .................................................................................................................................. K- 2 Every Three Months .............................................................................................................. K - 2 Electrolyte Level and Water .................................................................................................. K- 2 Cleaning Batteries .......................................................•......................................................... K- 4 Prolonged Storage ................................................................................................................ K- 4 Battery Installation ................................................................................................................. K- 5 Battery Charging ................................................................................................................... K - 5 AC Voltage ............................................................................................................................ K- 5 K-6 TROUBLESHOOTING Hydrometer............................................................................................................................ K -6 Using a Hydrometer............................................................................................................... K-6

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

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

Repair and Service Manual

Page K-i

[l(

BATTERIES AND CHARGING

Notes: ___________________________

Page K-ii

Repair and Service Manual

______ -ec-t-io-n--l(i -B�_IT_E _ R_ EI _ _ _A N_ _ _ _A _R _G_N G I _ ___ DCH S S SAFETY •

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

•

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

•

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

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

A

WARNING

A

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

A

WARNING

A

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

WRAP WRENCHES WITH VINYL TAPE TO PREVENT THE POSSIBILITY OF A DROPPED WRENCH FROM 'SHORTING OUT' A BATTERY WHICH COULD RESULT IN AN EXPLOSION AND SEVERE PERSONAL INJURY.

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

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

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

Repair and Service Manual

Page K-1

BATTERIES AND CHARGING GENERAL

PORTABLE CHARGER

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

At Each Charging Cycle

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

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

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

MAINTENANCE Tool List

Qty. Required

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

Before charging the batteries, confirm that the ground pin on the AC cord has not been removed, bent or damaged in any manner. Inspect the connector housing of the bat­ tery charger and vehicle connector housing for dirt, debris, signs of misalignment, discoloration or pitting. A deformed housing or one that is broken is an indication of a connector that requires replacement. A deficient con­ nector system may adversely effect the ability of the charger to fully charge the batteries.

Charge the batteries after each day's use.

Monthly •

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

•

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

•

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

•

Clean the batteries and terminations.

O\'lJ@u�

Insulated wrench, 1/2" ................................................. 1 Battery carrier .............................................................. 1 Hydrometer P/N 50900-G1 .......................................... 1 Battery maintenance kit P/N 25587-G01 ..................... 1 Flashlight ..................................................................... 1 Wire brush ................................................................... 1 Lubricant, Stoner K313 P/N 27934-G02 ...................... 1

ONBOARD CHARGER At Each Charging Cycle

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

Every Three Months In addition to each of the monthly inspections, spray the connector, receptacle housing and contacts with Stoner K313 lubricant P/N 27934-G02 and allow 15 minutes dry­ ing before inserting the connector. This lubricant reduces the engagement force required to insert the connector and improves the life of the connector system.

Before charging the batteries, inspect the power (AC) cord for insulation corrosion or deterioration, frayed wires and broken /bent prongs. Confirm that the ground pin has not been removed, bent or damaged in any manner.

(See Fig. K-2 "Water Purity Table" on page K-3)

Charge the batteries after each day's use.

(See Fig. K-3 "Automatic Watering Gun" on page K-3)

Monthly

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

•

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

•

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

•

Clean the batteries and terminations.

Page K-2

Electrolyte Level and Water (See Fig. K-1 "Correct Electrolyte Level" on page K-2)

CAUTION DO NOT OVERFILL BATTERIES.

Repair and Service Manual

BATTERIES AND CHARGING Impurity VENT CAP EXPANSION SPACE �

ij (

1/4" TO 3/8"

.L-J,--""

�-��-

i---

I

PLATES

GAS VENT VENT

___l

--i1/2"

ELECTROLYTE LEVEL SHOULD BE AT LEAST 1/2" ABOVE THE PLATES AND 1/4" TO 3/8" BELOW THE VENT

Fig. K-1 Correct Electrolyte Level A battery being charged will 'gas' with the majority of the gassing taking place at the end of the charging cycle.

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

If the battery electrolyte level is too high, the electrolyte will block the vent tube where the gas will force it out of the vent tube and battery cap. The water will evaporate but the sulfuric acid will remain where it can damage vehicle components. Sulfuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery.

Color Suspended Total Solids Calcium & Magnesium Oxides Iron Ammonia Organic & Volatile Matter Nitrites Nitrates Chloride

Ei!-GDh:£fot•W

5

8 50 5

10 5

Fig. K-2 Water Purity Table Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it does not exceed the impurity levels specified in the table.

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

WATERING GUN SIMILAR TO THE TYPE INCLUDED IN THE E-Z-GO BATTERY MAINTENANCE KIT

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

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

Parts Per Million Clear Trace 100 40

VALVE CONSISTENTLY FILLS TO A PREDETERMINED LEVEL PURE WATER

ELECTROLYTE LEVEL -------SINGLE BATTERY CELL

Fig. K-3 Automatic Watering Gun

Repair and Service Manual

Page K-3

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

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

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

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

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

A

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

In high temperatures the chemical reaction is faster, while low temperatures cause the chemical reaction to slow down. A vehicle that is stored at 90° F will lose .002 Page K-4

0

0

- -� :-&,& h �--% w.::,:, :-:,:,:.:, ¼- ,M fl'X«/l«'"» 0'H.'f'='f"'"f'""'f'"�' E F C : L +15 -9.4 .,_F, c-1-++-r++-++-ir+H-+-+-+-H-+i E i-� +--f-=J!o,·· +-+�H-+--+-+-+-+-+ --1f--+-++-t-l---f C +5 -15 4 -20.6 1:i-i ----"""''•_."'%+, _ -------5 � "' 0 -15 -26.1 tri-_. +-+-+--+-+-+-si-+-+-+-.i,1 1-+-+-+-+-+-++-1-+-ii -t-t-t-+-+-t-1t-t--t-t-tt�t-t--t-1H--t-t-1-t--i L y -25 -31.7 ;r. +-+-++-+-+--iH-+-+-+-'lt:¼- +-+-+-H--H-+i ¾W':,:,:,:,!,

t

··q.·

»m

"�

ll

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

WARNING

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

Although the chemical reaction is slowed in cold temper­ atures, the battery must be stored fully charged, and dis­ connected from any circuit that could discharge the battery. The battery must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge. The battery should be tested or recharged at thirty day intervals.

t-

Prolonged Storage

A

of specific gravity each day. If a fully charged battery has a specific gravity of 1.275, and the battery is allowed to sit unused, it will become partially discharged. When it reaches 1.220 which it will do in less than twenty days, it should be recharged. If a battery is left in a discharged state, sulfation takes place on and within the plates. This condition is not reversible and will cause permanent damage to the battery. In order to prevent damage, the battery should be recharged. A hydrometer can be used to determine the specific gravity and therefore the state of charge of a battery.

i.-l--------lsi ----

""" � -35 -37.2 � i.•. ....+-+-+-+-+--,i -45-42.8 i-i. +-+-+--+-+-+-si-+-+-+-+-+-+-,:;i,,t t\ T E -55 -48.3 +-+-+--+-+-+-si-+-+-+-+-+-++-1ii,-1 +-++-1-+-ii M -65 -54 1-------------

-----------, -+. -ij :1- ·

p

E -75 -59.5 R -85-65

l;,--+-+-+-+-1---+-<1-+-+-+-+-+-+--+-tf--lo-;;';+-· -+-1----1--'/ '

"" T -95 -70.6 ="'*"'"'�""-"'=t=""""'����"*""'1=twim,· •w·

u

1.100

R E

1.140 1.120

1.180

1.160

1.220

1.200

1.260

1.240

1.300

1.280

SPECIFIC GRAVITY

Fig. K-4 Freezing Point of Electrolyte

Repair and Service Manual

EiZliDii=>:;i;{•l:I

BATTERIES AND CHARGING Battery Charging

Battery Installation »

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

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

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

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

A.

WARNING

A.

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

FRONT OF VEHICLE

BL­ FROM POWER HARNESS

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

Before charging, the following should be observed: •

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

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

•

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

•

The charger connector is fully inserted into the vehicle receptacle.

•

The charger connector/cord set is protected from damage and is located in an area to prevent injury that may result from personnel running over or tripping over the cord set.

A.

WARNING A_

TO PREVENT AN ELECTRICAL ARC THAT WILL RESULT FROM DISCONNECTING A LIVE CIRCUIT, WHICH MAY BE HAZARDOUS IN THE PRESENCE OF HYDROGEN GAS, DO NOT DISCONNECT THE CHARGER FROM THE VEHICLE WHILE THE CHARGER IS STILL IN THE CHARGING CYCLE. IF THE CHARGER MUST BE DISCONNECTED WHILE IN THE CHARGING CYCLE, THE AC POWER TO THE CHARGER MUST BE DISCONNECTED FIRST.

AC Voltage BL+ FROM SOLENOID

Fig. K-5 Battery Connections

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

Repair and Service Manual

Page K-5

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

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

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

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

BULB

FLOAT

1175 200 225 250

t

ADD TO FLOAT READING

275

300

SUBTRACT FROM FLOAT READING

i

WEIGHT

Hydrometer (See Fig. K-6 "Hydrometer" on page K-6)

THERMOMETER

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

_A WARNING _A

NEVER INSERT A METAL THERMOMETER INTO A BATTERY. USE A HYDROMETER WITH A BUILT IN THERMOMETER THAT IS . · DESIGNED FOR TESTING BATTERIES. Hydrometers are used to test the state of charge of a bat­ tery cell. This is performed by measuring the density of the electrolyte, which is accomplished by measuring the specific gravity of the electrolyte. The greater the concen­ tration of sulfuric acid, the more dense the electrolyte becomes. The higher the density, the higher the state of charge.

Specific gravity is the measurement of a liquid that is compared to a baseline. The baseline is water which is assigned a base number of 1.000. The concentration of Page K-6

Fig. K-6 Hydrometer sulfuric acid to water in a new vehicle battery is 1.280 which means that the electrolyte weighs 1.280 times the weight of the same volume of.water. A fully charged bat­ tery will test at 1.275 - 1.280 while a discharged battery will read in the 1.140 range.

The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80° F. High quality hydrometers are equipped with an internal ther­ mometer that will measure the temperature of the elec­ trolyte and will include a conversion scale to correct the float reading. It is important to recognize that the electro­ lyte temperature is significantly different from the ambient temperature if the vehicle has been operated.

Using a Hydrometer 1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte

Repair and Service Manual

cK

BATTERIES AND CHARGING [R!]@u@

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.

temperature and note the reading. Examine the color of the electrolyte. A brown or gray coloration indicates a problem with the battery and is a sign that the bat­ tery is nearing the end of its life.

2. Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder.

3. Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float.

4. Add or subtract four points to the reading for every ten degrees F above or below 80°. Adjust the reading to conform with the electrolyte temperature. Eg. If the reading indicates a specific gravity of 1.250 and the

electrolyte temperature is 90° F, add four points to the 1.250 which gives a corrected reading of 1.254. Simi­ larly if the temperature was 70° F, subtract four points from the 1.250 to give a corrected reading of 1.246.

5. Test each cell and note the readings (corrected to 80° F). A variation of fifty points between any two cell readings (example 1.250 - 1.200) indicates a problem with the low reading cell(s).

As a battery ages the specific gravity of the electrolyte will decrease at full charge. T his is not a reason to replace the battery, providing that all cells are within fifty points of each other.

Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should be recharged and the test repeated. If the results indicate a weak cell, the battery or batteries should be removed and replaced with one of the same brand, type and approximate age that is known to be good.

