EZGO Textron Electric Powered Golf Car Owner's Operation Service Manual

ELECTRIC POWERED GOLF CAR OWNER'S OPERATION & SERVICE MANUAL

MODEL YEARS: 1983

MANUAL NO.: 19000-G01

ISSUED: 10/01/83

LIMITED WARRANTY Electric md Gasoline Golf Cars The E-Z-Go Division of Textron, Inc. ("E-Z-Go") warrants: ,

I . That the fork of each of its three wheel golf cars shall be free of defects in material and workmanship during the lifetime of the first retail purchaser of such car, so long as such first purchaser continues to own such car; and 2. That all other parts of its three wheel golf car, and all its four wheel golf cars, shall, except as provided for below, be free from defects in material and workmanship for a period of one year from the date of first retail purchase.

E-Z-Go makes no warranties or representations with respect to batteries and tires, which are separately warranted by the manufacturer of the batteries and tires.

All warranties contained herein are expressly conditioned upon normal use and proper service and maintenance of the golf cars.

THIS WARRANTY IS VOID FOR ANY E-Z-GO VEHICLE THAT IS MODIFIED IN A MANNER THAT WILL ALTER THE WEIGHT OR WEIGHT DISTRIBUTION OF THE VEHICLE OR INCREASE THE OPERATING SPEED ABOVE FACTORY SPECIFICATIONS. (SEE IMPORTANT WARNING BELOW.)E-Z-Go's only obligation under this Warranty is to repair, or at E-Z-Go's sole option, to replace defective parts. The cost of labor associated with the repair or replacement of any defective part or the front fork is not covered by this Warranty. In order to make a claim under this Warranty, you must send the defective part, freight prepaid, to E-Z-Go, Warranty Department, P. O. Box 388, Marvin Griffin Road, F. O. B., Augusta, Georgia 30913-2699. All such parts shall become the property of E-Z-Go.

THE DURATION OF ANY IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE DURATION OF THE EXPRESS WARRANTY SET FORTH ABOVE. E­ Z-GO DISCLAIMS ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

No agent, employee or representative of E-Z-Go, or any other person, has any authority to bind E-Z-Go to other affirmation, representation, or warranty concerning the goods sold under this Warranty.

any

For further information, call (404) 798-4311 or write to E-Z-Go Division of Textron, Inc., P. O. Box 388, Augusta, Georgia 30913-2699.

IMPORTANT WARNING TO DEALERS, CUSTOMERS, AND USERS OF E-Z-GO GOLF CARS: THESE MODIFICATIONS CAN MAKE THE GOLF CARS UNSAFE AND THUS CAUSE SERIOUS PERSONAL INJURY. E-Z-GO PROHIBITS AND DISCLAIMS RESPONSIBILITY FOR THESE MODIFICATIONS OR ANY OTHER MODIFICATION OR ALTERATION WHICH WOULD ADVERSELY AFFECT THE SAFETY OF OUR GOLF CARS.

OPERATION & SERVICE MANUAL SECTION TITLE: INTRODUCTION

MODEL: ELECTRIC GOLF CAR

INTRODUCTION This Operation and Service Manual has been designed to enable you to maintain the vehicle in accordance with procedures developed by E-Z-Go. Adherence to these procedures and trouble-shooting tips will ensure you of the best possible service from the product.

This manual is divided into individually numbered sections.

Please note that Sections I, 0 and Q are not used.

Throughout this manual you will find NOTE, CAUTION, and WARNING used. For the protection of all personnel and the vehicle, please observe the following:

NOTE: CAUTION: WARNING:

Indicates a condition that should be observed.

INDICATES A CONDITION THAT MAY RESULT IN DAMAGE TO VEHICLE.

INDICATES A CONDITION THAT MAY BE HAZARDOUS TO 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 operation of all vehicles.

If part replacement is necessary, the part must be replaced with the specified replacement part. 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 desi'gned for the purpose.

Accordingly, anyor'i"e .who intends to use a replacement part, service procedure or tool, which is not recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the replacement part, service procedure or tool selected.

It is important to note that this manual contains various NOTES, 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.

E-Z-GOUDUJ•m

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GOU:f3ht•m ii

OPERATION & SER.VICE MANUAL SECTION TITLE: TABLE OF CONTENTS

MODEL: ELECTRIC GOLF CAR

SECTION

PAGE NO.

GENERAL • • • • • • • • • • • • • • • • • • • • • • • • • • •

A

I

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

A

Before Starting • • • • • • • • • • • • • • • • • • • • • • •

A

2

Towing • • • • • • • • • • • • • • • • • • • • • • • • • • •

A

4

Servicing - Initial • • • • • • • • • • • • • • • • • • • • •

A

4

Preventative Maintenance • • • • . • . • • • • • • • • • •

A

5

Vehicle Specifications • • • • • • • • • • • • • • • • • • •

A

10

Operating Controls

SAFETY PROCEDURES

. . . . . . . . . . . . . . . . . . .

B

General Precautions • • •

B

Battery Removal

B

.....................

Lifting Procedures . . . . . . . . . . . . . . . . . . . .

B

WHEELS AND TIRES . . . . .

................

• • • • • • . . . . . . . . . . . . . . . .

C

• • • • • • • •

C

STEERING • • • • • • • • • • • • • • • • • • • • • • • • • • •

D

Steering Assembly • • • • • • • • • • • • • • • • • • • • • Steering Dis�ssembly

...................

D D

................

E

• • • • • • • • • • • • • •

E

Tire Repair Tire Mounting

•

SUSPENSION . . . . . . . . . .

Front Suspension Disassembly

2

C

• • • • • • • • •

E

• • • • • • • • • •

Front Wheel Alignment • • • • • • • • • • • • • • • • • •

E E

7

Rear Suspension