Repair and Service Manual

Page K-7

BATTERIES AND CHARGING

1 1/2 GALLONS CLEARWATER

+ 1/4CUP SODIUM BICARBONATE (BAKING SODA)

NON METALWAND ---\

2 GALLON GARDEN SPRAYER (1 1/2 GALLONS OFWATER)

Fig. K-7 Battery Maintenance Kit

Page K-8

Repair and Service Manual

E'2E5Dii!:tid•l:I

BATTERIES AND CHARGING

of

oC +32 +30 +28 +26

160

71.1

150

65.6

140

60.0

+24

130

54.4

+22 +20

120

48,9

110

43.3

100

37.8

90

32.2

80

26.7

0 -2

70

21.1

-4

60

15.6

50

10

40

4.4

+18 +16 +14 +12 +10 +8 +6 +4 +2

-6

30

-1.1

20

-6.7

10

EXAMPLE#1 TEMPERATURE ABOVE 80° F (26.7° C) HYDROMETER READING 1.240 ELECTROLYTE TEMPERATURE 110° F (43.3° C) 1.240 + .012 = 1.252 CORRECTED SPECIFIC GRAVITY READING

--8 -10 -12 -14

EXAMPLE#2 TEMPERATURE BELOW 80 ° F (26.7° C) HYDROMETER READING 1.270 ELECTROLYTE TEMPERATURE 30 ° F (-1.1 ° C) 1270 - .020 = 1.250 CORRECTED SPECIFIC GRAVITY READING

-16 -18 -20 -22 -24 -26 -28

Fig. K-8 HydrometerTemperature Correction

Repair and Service Manual

Page K-9

BATTERIES AND CHARGING

·I{ ·• ·.· · . . . ·. I

Notes: ___________________________

Page K-10

Repair and Service Manual

eaGCHi=i:ji;M:I

HORN AND ACCESSORY WIRING

Section

TABLE OF CONTENTS FOR SECTION 'N' SECTION TITLE

PAGE NO.

HORN CIRCUIT (IF EQUIPPED) N-1 Testing the Hom Circuit........................................................................................................ N - 1 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 1 CHECK BATTERY CONDITION .............................................................................. N - 1 CHECK WHITE POWER WIRE ................................................................................ N - 1 CHECK FUSE .......................................................................................................... N - 3 CHECK WIRE TO SWITCH ...................................................................................... N - 3 CHECK SWITCH ......................................•............................................................... N - 3 CHECK YELLOW WIRE TO HORN ......................................................................... N - 3 CHECK BLACK WIRE TO HORN ............................................................................ N - 3 N-3 HEADLIGHT AND TAILLIGHT CIRCUIT (IF EQUIPPED) Testing the Headlights and Taillights Circuit ........................................................................ N - 3 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 3 CHECK BATTERY CONDITION .............................................................................. N - 3 CHECK WHITE POWER WIRE ................................................................................ N - 4 CHECK FUSE .......................................................................................................... N - 4 CHECK POWER TO HEADLIGHTS ......•.................................................................. N - 4 ACCESS LIGHT SWITCH ......................•................................................................. N - 4 CHECK WHITE/BLUE WIRE FROM FUSE BLOCK ................................................ N - 4 CHECK LIGHT SWITCH .......................................................................................... N - 5 CHECK WHITE/BLUE WIRE TO HEADLIGHTS ...................................................... N - 5 CHECK WHITE/BLUE WIRE TO TAILLIGHTS ........................................................ N - 5 IF ONE OR MORE LIGHTS ARE OPERATIONAL ................................................... N - 5 BRAKE LIGHT CIRCUIT (IF EQUIPPED) N-5 Testing the Brake Light Circuit ............................................................................................. N - 5 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 5 CHECK BATTERY CONDITION .............................................................................. N - 5 CHECK WHITE POWER WIRE ................................................................................ N - 5 CHECK FUSE .......................................................................................................... N - 6 CHECK FUNCTION OF BRAKE PEDAL MICRO SWITCH (MECHANICAL BRAKES ONLY)I ........................................................................................................ N - 6 CHECK PARK BRAKE MICRO SWITCH (MECHANICAL BRAKES ONLY) ............ N - 6 CHECK BROWN WIRE ............................................................................................ N - 6 REPLACE LAMP ...................................................................................................... N - 6 IF ONLY ONE BRAKE LIGHT IS INOPERATIVE .................................................... N - 6 N-6 TURN SIGNALS AND FLASHER CIRCUIT (IF EQUIPPED) Testing the Tum Signal/Flasher Circuit ................................................................................ N - 6 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 6 CHECK BATTERY CONDITION ......................... : .................................................... N - 6 CHECK WHITE POWER WIRE ................................................................................ N - 8 CHECK FUSE .......................................................................................................... N - 8 CHECK FLASHER ................................................................................................... N - 8 CHECK TURN SIGNAL CONNECTOR .................................................................... N - 8 IF LEFT, RIGHT OR EMERGENCY FLASHER WORKS ......................................... N - 8 N-8 HOUR METER CIRCUIT (IF EQUIPPED) Testing Hour Meter Circuit.................................................................................................... N - 8 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 8 RAISE VEHICLE ...................................................................................................... N - 8 CHECK BATTERY CONDITION .............................................................................. N - 8 CHECK HOUR METER ............................................................................................ N - 9 STATE OF CHARGE METER (IF EQUIPPED) N-9 Testing State of Charge Meter Circuit .................................................................................. N - 9 CHECK FOR LOOSE OR BARE WIRES ................................................................. N - 9 CHECK BATTERY CONDITION .............................................................................. N - 9 CHECK STATE OF CHARGE METER ..................................................................... N - 9

Eil!HiDii:f:frM/1

Repair and Service Manual

Page N-i

-----------HO _R _N_ _ N_ _ _ _ _ _ S_SO_ R_ _ _ R_ _N_ _ Y WI I G A DACCE N TABLE OF CONTENTS FOR SECTION 'N' (CONT.) SECTION TITLE

PAGE NO.

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

VOM .................................................................................................................................. N -1 Accessory Harness Power Connection ............................................................................ N - 1 Wiring Diagram (Mechanical Brakes) ............................................................................... N - 2 Wiring Diagram (Hydraulic Brakes) .................................................................................. N - 3 Headlight Connector ......................................................................................................... N - 4 Key/Light Switch ............................................................................................................... N - 4 Brake Pedal Micro Switch Operation ................................................................................ N - 7 State of Charge Meter ...................................................................................................... N - 9

Page N-ii

Repair and Service Manual

EiEE50iit:ii;{•l:I

HORN AND ACCESSORY WIRING

*

The VOM shown and recommended is available through the E-Z-GO Service Parts Department as P/N 27481G01. For the purpose of this section, the red probe (+) and black probe (-) are used. Any digital VOM may be used, however the controls, displays, accuracy and fea­ tures may vary depending on the make and model.

Always follow the meter manufacturer's recommenda­ tions and instructions for the use and care of the meter.

GRN

,.

Fig. N-2 Accessory Harness Power Connection

88.81

1. CHECK FOR LOOSE OR BARE WIRES Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT.

Ill

CilO

m· o

2. CHECK BATTERY CONDITION

00 00

lSlli3

FRONT OF VEHICLE

(See Fig. N-1 "VOM" on page N-1)

{530 .

(See Fig. N-2 '�ccessory Harness Power Connection" on page N-1)

Check for adequate battery volts(nominal 12 VDC) by setting VOM to 30 VDC range and place the red probe (+) on the battery post with the white wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 VDC or greater indicates adequate battery condition. No reading indicates(a) a poor connection between the probes and the battery terminals; (b) a faulty VOM; (c) broken wire or I oose terminals. A voltage reading below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

Fig.:_N-1 VOM

HORN CIRCUIT (IF EQUIPPED) The horn circuit is a 12 volt system and consists of a horn switch, fuse block, fuse, horn and accessory wiring harness.

When the horn switch is depressed, the horn circuit is completed permitting current to flow from the battery to the fuse and through the horn causing it to sound. The horn will operate if the key switch is in either the 'ON' or 'OFF' position.

Testing the Horn Circuit Tool List

[�J.@u�

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

3. CHECK WHIT E POWER WIRE Firmly attach the black probe (-) to the battery post with the black wire attached and the red probe(+) to the white terminal at the fuse block. A reading of bat­ tery voltage indicates that the white wire is in good condition.

Qty. Required

VOM, digital ................................................................... 1

The white wire su

Repair and Service Manual

U\{]@u�

lies power to the entire fuse block.

Page N-1

HORN AND ACCESSORY WIRING

DRIVER'S SIDE TURN SIGNAL � WHT

PASSENGER SIDE

�

HEADLIGHT

HEADLIGHT

BLK

FROM --KEY SWITCH (FIBERGLASS VEHICLES O NLY)

BLU

BLU

YT

BLK -------WHT/BLU-------

- GAN+BLK �

BLK

STATE OF CHARGE

RED

�

1r "t*

lr "tl

RrDY BLK

�

!

+.

J WHT/BLU

TURN SIGNAL

T

T GRN B K ,

GRN -------

BLK

-- --+----BLK-----'

WHT/BLU�')--- -1------WHT/BLU-----------, LIGHT SWITCH

--+--------RED -----+---er 0-WHT--0--0-----BRN- -l---e PARK BRAKE BRAKE SWITCH LIGHT SWITCH NO NC WHT/BLU I WHT/BLU \ I ...__.____,__ RED µ,WHT/YEL ) ',

JI

WHT/GRN

BLK

WHT

HORN SWITCH

BAN

HORN

RED-0 ___[_ 0--Ya -9--- BLK----.

...------+----------------------BRN-------�------�-­ a-----+-------------------BLK ...---i-----+-------WHT/BLU--------------+-----

1L

1 Bx i 1'

BAN WHT/

L·uTu t

TURN BRAKE TAIL SIGNAL LIGHT LIGHT

SPARE ;::--v10

RED �0--VIO---- -- ---, REVERSE WARNING l MICRO SWITCH

t 1'

�

w!rj

�

W T

BACK UP LIGHT

"' Tl

�

t

T

��ffO) + �

BACK UP LIGHT

iA

BAN WHT

SPARE

,T

TAIL BRAKE TURN LIGHT LIGHT SIGNAL

Fig. N-3 Wiring Diagram (Mechanical Brakes)

Page N-2

Repair and Service Manual

eamcHi=i:ii;t-i:1

HORN AND ACCESSORY WIRING probe (+) to the terminal of the black wire. A reading of .00 or less than .02 ohms indicates that the black wire is in good condition. All wiring has now been checked; therefore the horn is faulty. Replace with a good horn.

WIRING DIAGRAM FOR VEHICLES EQUIPPED WITH HYDRAULIC BRAKES SAME AS FIG. N-3 EXCEPT DIFFERENT BRAKE SWITCHES AS NOTED BELOW:

7

1

-wHT-O�O--a<

++

HYDRAULIC BRAKE PRESSURE SWITCH NO

.l

BRN

RED WHT/YEL

WHTJ-

I

r+;:j-WHT/GRN

HEADLIGHT AND TAILLIGHT CIRCUIT (IF EQUIPPED) The headlight and taillight circuit is a 12 volt system and consists of a light switch either incorporated in the key switch or separately mounted on the dash panel, fuse block, fuse, headlights, taillights and accessory wiring harness.

When the light switch is turned on the circuit is com­ pleted, permitting current to flow from the battery to the fuse and through the lights causing them to illuminate.

Testing the Headlights and Taillights Circuit Tool List

Qty. Required

VOM, digital .................................................................... 1 Fig. N-4 Wiring Diagram (Hydraulic Brakes) 4. CHECK FUSE Place the red probe(+) to the red wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a faulty fuse; replace with a good 15 amp fuse.

5. CHECKWIRE TO SWITCH Place the red probe (+) to the red connection at the horn switch. A reading of battery voltage indicates that the red wire supplying power to the switch is in good condition. If no reading is indicated, the red wire is faulty.

6. CHECK SWITCH

°

Place the red probe(+) to the other horn switch termi­ nal (yellow wire) and depress horn switch button. A reading of battery voltage indicates a good switch. No reading indicates a faulty switch; replace it with a good horn switch.

7. CHECKYELLOW WIRE TO HORN Place the red probe (+) to the horn terminal with the yellow wire. Depress horn button. A reading of bat­ tery voltage indicates a good yellow wire. No reading of battery voltage indicates a faulty yellow wire.

8. CHECK BLACKWIRE TO HORN Remove the black wire from the horn. Select continu­ ity (K ohms) 1 position on the VOM. Place the red

If the vehicle runs but the headlights and taillights are inoperative, proceed to Step 1. If any lights are functional, proceed to Step 11.

1. CHECK FOR LOOSE OR BARE WIRES Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT.

[K!]@u[g

If any VOM readings indicate a faulty wire, it is recom­ mended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct com­ ponents and wire tied to the harness bundle. The faulty wire should be cut back close ·to the harness and the ends pro­ tected with vinyl electrical tape.

2. CHECK BATTERY CONDITION (See Fig. N-1 "VOM" on page N-1) (See Fig. N-2 "Accessory Harness Power Connection" on page N-1)

Check for adequate battery volts(nominal 12 VDC) by setting VOM to the 30 VDC range and place the red probe (+) on the battery post with the white wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 or better indicates adequate battery condition. No read­ ing indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty VOM; (c) broken wire or loose terminals. A voltage reading

Repair and Service Manual

voe

Page N-3

I HORN AND ACCESSORY WIRING below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

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 accept­ 1� ·; able.

\

. . ""

]

'A'.

NJ·<·

'i,,,

'_;.�

age is indicated then the light switch is good and the bulb must be replaced. If NO voltage is indicated then the switch is suspect and must be checked.

6. ACCESS LIGHT SWITCH On the fiberglass vehicles, drive out the plastic push rivets on the key switch plate and pull out the key/light switch plate. For the metal body vehicles, remove four screws securing the dash housing for accessabil­ ity.

3. CHECK WHITE POWER WIRE Firmly attach the black probe (-) to the battery post with the black wire attached to perform Steps 3 through 4 and the red probe(+) to the white terminal at the fuse block. A reading of battery voltage indi­ cates that the white wire is in good condition.

KEY/LIGHT SWITCH FIBERGLASS BODY VEHICLES

�-•BLU FROM CONTROL HARNESS

i This wire suoolies pow�o�!!re fuse block.

4. CHECK FUSE Place the red probe(+) to the white/blue wire terminal on the fuse block. A reading of battery voltage indi­ cates that the fuse is in good condition. No reading indicates a faulty fuse, replace with a good 15 amp fuse.

�---WHT/BLU FROM ACCESSORY HARNESS

GRN FROM STATE OF CHARGE METER

i

5. CHECK POWER TO HEADLIGHTS (See Fig. N-4 "Headlight Connector" on page N-4)

BLU FROM CONTROL HARNESS

LIGHT SWITCH METAL BODY VEHICLES

WHT/BLU TO HEADLIGHTS

RED PROBE(+) TO WHITE/BLUE WIRE TERMINAL

.&

BLACK PROBE(-) TO BLACK WIRE TERMINAL

FROM�J: �LOCK L

Fig. N-6 Key/Light Switch 7. CHECK WHITE/BLUE WIRE FROM FUSE BLOCK (See Fig. N-5 "Key/Light Switch" on page N-4)

Fig. N-5 Headlight Connector Turn lights on and disconnect both connectors at one headlamp. Place the red probe (+) to the white/blue wire end and the black probe(-) to the black wire end of the harness going to the headlamps. If battery voltPage N-4

With the key switch 'OFF', place the red probe(+) to the white/blue connections at the key switch and the black probe(-) to the battery post with the black wire attached to perform steps 7 - 11. A reading of battery voltage from one of these connections indicates that the white/blue wire from the fuse is in good condition.

Repair and Service Manual

E.Zl3Dii:S:ji;M:I

HORN AND ACCESSORY WIRING If no battery voltage is indicated, the white/blue wire from the fuse is faulty and must be replaced.

If the vehicle runs but the brake lights are inopera­ tive, proceed to Step 1. If any lights are functional proceed to Step 9.

8. CHECK LIGHT SWITCH

1. CHECK FOR LOOSE OR BARE WIRES

Place the red probe(+) to the white/blue wire terminal that did not have voltage and turn the key switch to lights. An indication of battery voltage indicates a good key switch. No voltage indicates a faulty switch.

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT.

9. CHECK WHITE/BLUE WIRE TO HEADLIGHTS

2. CHECK BATTERY CONDITION

Turn lights on and move the red probe(+) to each of the white/blue wire terminals at the connections of the headlights. If no battery voltage is shown, it indicates that the white/blue wire is faulty and must be replaced. The white/blue wires are joined internally in the harness. One may be faulty and the other good.

(See Fig. N-1 "VOM" on page N-1) (See Fig. N-2 "Accessory Harness Power Connection" on page N-1)

Check for adequate battery volts (nominal 12 VOC) by setting VOM to the 30 voe range and place the red probe (+) on the battery post with the white wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 voe or better indicates adequate battery condition. No read­ ing indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty VOM; (c) broken wire or loose terminals. A voltage reading below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

1O. CHECK WHITE/BLUE WIRE TO TAILLIGHTS Turn lights on and place the red probe (+) at the white/blue wire connections at the taillights. If battery voltage is not indicated, the white/blue wire is faulty and must be replaced.

11. IF ONE OR MORE LIGHTS ARE OPERATIONAL Check for faulty wiring or a faulty bulb. Turn lights on and check for battery voltage at each of the white/ blue terminals at the headlights and taillights. Place the red probe(+) on the white/blue wire terminals and the black probe (-) on the battery post with the black accessory harness wire attached. A reading of battery voltage indicates that either the socket is corroded or faulty, or that the bulb is faulty. Replace the bulb after inspecting the socket and reconnect the wiring.

�@u�

Due to the resistance of the wires involved within the har­ ness, voltage readings may be somewhat lower than battery , voltage. A reading of 1 volt below battery voltage is accept­ ;;; able.

3. CHECK WHITE POWER WIRE

BRAKE LIGHT CIRCUIT (IF EQUIPPED) The brake light circuit is a 12 volt system and consists of a fuse block, fuse, brake lights and an accessory wiring harness. Vehicles with mecbanical brakes also have a brake pedal micro switch and a park brake micro switch.

Vehicles with hydraulic brakes have a pressure switch located on the master cylinder.

When the service brake pedal is depressed, the brake pedal micro switch or the pressure switch is activated.

This completes the brake light circuit and permits current to flow to the brake lights. The brake lights will operate if the key switch is in either the 'ON' or 'OFF' position.

Testing the Brake Light Circuit Tool List

Qty. Required

VOM, digital ................................................................... 1

Firmly attach the black probe (-) to the battery post with the black wire attached to perform Steps 3 and 4 and the red probe(+).to the white terminal at the fuse block. A reading of battery voltage indicates that the white wire is in good condition.

�

The white wire suoolies��r!;e entire fuse block.

�@u�

If any VOM readings indicate a faulty wire, it is recom­ mended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct com­ ponents and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends pro­ tected with vinyl electrical ta

Repair and Service Manual

Page N-5

I HORN AND ACCESSORY WIRING 4. CHECK FUSE

9. IF ONLY ONE BRAKE LIGHT IS INOPERATIVE

Place the red probe(+) to the red wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a faulty fuse, replace with a good 15 amp fuse.

5. CHECK FUNCTION OF BRAKE PEDAL MICRO SWITCH (MECHANICAL BRAKES ONLY)I Depress service brake pedal and listen for audible click from micro switch. Release pedal and listen for an audible click. An audible click in both the up and down pedal positions indicates a correct micro switch adjustment. If the switch is not activated and released correctly, it may be adjusted by loosening the two bolts that secure the micro switch and moving the switch until the appropriate adjustment is achieved. If the switch is in correct adjustment and the brake lights are not activated, it is necessary to check for correct switch function. With the service brake pedal depressed, perform a check of the service brake micro switch. If no power is indicated, replace the switch. If power is indicated, check for faulty wiring or components.

6. CHECK PARK BRAKE MICRO SWITCH (MECHANI­ CAL BRAKES ONLY) Set the VOM to the 30 voe range and attach the black probe (-) to the negative battery post with the black wire attached. Place the red probe (+) to the micro switch terminal with the brown wire attached.

Depress the brake pedal. A reading of battery voltage indicates that the park brake micro switch is operating correctly. If no voltage is indicated, the micro switch must be tested. Move the red probe (+) to the park brake micro switch terminal with the white wire attached. A reading of battery voltage indicates that the white wire is in !;!OOd conpition.

7. CHECK BROWN WIRE Move to the rear of the vehicle and access the tail­ lights. Move the red probe(+) to the brake light con­ nector at the brown wire. Depress the service brake.

A reading of battery voltage indicates that the brown wire is in good condition. No voltage indicates the brown wire is faulty. Replace. Check both brake lights. If either brake light does not come on, test the bulb. If bulb is good, inspect/replace light socket.

8. REPLACE LAMP Unplug the lamp from the plug and replace with new bulb. Replace all wires disconnected in the test.

Page N-6

The overall system is functional; therefore the follow­ ing steps should be followed. Assure that the brown wire from the harness is attached to the brown wire from the inoperative lamp plug. If the lamp still fails to light when the brake pedal is depressed, separate the brown wire from the lamp connector. Select the 30 voe range of the VOM. Place the red probe(+) to the brown wire and the black probe (-) to the black wire connection at the battery. Depress the brake pedal. A reading of battery voltage indicates that the lamp is faulty. Replace lamp and reconnect all wires discon­ nected in the test.

TURN SIGNALS AND FLASHER CIRCUIT (IF EQUIPPED) The turn signal and flasher is a 12 volt system and con­ sists of a turn signal/flasher switch, fuse block, fuse, front and rear lamps and an accessory wiring harness.

When the turn signal/flasher switch is activated, the cir­ cuit is completed permitting current to flow from the bat­ tery to the fuse and through the flasher causing the appropriate lights to flash. The turn signal/flasher will operate if the key switch is in either the 'ON' or 'OFF' position.

Testing the Turn Signal/Flasher Circuit Tool List

Qty. Required

VOM, digital .................................................................... 1 If the vehicle runs but all turn signals and flasher are inoperative, proceed to Step 1. If any lights are func­ tional proceed to Step 7.

1. CHECK FOR LOOSE OR BARE WIRES Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. CHECK BATTERY CONDITION (See Fig. N-1 "VOM" on page N-1) (See Fig. N-2 "Accessory Harness Power Connection" on page N-1)

Check for adequate battery volts (nominal 12 VDC) by setting VOM to the 30 voe range and place the red probe (+) on the battery post with the white wire attached. Place the black probe(-) on the battery post with the black wire attached. A reading of 11 voe or better indicates adequate battery condition. No read­ ing indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty VOM; (c) broken wire or loose terminals. A voltage reading

Repair and Service Manual

HORN AND ACCESSORY WIRING

NORMAL DRIVING POSITION

NO MICRO SWITCH IN CLOSED POSITION WITH PARK BRAKE DISENGAGED PARK BRAKE

FLOORBOARD

t

� --BLK FROM BRAKE SWITCH WIRE HARNESS NC MICRO SWITCH IN OPEN POSITION BRAKING POSITION PRESSURE

NO MICRO SWITCH IN CLOSED POSITION WITH PARK BRAKE DISENGAGED PARK BRAKE

t

��ro

J

--BLK FROM BRAKE SWITCH WIRE HARNESS

,\� '/' 1'

B8:--::--q)�

NC MICRO SWITCH IN CLOSED POSITION- BRAKE LIGHTS ACTIVATED

Fig. N-7 Brake Pedal Micro Switch Operation

EiZliDh½:ii;M:•

Repair and Service Manual

Page N-7

HORN AND ACCESSORY WIRING below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

i

W

@u � � Due to the resistance of the wires involved within the har­

ness, voltage readings may be somewhat lower than battery voltage. A reading of 1 volt below battery voltage is accept­ able.

3. CHECK WHITE POWER WIRE Firmly attach the black probe (-) to the battery post with the black wire attached to perform Steps 3 through 4 and the red probe(+) to the white terminal at the fuse block. A reading of battery voltage indi­ cates that the white wire is in good condition.

�@u�

The white wire supplies oower to the entire fuse block.

�@u�

If any VOM readings indicate a faulty wire, it is recom­ mended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct com­ ponents and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends pro­ tected with vinyl electrical tape. '

7. IF LEFT, RIGHT OR EMERGENCY FLASHER WORKS Select the 30 VDC range of the VOM. Place the black probe (-) to the black wire connection at the negative post of the battery and place the red probe(+) to: Left front ....................................................Red wire Left rear .................................................. Yellow wire Right front............................................... Green wire Right rear ................................................ White wire Turn on the appropriate turn signal. A pulsating read­ ing of the battery voltage indicates that power is avail­ able to the light, therefore, the light module is faulty. If no voltage is present a faulty wire is indicated.

HOUR METER CIRCUIT (IF EQUIPPED) The hour meter circuit is a 36 volt system for electric vehicles. It consists of a hour meter and an accessory wiring harness.

The hour meter will only operate when the vehicle is run­ ning.

Testing Hour Meter Circuit

4. CHECK FUSE Place the red probe(+) to the red wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a faulty fuse, replace with a good 15 amp fuse.

5. CHECK FLASHER The flasher is located behtnq the four cup console on the fiberglass body vehicles. It should be accessable without removing the console. ·The flasher is located behind the dash housing on the metal body vehicles.

Remove the four screws securing the housing to the dash for accessability. Remove the flasher from its socket. Select K ohms (continuity) position on the VOM. Place the red probe (+) on one of the flasher terminals and the black probe (-) on the other flasher terminal. A reading of .00 to .20 indicates that the flasher is in good condition. Inspect the flasher socket for corrosion before replacing the flasher.

6. CHECK TURN SIGNAL CONNECTOR Separate the harness to turn signal connector and inspect for corrosion and correct placement of pins Page N-8

and sockets in the connector housing. Check that the black wire from the flasher socket is attached to the red wire from the harness and the yellow wire from the flasher is attached to the turn signal. If the system does not function after the above check, the turn sig­ nal switch must be replaced.

Tool List

Qty. Required

VOM, digital .................................................................... 1 If the vehicle runs but the hour meter is inoperative: 1. CHECK FOR LOOSE OR BARE WIRES Check for loose wires at each terminal connection and for worn insulation ot bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. RAISE VEHICLE Raise the vehicle (see Safety procedures in Section B) 3. CHECK BATTERY CONDITION Check for adequate battery volts (nominal 36 VDC) by setting VOM to 36 VDC range to 300 VDC range, unplug the yellow and black wires from the rear of the hour meter. Place the black probe (-) on the black wire terminal. Place the red probe (+) on the yellow wire terminal. Turn key switch to ON and depress accelerator pedal. A reading of 31.5 VDC or better

Repair and Service Manual

E�l3Dii=>:fo!•W

HORN AND ACCESSORY WIRING

A

WARNING

A

TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LISTING PROCEDURE IN SECTION "B" OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF AND BEHIND THE REAR WHEELS AND CHECK THE STABILITY OF THE VEHICLE ON THE JACK STANDS BEFORE STARTING ANY REPAIR PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE. THIS TEST WILL CAUSE VEHICLE WHEELS TO TURN. BE SURE THAT VEHICLE IS ADEQUATELY SUPPORTED WITH BOTH REAR WHEELS CLEAR OF FLOOR. KEEP CLEAR OF ROTATING WHEELS. CLOTHING BECOMING TRAPPED BY WHEEL i COULD CAUSE SERIOUS PERSONAL INJURY. indicates adequate battery condition. No reading indi­ cates (a) a poor connection between the probes and the terminals; (b) a faulty VOM; (c) broken wire or loose terminals. A voltage reading below 31.5 volts indicates poor battery charge and the vehicle should be recharged before proceeding with the test.

4. CHECK HOUR METER If battery voltage is in excess of 31.5 VDC and the hour meter does not function, the hour meter should be replaced being careful to rewire with black to the negative terminal (-) and yellow to the positive termi­ nal(+).

STATE OF CHARGE METER (IF EQUIPPED) The state of charge circuit is a 36 volt system and con­ sists of a state of charge meter and accessory wiring har­ ness and indicates the charge condition of the battery set. The state of charge meter will only operate if the key switch is in the 'ON' or 'LIGHT' position.

frame. BARE WIRES MAY CAUSE A SHORT CIR­ CUIT. 2. CHECK BATTERY CONDITION With the key switch on, check for adequate battery volts (nominal 36 VDC) by setting VOM to 36 VDC range, unplug the wires from the rear of the state of charge meter. Place the red probe (+) on the green wire terminal. Place the black probe (-) on the black wire terminal. A reading of 36 VDC ± 2V or better indi­ cates adequate battery condition. No reading indi­ cates (a) a poor connection between the probes and the battery terminals; (b) a broken wire in the har­ ness; (c) a faulty VOM. A voltage reading below 34 volts indicates poor battery charge and the vehicle should be recharged before proceeding with the test.

3. CHECK STATE OF CHARGE METER If battery voltage meets the criteria specified and the state of charge meter does not function, the state of charge meter should be replaced. Metal body vehi­ cles are to be rewired with black to the negative termi­ nal and green to the positive terminal. Fiberglass body vehicles are to be rewired with the green wire to terminal 1, the black wire to terminal 2 and the wire from the key switch to terminal 4.

METAL BODY VEHICLES

GRN ==�i!T (FROM BATTERY 36V)

Testing State of Charge Meter Circuit Tool List

�-H---BLK (GROUND)

FIBERGLASS BODY VEHICLES BLK (GROUND)

Qty. Required

VOM, digital ................................................................... 1

If the vehicle runs but the state of charge meter is inoperative: 1. CHECK FOR LOOSE OR BARE WIRES Check for loose wires at each terminal connection and for worn insulation or bare wires touching the

Repair and Service Manual

----TO KEY SWITCH

Fig. N-8 State of Charge Meter Page N-9

HORN AND ACCESSORY WIRING Notes: ___________________________

Page N-10

Repair and Service Manual

..----------D I REAR SUSPENSION

Section

LJ

TABLE OF CONTENTS FOR SECTION 'P' SECTION TITLE REAR SUSPENSION

PAGE NO. P -1

p -1 GENERAL Shock Absorber Removal ......................................................................................................P - 1 Shock Absorber lnstallation ...................................................................................................P - 1 Rear Spring Removal ............................................................................................................P -1 Rear Spring Installation .........................................................................................................P - 2

LIST OF ILLUSTRATIONS Fig. P-1 Shock Absorber Removal ..................................................................................................P -1 Fig. P-2 Rear Spring Removal ........................................................................................................ P -2

Repair and Service Manual

Page P-i

REAR SUSPENSION Notes: _____________________________

Page P-ii

Repair and Service Manual

eamt:11,,.;u.i-i:1

..------�n �

I REAR SUSPENSION

Section

REAR SUSPENSION

Compress the shock absorber (item 2) and remove the top shock absorber nut (item 4).

Remove the shock absorber (item 2).

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

GENERAL (See Fig. P-2 "Rear Suspension" on page P-3)

Tool List

Qty. Required

Wheel chocks.............................................................. 4 Jack stands ................................................................. 4 Floor jack .................................................................... 1 Wrench, closed end, 9/16" .......................................... 1 Socket, 9/16" ............................................................... 1 Wrench, closed end, 15/16" ........................................ 1 Socket, 15/16" ............................................................. 1 Torque wrench, 1/2" .................................................... 1 T he rear suspension consists of the rear axle and attach­ ments that secure it to the springs and shock absorbers.

Rear axle removal is covered in Section R.

Shock Absorber Removal (See Fig. P-2 "Rear Suspension" on page P-3)

A

WARNING

A

TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LIFTING PROCEDURE IN SECTION B OF THIS MANUAL. PLACE WHEEL CHOCKS IN FRONT OF .AND BEHIND THE FRONT WHEELS AND CHECK THE STABILITY OF THE VEHICLE ON THE JACK STANDS BEFORE STARTING ANY REPAIR PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE. Raise the rear of the vehicle in accordance with the instructions provided in Section B (Safety) of this manual and support the rear of the vehicle on the outer ends of the rear bumper.

Remove the hardware (item 1) securing the shock absorber (item 2) to the bracket welded to the rear axle (item 3).

Fig. P-1 Shock Absorber Removal

Shock Absorber Installation (See Fig. P-2 "Rear Suspension" on page P-3)

Shock absorber installation is in the reverse order of dis­ assembly except that the shock absorber nut (item 4) located at the top must be tightened until the shock absorber bushings (item 5) expand to the diameter of the shock absorber washer (item 6).

Rear Spring Removal (See Fig. P-2 "Rear Suspension" on page P-3)

Remove the nuts (item 7) and 'U' bolts (item 8) securing the spring (item 9) to the axle.

Repair and Service Manual

Page P-1

!l�R_ E_AR�S_U_SP _ E _ S_N_I_O______________ _N � Rear Spring Installation

[K!]@u�

i

The shock absorber does not have to be removed to replace 1 : spring.

If both springs are to be replaced and the rear axle is not to be removed, it is important to remove and replace one spring at a time.

Support the rear axle with jack stand to prevent axle from completely extending the shock absorber. This will be advan­ tageous for the spring installation process.

(See Fig. P-2 "Rear Suspension" on page P-3)

Spring installation is in the reverse order of disassembly.

Tighten all hardware to 21 - 25 ft. lbs. torque.

[K!]@u�

The hardware may be assembled either toward the inside or outside of vehicle, but the spring shackle with the larger hole must be on the side that the shoulder bolt is inserted.

Remove the hardware (item 10), spring shackles (item 11) and bushings (item 12) toward the rear of the vehicle.

Remove the mounting hardware (item 13) and washers (item 14) toward the front of the vehicle.

Remove the spring (item 9).

MOUNTED TO WELDED BRACKET ON FRAME

Fig. P-2 Rear Spring Removal

Page P-2

Repair and Service Manual

eamc1,,.:,i;t-i:1

•

_ __ _ _ _ ;,.- _ S-ec-tt-o . -n-.... . . ,.. "� R E A R A X L E _____________ TABLE OF CONTENTS FOR SECTION 'R' SECTION TITLE

PAGE NO.

REAR AXLE ASSEMBLY REMOVAL

R -1

REAR AXLE ASSEMBLY INSTALLATION

R -1

REAR AXLE DISASSEMBLY R-2 Axle Shaft Removal and Disassembly ................................................................................. R - 2 Axle Shaft Seal Removal and Replacement ........................................................................ R - 3 Axle Shaft Replacement ....................................................................................................... R - 4

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

E�lit:ni=f:ii;M:1

Rear Axle Removal........................................................................................................... R -1 Motor Wiring ..................................................................................................................... R -1 Removing/Installing Outer Snap Ring .............................................................................. R - 2 Removing/Installing Axle Shaft ......................................................................................... R - 2 Pressing Bearing from Axle Shaft..................................................................................... R - 3 Removing/Installing Inner Snap Ring ............................................................................... R - 3 Removing Seal ................................................................................................................. R - 3 Installing Seal ................................................................................................................... R - 4 Cut Away of Outer Bearing and Brake Drum ..........•......................................................... R - 4

Reapir and Service Manual

Page R-i

-r:R --------------- - _ _ _ _ _ RE A R A LE---, X Notes: ______________________________

Page R-ii

Repair and Service Manual

E.ZGCii½:iiit•):1

...-R_E_A_R_A _X_LE_____________ _e_ct-io_n_

S

For further axle information, see Electric Rear Axle Manual E-Z-GO P/N 28147-G01.

''T' connection on the axle housing. Drain fluid and dis­ card. Bleeding the hydraulic brakes is madatory.

REAR AXLE ASSEMBLY REMOVAL

Remove the wires to the motor, being careful to prevent the axle assembly (item 1) from rotating. Remove the hardware (item 2) securing the bottom of the shock absorber (item 3) to the axle. Remove the 'U' bolt hard­ ware (item 4).

(See Fig. R-1 "Rear Axle Removal" on page 1).

Qty. Required

Tool List

Wrench, open end, 1/2" .............................................. 1 Wrench, open end, 9/16" ............................................ 1 Jack ............................................................................. 1 Jack stands ................................................................. 4 Chocks ........................................................................ 4 Remove the cargo deck to gain access to the motor and axle.

Loosen both rear wheel and tire assemblies by loosening each lug nut approximately one turn.

Lift the rear of the vehicle according to lifting procedure in Section B. Place two additional jack stands under the rear axle to support the axle when hardware is removed.

A

1

!' f' !

l

R

WARNING

The rear axle and motor assembly can now be lifted from the jack stands and lowered to the floor.

Removing the rear axle assembly will require the use of an overhead hoist that can support the motor. The position of the motor will cause the rear axle assembly to rotate when the 'U' bolts (item ) are removed. If no hoist is available, the motor may be held in position by a second person. With the springs removed, both persons can lift the entire assembly from the jack stands and lower it to the floor.

A

TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, FOLLOW THE LIFTING PROCEDURE IN SECTION B 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 THE PROCEDURE. NEVER WORK ON A VEHICLE THAT IS SUPPORTED BY A JACK ALONE. THE REAR AXLE ASSEMBLY IS TOP HEAVY. TO REDUCE THE POSSIBILITY OF PERSONAL INJURY WHILE REMOVING THE REAR AXLE, BE SURE TO SUPPORT THE AXLE AND MOTOR ASSEMBLY WHEN REMOVING THE SPRINGS. IF NO LIFTING DEVICE IS AVAILABLE, A SECOND PERSON SHOULD HOLD THE MOTOR IN THE CORRECT POSITION UNTIL THE SPRINGS ARE REMOVED. BOTH PERSONS SHOULD REMOVE THE REAR AXLE AND MOTOR ASSEMBLY.

Disable the electrical system to the motor by turning the key switch to the 'OFF' position and remove battery wire.

Disconnect the brake cables from their actuating levers.

Disconnect the hydraulic brake line (if equipped) at the

Fig. R-1 Rear Axle Removal

REAR AXLE ASSEMBLY INSTALLATION (See Fig. R-2 "Motor Wiring" on page R-1)

Tool List

Qty. Required

Torque wrench, in. lbs ................................................. 1

Repair and Service Manual

Page R-1

REAR AXLE Installation is in the reverse order of disassembly. Tighten motor terminal hardware to 66 in. lbs torque.

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

MOTOR TERMINAL

FROM

S1

DIRECTION SELECTOR B

S2

DIRECTION SELECTOR D

Axle Shaft Removal and Disassembly

A1

SOLENOID

(See Fig. R-3 "Removing/Installing Outer Snap Ring" on page R-2)

A2

SPEED CONTROLLER A2

(See Fig. R-4 "Removing/Installing Axle Shaff' on page R-2) (See Fig. R-5 "Pressing Bearing from Axle Shaft" on page R-3) (See Fig. R-9 "Cut Away of Outer Bearing and Brake Drum" on page R4)

Fig. R-2 Motor Wiring

Tool List

Qty. Required

Arbor press .................................................................. 1 Pliers, needle nose ........•............................................. 1

Pliers, snap ring, internal ............................................. 1

REAR AXLE DISASSEMBLY

A

A

WARNING

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

Slide hammer, E-Z-GO P/N 18753-G1 ........................ 1 F or BRAKE DRUM REMOVAL, see page E-4.

Remove the outer snap ring from the axle tube. (Ref. Fig. R-3)

CAUTION THE REAR AXLE/MOTOR IS A PRECISION : ASSEMBLY, AND THEREFORE ANY REPAIR OR � REPLACEMENT OF PARTS MUST BE DONE WITH .

EXTREME CARE IN A CLEAN ENVIRONMENT. BEFORE ATTEMPTING TO PERFORM ANY SERVICE ON THE AXLE, READ AND UNDERSTAND , ALL OF THE FOLLOWING TEXT AND i ILLUSTRATIONS BEFORE ADJUSTING OR DISASSEMBLING THE UNIT. SNAP RINGS MUST BE REMOVED/INSTALLED WITH CARE TO PREVENT DAMAGE OF BEARINGS, SEALS AND BEARING BORES.

Page R-2

Fig. R-3 Removing/Installing Outer Snap Ring Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube. (Ref. Fig. R-4)

Repair and Service Manual

E.ZliDii=i:iiiM:I

REAR AXLE Axle Shaft Seal Removal and Replacement (See Fig. R-6 "Removing/Installing Inner Snap Ring" on page R-3) (See Fig. R-7 "Removing Seal" on page R-3) (See Fig. R-8 "Installing Seal" on page R-4) (See Fig. R-9 "Cut Away of Outer Bearing and Brake Drum" on page R4)

Qty. Required

Tools List

Pliers, snap ring, internal ............................................. 1 Puller, seal ................................................................... 1 Seal installer ................................................................ 1 Hammer, ball pein ....................................................... 1

CAUTION

Fig. R-4 Removing/Installing Axle Shaft Remove the bearing by supporting the inner race of the bearing on an arbor press bed and apply pressure to the threaded end of the axle shaft. (Ref. Fig. R-5)

USE CARE TO PREVENT DAMAGE TO THE INNER SURFACE OF THE AXLE TUBE AT THE SEALING AREA. Remove the inner snap ring. (Ref. Fig. R-6)

\ Fig. R-5 Pressing Bearing from Axle Shaft

Fig. R-6 Removing/Installing Inner Snap Ring

Repair and Service Manual

Page R-3

REAR AXLE Use a puller to remove the seal. (Ref. Fig. R-7)

Axle Shaft Replacement (See Fig. R-3 "Removing/Installing Outer Snap Ring" on page R-2) (See Fig. R-9 "Cut Away of Outer Bearing and Brake Drum" on page R4)

Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with the differential side gears. Install the outer snap ring.

Coat the outboard spline of the axle with an anti-seize compound. Install the brake hub and drum, thrust washer, nut and new cotter pin.

Tighten the castellated axle nut to 70 ft. lbs. torque minimum, 140 ft. lbs. torque maximum. Continue to tighten until the slot in the nut aligns with the cotter in hole.

Fig. R-7 Removing Seal To install the seal, use the special E-Z-GO seal installer to drive the seal into its correct position. (Ref. Fig. R-8)

WASHER

Fig. R-9 Cut Away of Outer Bearing and Brake Drum

Fig. R-8 Installing Seal Install the inner snap ring.

CAUTION TO PREVENT SEAL DAMAGE, LIGHT LY COAT THE AXLE SHAFT WITH BEARING GREASE AND SUPPORT THE SHAFT DURING INSTALLATION.

Page R-4

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�P._A_I_N_T______________ _e_ct-io-n-SJ S TABLE OF CONTENTS FOR SECTION 'S' SECTION TITLE

PAGE NO.

PAINT SYSTEM INFORMATION

S-1

POLANE® REPAINTING INSTRUCTIONS

S-1

VENDOR WET COAT/AIR DRY PROCEDURE

S-2

Repair and Service Manual

Page S-i

r S·. · . : -----------, ..

, ,,,.,,,

PAINT

,.

Notes: ______________________________

Page S-ii

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.--P- _ _________________ _e_c_ti-·o_n_ N AI T

S

PAINT SYSTEM INFORMATION E-Z-GO uses powder coatings in its production facility for two reasons: First, these coatings provide high quality finish, excellent color retention and maximum weather­ ability. Secondly, as a continuous high volume painting facility, E-Z-GO conforms with E.P.A. regulations. Note this system requires the facilities for baking the paint.

There are significant problems involved with using high solids Polane® paint in a low volume body shop environ­ ment. Primer and top paint mixing is more complicated than when using the old Polane® and the mixed primer and paint has a shorter pot life (two hours).

Some minor difference in luster may be determined between side by side panels painted with the two sys­ tems. Polane® may fade somewhat faster with extended U.V. exposure.

Panels that are to be touched up should be painted in their entirety to assure accurate color match. Spray cans are not available in powder coatings but are compatible with air dry liquid paints. Spray cans are only recom­ mended for touching up a minor imperfection.

POLANE® REPAINTING INSTRUCTIONS

�@u�

Step 2 Step 3

s

J

Clean surface with Sherwin Williams 2200 sol­ vent.

Mix Polane® catalyst #V66-V29 at a ratio of 1 to 8 (16 oz. per gallon of paint). Reduce with thinner #R7K212 to a viscosity of 24-26 Saybolt Universal Seconds. Add retarder R7K6251 as necessary to slow drying time.

Viscosity should be measured by standard cup such as a Zahn or Ford. The cup can be purchased at most paint sup­ ply outlets. A cup filled with paint mixture should flow through the bottom orifice in the above time frame.

Step 4

Apply paint spray in a light tack coat followed by the heavier coat until a thickness of 1 mil is obtained.

A 1 mil thickness is the normal coverage required to hide rimer or bare metal.

Step 5

Allow 4-6 hours drying time in a dust free envi­ ronment for finished coat. Most topcoats have small transparent bubbles at initial application.

Most will disappear after a cure of 2-3 days.

Follow all paint manufacturer'sinstructions and safety warn­ ins.

Step 1

Lightly sand with water using #400 paper until all gloss is removed. Do not remove the gal­ vanneal surface from the metal. Silver chips in the sanding dust will indicate galvanneal removal.

Repair and Service Manual

Page S-1

I PAINT GS-662-014 EFFECTIVE: 03-09-94

REVISION: A

--------

SUPERCEDES: C

TITLE:

VENDOR WET COAT/AIR DRY PROCEDURE '

I.

The purpose of this procedure is to detail the proper method for application of air dry liquid coating to prepainted or primed metal surfaces.

II.

Scuff entire surface to be painted with 400 grit sand paper or equivalent abrasive material. Do not remove Gal­ vanneal surface. Wipe clean with Sherwin Williams 2200 series solvent or equivalent.

Ill.

Apply minimum 1.0 Mil of air dry acrylic liquid to primed surface(s) per Polane painting instructions as follows: A.

Mix Polane® catalyst #V66-V29 at a ratio of 1 to 8 (16 ounces per gal of paint). Reduce with thinner #R7K212 to viscosity of 24-26 Saybolt Universal Seconds. Add retarder R7K6251 as necessary to slow drying time.

B. Apply paint spray in light tack coat followed by heavier coat until a thickness of 1 mil minimum is obtained.

IV.

Allow minimum dry time of 4-6 hours before handling as parts must be dry to the touch.

V.

Refrain from using any type of wax, sealer or abrasive on the painted surfaces for a minimum of 30 days. Wash only with soft cloth and mild soap solution. Do not use any type of bristle brush or similar scrubbing device until paint is fully cured.

VI.

Gloss level must conform to paint specifications of 82 units minimum.

Page S-2

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7',1 ·1! .--T_ _O_ _ _ _ _ _ _O_O_T _ _ _ __________ _e_c_ti_o_n--.�. <c ING R UBLESH S :',_/:_E

TABLE OF CONTENTS FOR SECTION 'T' SECTION TITLE

I

PAGE NO.

T-1 ELECTRICAL SYSTEM Basic Electrical Power System Troubleshooting ................................................................... T-2 Basic Electrical Troubleshooting ........................................................................................... T - 2 Suspension and Steering ...................................................................................................... T - 4

LIST OF ILLUSTRATIONS Fig. T-1 Wiring Diagram .................................................................................................................. T-3

Repair and Service Manual

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::_,,, ---------------TR_ _O _____O__ O _ T _ ___,

�:�--·&r--

U BL E S H

IN G

Notes: ____________________________

Page T-ii

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�Fl. � k:t•. .·:I. ---------------------------------------------.

1 TROUBLESHOOTING Section ;�,, .

ELECTRICAL SYSTEM I:

. Correction

Possible Cause

Condition VEHICLE WILL NOT MOVE

Key 'OFF' or no direction selected

Turn key 'ON' and select direction

Batteries discharged

Charge batteries

Batteries unable to be charged

Replace batteries

Corroded or loose battery connections Clean and tighten battery connections Apply a coat of commercial terminal protectant to all terminals Corroded or loose battery connections Repair or replace faulty wiring to ESC controller, direction switch or motor Solenoid has failed

Replace solenoid

Key switch has failed

Replace key switch

Micro switch MS2 at direction switch has failed

Replace micro switch

Connector loose or separated

Install connector correctly

Faulty motor

Repair or replace motor Test by checking continuity of field coils (S1 - S2) and armature (A1 -A2) Check for continuity of armature to ground and field coils to ground which indicates a shorted condition

Faulty ESC system

Test and replace components as indicated by test procedure

VEHICLE SPEED ERRATIC

Faulty ESC system

Test and replace components as indicated by test procedure

MOTOR NOISY

Damaged bearing

Replace bearing

Raised commutator bar(s)

Repair or replace motor

Loose motor mounting hardware

Tighten

Charger not functioning correctly

Repair or replace charger

Vehicle charging wiring faulty

Repair or replace wiring

Vehicle/charger connector damaged

Repair or replace connector

Battery case damage

Replace battery

Low electrolyte level

Maintain correct electrolyte level

Battery capacity deficient

Hydrometer/load test Replace battery if required

:

.

BATTERIES WILL NOT CHARGE

E�HSDii=UiiM:I

Reapir and Service Manual

Page T-1

,, TROUBLESHOOTING Basic Electrical Power System Trouble­ shooting

A

WARNING

A

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

tor in forward and the key switch to on. Check for battery voltage at the direction selector B, C and D connections.

If battery voltage is not present, check the wire at the con­ nection without power. If the wiring is satisfactory, the di­ rection selector switch should be replaced.

Basic Electrical Troubleshooting If the vehicle is equipped with factory installed accessory or optional wiring system (Head/taillights, horn etc.) refer to the appropriate section within this manual for detailed troubleshooting information.

Place the direction selector in forward, turn the key to 'on' and depress the accelerator pedal. If the solenoid clicks, the control wiring to the solenoid is in good condition. If the solenoid does not click, check the function of the key switch, accelerator micro switch, direction selector micro switch, solenoid and associated wiring.

Proceed to the troubleshooting section for the ESC sys­ tem. If the cause is external to the ESC system use the following to locate the faulty component(s).

If the solenoid does click, check for battery voltage at the direction selector switch at each of the four connections.

If battery voltage is present the wiring to the direction se­ lector switch is in good condition. If there is no battery voltage to any of the four connections, the wire from the BL+ at the battery to the solenoid should be checked. If that wire is in good condition, the wire from the other large solenoid connection to the controller B+ must be checked.

If that wire is in good condition, the wire and connection from the controller A2. to th� direction selector switch A must be checked.

If there is power to the direction selector switch and there is no evidence of burned contacts that would suggest a failed direction selector switch, the key should be turned off and the direction selector placed in neutral. Perform a continuity check between motor connections S1 and S2 to determine if the field coil is satisfactory. Check for conti­ nuity between the motor housing and the field coil termi­ nals. Continuity between the field coil terminals indicates a good coil winding. Continuity to the motor housing indi­ cates a shorted condition.

Repeat the test with the armature terminals.

If the motor is in good condition, place the direction selecPage T-2

Repair and Service Manual

EiZl3Dii:i:ji;M:I

Irp

Iii D

I

DIRECTION SELECTOR MICRO SWITCH

ACCELERATOR MICRO SWITCH

0---0--0---C

<:=<> REVERSE ._. FORWARD

250 OHM RESISTOR 5W (MP-2)

l::i

l::t· l::i � � CJ)

n· ('I)

� �

..... l::i

co· ·.h·:j .... ::e:::;· cas· "Tl �

KEY

SWITCH

I I I SOLENOID:

DIRECTION SELECTOR SWITCH

-=-. 36V

A1

�-ii1

(MP-1) DIODE

3

S2 / L_

8M-

B+

A2 I l'----1------+----� CONTROLLER

POTENTIOMETER (0-5K) 0 OHMS = FULL OFF 5000 OHMS = FULL ON

I I I I I

A2:

___ J

MOTOR

...:D

0 C m r­

m

en :c 0

0 ::I 2 G)

TROUBLESHOOTING Suspension and Steering Condition UNEVEN TIRE WEAR PLAY IN STEERING

VIBRATION

STEERING PULLS TO ONE SIDE

Page T-4

· Correction

Possible.Cause . . ·' Incorrect tire pressure

Inflate to recommended pressure

Improper alignment (Incorrect toe in)

Align vehicle

Steering wheel loose

Inspect splines - replace if required Tighten steering wheel nut

Steering components worn

Repair or replace

Loose wheel bearings

Adjust or replace

Steering components worn

Repair or replace

Damaged wheel bearings

Adjust or replace

Out of round tires, wheels, or brake drums

Inspect and replace if required

Loose lug nuts

Tighten to 50 - 60 ft. lbs.

Incorrect tire pressure

Inflate to recommended pressure

Dragging wheel brakes

Adjust

Suspension component failure

Repair

Improper alignment

Align

Repair and Service Manual

E.ZGDii:t:ii;!•)II

..--L_ I_G _H_TN_ IN_ _ G_P_R _O_T_EC_ T_IO _ _N _A_ N_D_G_R_ O_U_ N_D_IN_ _G__ S_ec-ti-.o-n-l,l

I

TABLE OF CONTENTS FOR SECTION 'U' SECTION TITLE

PAGE NO.

Grounding Requirements ................................................................................................................ U - 1 Ground Systems ............................................................................................................................ U - 1 Lightning Protection Requirements ................................................................................................ U - 1 Equipment Fault and Personal Safety System ............................................................................... U - 1 Ground Network Requirements ...................................................................................................... U - 2 External Grounding Requirements ................................................................................................. U - 2 Materials ......................................................................................................................................... U - 2 Earth Electrode System ................................................................................................................. U - 2 Lightning Protection System .......................................................................................................... U - 3 Equipment Fault and Personal Safety System ............................................................................... U - 3

Repair and Service Manual

Page U-i

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t :;

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• Cifo·..,·· ,\\,,,.

----------,

LIGHTNING PROTECTION AND GROUNDING

Notes: __________________________

Page U-ii

Repair and Service Manual

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_L_IG _ H _ T _ N_ -IN_ G_P_R _O_T_EC_ T_IO _ _N A _ _ N_D _G_ R_ O_U_ N_DI _ N_ G _ __ S_ec-t-io_n_:11

I

--------

GS-726-006

REVISION:

EFFECTIVE:

SUPERCEDES:

................

10/19/92

C

TITLE:

General Specification: Lightning Protection and Grounding

C

C

1. Grounding Requirements For the purpose of this specification, building ground systems should serve two primary functions: personal safety and equipment protection. In order to be effective, all elements and functions of building ground system must receive equal consideration in design and installation. Once installed, it is up to the owner to adequately maintain the system by implementing periodic inspections and ground tests in order to determine its effectiveness.

2. Ground Systems All electronic equipment is inherently related to earth by capacitive coupling, accidental or incidental contact and intentional connection. The earth forms a natural readily available form of common potential reference for all electri­ cal circuits. For maximum effectiveness, grounding must be looked at from a total system viewpoint, with various sub-systems comprising the total facility ground system. The interconnection of the various sub-systems into a building ground system will provide a direct path, of known low impedance, between earth and the various electrical and other equipment. This effectively extends an approximation of ground reference throughout the building. The total building ground system is composed of an earth electrode system, a lightning protection system and an equip­ ment fault protective system.

Resistance To Earth: The resistance to earth of the ground system should not exceed 10 ohms. Where the resis­ tance of 1O ohms cannot be obtained due to high soil resistivity, rock formations or other abnormal conditions, alter­ nate methods for reducing the resistance to earth must be considered.

Chemical Treatments: No salt, coke or other chemicals may be used to treat the soil in order to obtain the required ground resistance readings. Approved methods of enhancement are bentonite clay or the GEM product for ground enhancement as manufactured by Erico Products of Solon, Ohio.

Ground Tests: The resistance to earth of the ground system shall be measured by the "Fall of Potential Method".

Acceptable resistance meters/testers are those manufactured by Biddle or AEMC.

3. Lightning Protection Requirements The external lightning protection system shall be designed and installed by a contractor who specializes in the light­ ning protection field. The contractor must be listed with Underwriters Laboratories Inc. and be in good standing. All work shall be under Jhe direct supervision of a Certified Master Installer with currer:,t credentials from the Lightning Protection Institute.

The materials and design for the structure will comply with the most recent edition of the National Fire Protection Association Lightning Protection Code, NFPA 780 and the Materials Standard for Safety from Underwriters Labora­ tories UL96. Materials for this project may be those of Harger Lightning Protection, 1066 Campus Drive, Mundelein, Illinois (800-842-7437).

Upon completion of the project, the contractor will supply to the owner the Master Label issued by Underwriters Lab­ oratories.

4. Equipment Fault and Personal Safety System The standard method of providing an equipment fault protection ground network is to run a good ground conductor (green wire) through the conduit together with the AC distribution system. This method is required for all types of conduit, including metallic.

Eii!l&CJii:f:ii;t•l:I

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Page U-1

...---------:u.· ·1 7

I LIGHTNING PROTECTION AND GROUNDING GS-726-006 EFFECTIVE: 10/19/92

REVISION:

--------

;\;, '··"'

TITLE:

General Specification: Lightning Protection and Grounding

SUPERCEDES:

-·------

...

5. Ground Network Requirements Install the conduit in accordance with local regulations or as prescribed by the National Electrical Code.

6. External Grounding Requirements For optimum results, earth electrode installation must be accomplished early in the construction of a new site. The earth electrode system should be established at the same time utilities are installed to insure proper interconnection of all utility grounds/systems.

For existing sites, the earth electrode installation shall be constructed using the most economical means possible in order to meet the intent of this specification.

Prior to the installation or design of the ground system, a survey should be taken in order to determine the earth resistivity, types of soil or any man-made features that may have a significant effect upon the efficiency of the grounding system. Based on the information gathered, deviations from this specification (Exceeding normal require­ ments) may be necessary in order to achieve desired results.

7. Materials Ground Rod Electrodes: Ground rod electrodes shall have a minimum diameter of 5/8" and be no less than 10'-0" in length. Rods may be copper, copper-clad steel or stainless steel. Galvanized steel rods are not permitted unless it is determined that the galvanized rod will have a longer life expectancy due to soil conditions.

Ground Rod Spacing: Ground rods shall not be spaced at intervals exceeding 60'-0" around the perimeter of the structure.

Ground Loop Conductor: In no case shall the ground loop conductor be smaller than a 2/0 AWG bare, stranded, soft drawn copper wire. The ground loop must be installed at least 24" below grade and be at least 24" away from the structure. All bends in the conductor shall have a minimum radius of 8" and be no less than 90 degrees.

Ground Mats: In areas where electrodes cannot be driven, a ground mat consisting of a #6 solid copper or a copper­ copper clad steel mesh, utilizing a 12" x 12" cross pattern may be used. All inter-connections in the mesh shall be brazed or silver soldered.'.

Ground Plates: Ground plates if utilized shall be 24" x 24" x .032" thick solid copper. Ground plates should only be used if a ground rod cannot be driven.

Ground Connections: Unless otherwise specified or approved by the owner, all connections below grade shall be by exothermic weld (Cadweld). Where exothermic welds may not be practical, UL approved grounding clamps that uti­ lize two bolts for pressure may be used. NOTE: Prior approval must be obtained in order to use a mechanical con­ nection below grade.

8. Earth Electrode System The earth electrode system consists of a network of earth electrode rods, plates, mats or grids and their intercon­ necting conductors. The extensions into the building are used as the principle grounding point for connecting to the ground system serving the building. Ground potential is established by electrodes in the earth.

Page U-2

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E2E5Dii:S:§i;M:I

k'U �,

-------L-IG_ _ T_ N_ I_N _G_ _ R_ O_T _ _ T_ _O_N _ _ N_ D_G_R _O_ _N _D_IN_ G___, P H EC I U A

GS-726-006 EFFECTIVE:

10/19/92 .·'. .. ','. '·

-------SUPERCEDES: -------REVISION:

TITLE:

General Specification: Lightning Protection and Grounding ,,

An electrode may be a metallic water pipe that has no isolation joints, a system of buried, driven rods intercon­ nected with a bare wire that normally forms a ring around the building or a ground plane of horizontal buried wires.

Depending upon soil conditions, building design and the existing water pipe networks, an electrode may be a com­ bination of any of the above mentioned systems.

9. Lightning Protection System The lightning protection system provides a non-destructive path to ground for lightning energy contacting or induced onto or in a building. To effectively protect from lightning damage, air terminals are installed according to the National Fire Protection Association Lightning Protection Code (NFPA 780). Air terminals will intercept the discharge to keep it from penetrating or structurally damaging the building. This is done by providing a low impedance path from the air terminals to the earth electrode system.

10. Equipment Fault and Personal Safety System The equipment fault protective system ensures that personnel are protected from shock hazard and equipment is protected from damage or destruction resulting from faults {lightning induced surges) that may develop in the elec­ trical system. Deliberately engineered ground conductors (green wire safety ground) shall be provided throughout the AC distribution system to afford electrical paths of sufficient capacity, so that protective devices can operate promptly and efficiently. The use of conduit for grounding in lieu of a dedicated green wire is unacceptable.

Install the green wire ground {#6 stranded) with the AC power distribution conductors. There shall be no green wires spliced within the conduit. All splices shall be performed at the appropriate junction boxes.

Bond the ground conductor to all pull boxes, junction boxes and power panels.

In existing facilities where an existing conduit is not large enough to accommodate an additional ground conductor, or where a conduit section is insulated from other conduit sections, an external ground conductor may be installed to maintain continuity. All mounting hardware and connectors shall be UL approved.

All DC chargers are to be grounded to the green wire ground using UL approved connectors. At no point should the chargers be isolated from the grounding system.

All interior grounding should return to a single ground point. From this location it is then connected to the exterior ground system.

Optional Interior Ground .Halo: If an interior ground halo is to be installed around the inside perimeter of the struc­ ture, this conductor {#2/0 green insulated minimum) shall be securely fastened to the structure. All connections to the halo shall be made using UL listed connectors.

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I LIGHTNING PROTECTION AND GROUNDING ;

GS-726-006 EFFECTIVE: 10/19/92

REVISION: ,..________

SUPERCEDES:

................

TITLE:

General Specification: Lightning Protection and Grounding

·..

Transient Voltage Surge Suppression: TVSS shall be provided at the main electrical service entrance panel. Protection at this point shall be as follows: UL 1449 Listed device 25,000 ampere surge capacity with maximum 495 volt clamping voltage Protection should be Line to Ground, Neutral to Ground and Line to Neutral Internally fused for safety Failure mode indicator lights

Suppression may be as the 14000 series of Harger Lightning Protection, Inc., 1066 Campus Drive, Mundelein, IL (800-842-7437), or MBP 120EFI series from EFI Electronics Corporation, 2415 South 2300 West, Salt Lake City, UT (801-977-9009).

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.--G-EN_E _R_A_L_S_P_E_ C_IF_I _C__ J"_ I_O_N_ S________ _e_ct-io_n_.

S TABLE OF CONTENTS FOR SECTION 'V' SECTION TITLE

VJ

PAGE NO.

ELECTRIC PERSONNEL CARRIER PCX-952

V-1

ELECTRIC PERSONNEL CARRIER PCX-954

V-3

ELECTRIC PERSONNEL CARRIER PCX-955

V-5

ELECTRIC PERSONNEL CARRIER PCX-956

V-7

ELECTRIC PERSONNEL CARRIER PCX-957

V- 9

ELECTRIC BEVERAGE CARRIER BCX-960

V-11

ELECTRIC CARGO CARRIER Xl-875

V-13

ELECTRIC CARGO/PERSONNEL CARRIER Xl-875P

V-15

ELECTRIC CARGO CARRIER Xl-8 81

V-17

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� . Iv· _ ..

GENERAL SPECIFICATIONS

Notes: ___________________________

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-IO_N_S________ _ec-ti-o . -n G_E_N_E_R_A_L_S_P_E-CI-F-IC-�l" S

'V ]

ELECTRIC PERSONNEL CARRIER PCX-952 TWO PASSENGER CARGO TRUCK WEIGHT (without batteries) ....................................................... 840.0 lbs. (381.5 kg) LENGTH (total) .......................................................................... 129.0 in. (327.7 cm) LENGTH (from bulkhead) .......................................................... 74.0 in. (188.0 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) HEIGHT (at steering wheel) ....................................................... 45.5 in. (115.6 cm) HEIGHT (at deck) ....................................................................... 28.0 in. (71.1 cm) HEIGHT (at top if equipped)....................................................... 75.0 in. (190.5 cm) FLOOR HEIGHT ........................................................................ 11.0 in. (27.9 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) SEAT HEIGHT ........................................................................... 29.0 in. (73.7 cm) WHEEL BASE............................................................................ 52.5 in. (133.4 cm) WHEEL TREAD ......................................................................... 35.0 in. (88.9 cm) TURNING CLEARANCE DIAMETER ........................................ 22.0 ft. (6.71 m) INTERSECTING AISLE CLEARANCE ...................................... 77.0 in. (195.6 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE ...................................................................... 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 2,000.0 lbs. (908.3 kg) CARGO DECK WIDTH.:·............................................................ 46.0 in. (116.8 cm) CARGO DECK LENGTH ..... :..................................................... 74.0 in. (188.0 cm) SPEED....................................................................................... 12 mph (19.3 kph) CHASSIS ................................................................................... Welded high yield strength tubular steel BODY ......................................................................................... Fiberglass reinforced plastic SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral'

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_ - - -I N _ _________ _ S _ _ E_ C- I- - IC� _ _ _ _ S _ N _ E _GE l" O RAL P F

v]

LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights, backup lights and brake lights STEERING WHEEL ................................................................... Molded �igh impact plastic, dual handgrips, pencil holder and clipboard CARGO DECK ........................................................................... Removable for access to drive package FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION ................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion CENTER CONSOLE .................................................................. Instrument panel with four drink holders SEATING .................................................................................... Fabric backed vinyl over cushion foam BRAKES..................................................................................... Dual rear wheel mechanical drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Portable Total Charge® Ill

* Specifications subject to change without notice.

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GENERAL SPECIFICATIONS ELECTRIC PERSONNEL CARRIER PCX-954 FIVE PASSENGER COURTESY/CARGO VEHICLE WEIGHT (without batteries) ....................................................... 840 lbs. (381.5 kg) LENGTH (total) .......................................................................... 129.0 in. (327.7 cm) LENGTH (rear deck) .................................................................. 37.0 in. (94.0 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) HEIGHT (at steering wheel) ....................................................... 45.5 in. (115.6 cm) HEIGHT (at deck) ....................................................................... 28.0 in. (71.1 cm) HEIGHT (at top if equipped) ....................................................... 75.0 in. (190.5 cm) FLOOR HEIGHT ........................................................................ 11.0 in. (27.9 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) SEAT HEIGHT ........................................................................... 29.0 in. (73.7 cm) WHEEL BASE............................................................................ 52.5 in. (133.4 cm) WHEEL TREAD ......................................................................... 35.0 in. (88.9 cm) TURNING CLEARANCE DIAMETER ........................................ 22.0 ft. (6.7 m) INTERSECTING AISLE CLEARANCE ...................................... 77.0 in. (195.6 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE ...................................................................... 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 2,000.0 lbs. (908.3 kg) CARGO DECK WIDTH.,............................................................ 46.0 in. (116.8 cm) CARGO DECK LENGTH ..... :...................................................... 37.0 in. (94.0 cm) SPEED....................................................................................... 12 mph (19.3 kph) CHASSIS ................................................................................... Welded high y ield strength tubular steel BODY ......................................................................................... Fiberglass reinforced plastic SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral' LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights, backup lights and brake lights

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I GENERAL SPECIFICATIONS STEERING WHEEL ................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard CARGO DECK ........................................................................... Removable for access to drive package FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION ................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion CENTER CONSOLE .................................................................. Instrument panel with four drink holders SEATING .................................................................................... Fabric backed vinyl over cushion foam BRAKES ..................................................................................... Dual rear wheel mechanical drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Portable Total Charge® Ill

Specifications are subject to change without notice.

Page V-4

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GENERAL SPECIFICATIONS

ELECTRIC PERSONNEL CARRIER PCX-955 EIGHT PASSENGER COURTESY/CARGO VEHICLE WEIGHT (without batteries) ....................................................... 960 lbs. (436.0 kg) LENGTH (total} .......................................................................... 156.0 in. (396.2 cm) LENGTH (rear deck) .................................................................. 37.0 in. (94.0 cm) LENGTH (rear of driver's seat to front of rear seat) ................... 42.6 in. (108.2 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) HEIGHT (at steering wheel} ....................................................... 45.5 in. (115.6 cm) HEIGHT (at rear deck) ............................................................... 28.0 in. (71.1 cm) HEIGHT (at top of rear seat) ...................................................... 41.5 in. (105.4 cm) HEIGHT (at top if equipped) ....................................................... 75.0 in. (190.5 cm) FLOOR HEIGHT ........................................................................ 11.0 in. (27.9 cm) GROUND CLEARANCE (at differential} .................................... 5.0 in. (12.7 cm) SEAT HEIGHT ........................................................................... 29.0 in. (73.7 cm) WHEEL BASE............................................................................ 79.5 in. (202.0 cm) WHEEL TREAD ......................................................................... 35.0 in. (88.9 cm) TURNING CLEARANCE DIAMETER ........................................ 28.0 ft. (8.6 m) INTERSECTING AISLE CLEARANCE ...................................... 98.0 in. (248.9 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE ...................................................................... 50 psi cold (344.0 kPa) LOAD CAPACITY(inclucling operator, passengers, cargo and accessories) ............................. 2,500.0 lbs. (1,135.3 kg) CARGO DECK WIDTH .............................................................. 46.0 in. (116.8 cm) CARGO DECK LENGTH ........................................................... 37.0 in. (94.0 cm) SPEED....................................................................................... 12 mph (19.3 kph) CHASSIS ................................................................................... Welded high yield strength tubular steel BODY ......................................................................................... Fiberglass rein forced plastic

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_ _S__________ - I- C- - I_ N _G_ E_N_E_R_A_L_S_PE_ C- IF /t.T O

v]

SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral' LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights, backup lights and brake lights STEERING WHEEL ................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard CARGO DECK ........................................................................... Removable for access to drive package FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion CENTER CONSOLE .................................................................. Instrument panel with four drink holders SEATING .................................................................................... Fabric backed vinyl over cushion foam BRAKES ..................................................................................... Dual rear wheel hydraulic drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES ................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Portable Total Charge® Ill

Specifications are subject to change without notice.

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E 6- E_N _ _R_A_L_S_P_E _C _IF-IC_/t._J_ IO_ N_ S___,

ELECTRIC PERSONNEL CARRIER PCX-956 EIGHT PASSENGER COURTESY VEHICLE WEIGHT (without batteries) ....................................................... 840 lbs. (381.5 kg) LENGTH (total) .......................................................................... 129.0 in. (327.7 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) HEIGHT (at steering wheel) ....................................................... 45.5 in. (115.6 cm) HEIGHT (at top of rear seat) ...................................................... 41.5 in. (105.4 cm) HEIGHT (at top if equipped) ....................................................... 75.0 in. (190.5 cm) FLOOR HEIGHT ........................................................................ 11.0 in. (27.9 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) SEAT HEIGHT ........................................................................... 29.0 in. (73.7 cm) WHEEL BASE ............................................................................ 52.5 in. (133.4 cm) WHEEL TREAD ......................................................................... 35.0 in. (88.9 cm) TURNING CLEARANCE DIAMETER ........................................ 22.0 ft. (6.7 m) INTERSECTING AISLE CLEARANCE ...................................... 77.0 in. (195.6 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE ...................................................................... 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 2,000.0 lbs. (908.3 kg) SPEED ....................................................................................... 12 mph (19.3 kph) CHASSIS ......................;.-···:························································ Welded high yield strength tubular steel BODY ...................................:.•................................................... Fiberglass reinforced plastic SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral' LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights, backup lights and brake lights STEERING WHEEL ................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs

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-v _G_ E_ N_E _R_A_L_ S_PE_ C- I-F-IC-�-l"I _O_N _S--------] REAR SUSPENSION ................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion CENTER CONSOLE .................................................................. Instrument panel with four drink holders SEATING.................................................................................... Fabric backed vinyl over cushion foam BRAKES ..................................................................................... Dual rear wheel mechanical drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES ................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Portable Total Charge® Ill

Specifications are subject to change without notice.

Page V-8

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GENERAL SPECIFICATIONS ELECTRIC PERSONNEL CARRIER PCX-957 ELEVEN PASSENGER COURTESY VEHICLE WEIGHT (without batteries) ....................................................... 960 lbs. (436.0 kg) LENGTH (total) .......................................................................... 156.0 in. (396.2 cm) LENGTH (from rear of driver's set to front of rear seat)............. 42.6 in. (108.3 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) HEIGHT (at steering wheel) ....................................................... 45.5 in. (115.6 cm) HEIGHT (at top of rear seat) ...................................................... 41.5 in. (105.4 cm) HEIGHT (at top if equipped) ....................................................... 75.0 in. (190.5 cm) FLOOR HEIGHT ........................................................................ 11.0 in. (27.9 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) SEAT HEIGHT ........................................................................... 29.0 in. (73.7 cm) WHEEL BASE ............................................................................ 79.5 in. (201.9 cm) WHEEL TREAD ......................................................................... 35.0 in. (88.9 cm) TURNING CLEARANCE DIAMETER ........................................ 28.0 ft. (8.5 m) INTERSECTING AISLE CLEARANCE ...................................... 98.0 in. (248.9 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE······································································ 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 2,500.0 lbs. (1,135.3 kg) SPEED ..........................,-............................................................ 12 mph (19.3 kph) CHASSIS ............................. ,..................................................... Welded high yield strength tubular steel BODY ......................................................................................... Fiberglass reinforced plastic SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral' LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights, backup lights and brake lights STEERING WHEEL................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard

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...-----------v GENERAL SPECIFICATIONS

· ·...

FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion CENTER CONSOLE .................................................................. Instrument panel with four drink holders SEATING.................................................................................... Fabric backed vinyl over cushion foam BRAKES ..................................................................................... Dual rear wheel hydraulic drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES ................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Portable Total Charge Ill

Specifications are subject to change without notice.

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]

rV

GENERAL SPECIFICATIONS ELECTRIC BEVERAGE CARRIER BCX-960 TWO PASSENGER BEVERAGE VEHICLE

WEIGHT (without batteries) ....................................................... 1,130 lbs. (513.2 kg) LENGTH .................................................................................... 129.0 in. (327.7 cm) LENGTH (rear deck) .................................................................. 74.0 in. (188.0 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) HEIGHT (at steering wheel) ....................................................... 45.5 in. (115.6 cm) HEIGHT (at deck) ....................................................................... 28.0 in. (71 .1 cm) HEIGHT (at top if equipped) ....................................................... 75.0 in. (190.5 cm) FLOOR HEIGHT ........................................................................ 11.0 in. (27.9 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) SEAT HEIGHT ........................................................................... 29.0 in. (73.7 cm) WHEEL BASE............................................................................ 52.5 in. (113.4 cm) WHEEL TREAD ......................................................................... 35.0 in. (88.9 cm) TURNING CLEARANCE DIAMETER ........................................ 22.0 ft. (6.7 m) INTERSECTING AISLE CLEARANCE ...................................... 77.0 in. (195.6 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE ...................................................................... 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 2,000.0 lbs. (908.3 kg) SPEED ......................... .:. ..._. ........................................................ 12 mph (19.3 kph) CHASSIS .............................: •.................................................... Welded high yield strength tubular steel BODY ......................................................................................... Fiberglass reinforced plastic SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral' LIGHTING PACKAGE................................................................ Dual halogen headlights, taillights, backup lights and brake lights STEERING WHEEL ................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard

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_ _________ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _G C C S S N N IO E IFI /f.J EE LP A R

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FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion CENTER CONSOLE .................................................................. Instrument panel with four drink holders SEATING .................................................................................... Fabric backed vinyl over cushion foam BRAKES ..................................................................................... Dual rear wheel mechanical drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Portable Total Charge® 111

Specifications are subject to change without notice.

Page V-12

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GENERAL SPECIFICATIONS ELECTRIC CARGO CARRIER Xl-875 TWO PASSENGER PERSONNEUCARGO TRUCK

WEIGHT (without batteries) ....................................................... 995 lbs. (451.9 kg) LENGTH (total) .......................................................................... 118.0 in. (299.7 cm) LENGTH (from bulkhead) .......................................................... 72.0 in. (182.9 cm) LENGTH (internal storage) ........................................................ 14.0 in. (35.6 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) WIDTH (internal storage) ........................................................... 43.0 in. (109.2 cm) HEIGHT (at steering wheel) ....................................................... 47.0 in. (119.4 cm) HEIGHT (at deck) ....................................................................... 25.5 in. (64.8 cm) HEIGHT (internal storage) ......................................................... 12.0 in. (30.5 cm) HEIGHT (at bulkhead) ................................................................ 41.5 in. (105.4 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) WHEEL BASE ............................................................................ 53.0 in. (134.6 cm) TURNING CLEARANCE DIAMETER ........................................ 234 in. (594.4 cm) INTE RSECTING AISLE CLEARANCE ...................................... 77.0 in. (195.6 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE······································································ 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 3,000.0 lbs. (1,362.4 kg) CARGO DECK WIDTH .�·............................................................ 44.0 in. (111.8 cm) CARGO DECK LENGTH ..... :.•................................................... 72.0 in. (182.9 cm) SPEED ....................................................................................... 12 mph (19.3 kph) CHASSIS ................................................................................... Welded high yield strength tubular steel BODY ......................................................................................... Heavy duty four-way diamond pattern tread plate body panels SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral'

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GENERAL SPECIFICATIONS LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights and brake lights STEERING WHEEL ................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard CARGO DECK ........................................................................... Removable for access to drive package FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION ................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion SEATING.................................................................................... Fabric backed vinyl over cushion foam BRAKES..................................................................................... Dual rear wheel hydraulic drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Onboard Total Charge® Ill UNDERWRITERS LABORATORY (UL) ..................................... Approved Type "E"

Specifications are subject to change without notice.

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GENERAL SPECIFICATIONS

ELECTRIC CARGO/PERSONNEL CARRIER Xl-875P FOUR PASSENGER PERSONNEUCARGO TRUCK WEIGHT (without batteries) ....................................................... 1,117 lbs. (507.0 kg) LENGTH (total without optional foot rest) .................................. 114.0 in. (289.6 cm) LENGTH (from front bulkhead) .................................................. 66.5 in. (168.9 cm) LENGTH (from second seat) ..................................................... 29.5 in. (74.9 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.8 cm) HEIGHT (at steering wheel) ....................................................... 47.0 in. (119.4 cm) HEIGHT (at deck) ....................................................................... 25.5 in. (64.8 cm) HEIGHT (at second seat) ........................................................... 41.5 in. (105.4 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) WHEEL BASE ............................................................................ 53.0 in. (134.6 cm) TURNING CLEARANCE DIAMETER ........................................ 234 in. (594.4 cm) INTERSECTING AISLE CLEARANCE ...................................... 85.0 in. (215.9 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE ...................................................................... 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 2,000.0 lbs. (907.0 kg) CARGO DECK WIDTH .............................................................. 44.0 in. (97.0 cm) CARGO DECK LENGTH (seat in up position) ........................... 28.0 in. (61.7 cm) CARGO DECK LENGTH (seat in down position) ...................... 66.0 in. (145.3 cm) SPEED....................................................................................... 12 mph (19.3 kph) CHASSIS ................................................................................... Welded high yield strength tubular steel BODY ......................................................................................... Heavy duty four-way diamond pattern tread plate body panels SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch with 'neutral' LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights and brake lights

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GENERAL SPECIFICATIONS

;.

]

STEERING WHEEL ................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard CARGO DECK ........................................................................... Removable for access to drive package FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION ................................................................. Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. D ouble reduction rack and pinion SEATING .................................................................................... Fabric backed vinyl over cushion foam BRAKES ..................................................................................... D ual rear wheel hydraulic drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES ................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Onboard Total Charge® 111 UNDERWRITERS LABORATORY (UL) ..................................... Approved Type "E"

Specifications are subject to change without notice.

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Repair and Service Manual

EiilHiClii:£foMII

rV----------G _ E _ -�-r-1o _ P _ � _ CI _ IC _ L _ S _ A _ F -E_N_ ER N_ S ELECTRIC CARGO CARRIER Xl-881 TWO PASSENGER PERSONNEUCARGO TRUCK WEIGHT (without batteries) ....................................................... 1085 lbs. (492.1 kg) LENGTH .................................................................................... 142.0 in. (360.7 cm) WIDTH (outside of wheels) ........................................................ 44.0 in. (111.76 cm) HEIGHT (at steering wheel) ....................................................... 47.0 in. (119.4 cm) GROUND CLEARANCE (at differential) .................................... 5.0 in. (12.7 cm) WHEEL BASE ............................................................................ 80.0 in. (203.2 cm) TURNING CLEARANCE DIAMETER ........................................ 26.5 ft. (8.1 m) INTERSECTING AISLE CLEARANCE ...................................... 98.0 in. (248.9 cm) TIRES························································································ 18.5 x 8.5 x 8 TIRE PRESSURE ...................................................................... 50 psi cold (344.0 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ............................. 3000.0 lbs. (1360.8 kg) CARGO DECK WIDTH .............................................................. 44.0 in. (111.8 cm) CARGO DECK LENGTH ........................................................... 96.0 in. (243.8 cm) SPEED ....................................................................................... 12 mph (19.3 kph) CHASSIS ................................................................................... Welded high yield strength tubular steel BODY ......................................................................................... Heavy duty fiberglass reinforced plastic SAFETY ..................................................................................... Removable switch key, electric horn, brake lights, handgrips and hip restraints, reverse warning indicator, 'deadman' accelerator control, manual forward and reverse switch LIGHTING PACKAGE ................................................................ Dual halogen headlights, taillights and brake lights STEERING WHEEL ................................................................... Molded high impact plastic, dual handgrips, pencil holder and clipboard CARGO DECK ........................................................................... Removable for access to drive package FRONT SUSPENSION .............................................................. Heavy duty multiple leaf springs REAR SUSPENSION ................................................................ Heavy duty multiple leaf springs with hydraulic shock absorbers STEERING ................................................................................. Double reduction rack and pinion

Repair and Service Manual

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-v _ E _ --------_ _ _ _ S _ N _ _ E_ -CI- -IC_ _ I_ N _ S _GE F /f.JO RAL P SEATING .................................................................................... Fabric backed vinyl over cushion foam BRAKES ..................................................................................... D ual rear wheel hydraulic drum brakes MOTOR ...................................................................................... 6.5 hp at 1500 rpm BATTERIES ................................................................................ 6, six volt, 220 AH CHARGER ................................................................................. Onboard Total Charge® I ll UNDERWRI TERS LABORATORY (UL) ..................................... Approved Type "E"

Specifications are subject to change without notice.

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Repair and Service Manual

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WARNING

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AVOID DRIVING FAST DOWN HILL. SUDDEN STOPS OR CHANGE OF DIRECTION MAY RESULT IN A LOSS OF CONTROL. USE BRAKE TO CONTROL SPEED WHEN TRAVELING DOWN AN INCLINE. ALL TRAVEL SHOULD BE DIRECTLY UP OR DOWN HILLS. USE EXTRA CARE WHEN DRIVING THE VEHICLE ACROSS ANY INCLINE. STAY IN DESIGNATED AREAS AND AVOID STEEP SLOPES. USE THE PARKING BRAKE WHENEVER THE VEHICLE IS PARKED. KEEP FEET, LEGS, HANDS AND ARMS INSIDE VEHICLE AT ALL TIMES. AVOID EXTREMELY ROUGH TERRAIN. CHECK AREA BEHIND THE VEHICLE BEFORE OPERATING IN REVERSE. MAKE SURE THE DIRECTION SELECTOR IS IN CORRECT POSITION BEFORE ATTEMPTING TO START THE VEHICLE. SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. ALWAYS BRING VEHICLE TO A COMPLETE STOP BEFORE SHIFTING THE DIRECTION SELECTOR. STANDARD VEHICLE IS LIMITED TO THREE (3) OCCUPANTS MAXIMUM PER SEAT EXCEPT FOR FRONT SET THAT IS RESTRICTED TO TWO (2) OCCUPANTS. ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION.

Read and understand the following text and warnings before attempting to service the vehicle:

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

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

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

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

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WARNING

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BEFORE WORKING ON VEHICLE: REMOVE ALL JEWELRY. BE SURE THAT NO LOOSE CLOTHING OR HAIR CAN CONTACT MOVING PARTS OF POWERTRAIN. USE CARE NOT TO CONTACT HOT OBJECTS. RAISE REAR OF VEHICLE AND SUPPORT ON JACK STANDS BEFORE ATTEMPTING TO RUN. WEAR EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE EYES TO POTENTIAL INJURY. IN PARTICULAR USE CARE WHEN WORKING AROUND BATTERIES, USING SOLVENTS OR COMPRESSED AIR.

E-2-GO Division of Textron Inc. P.O. Box 388 Augusta, Georgia 30903-0388

Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc. Technical Communications Department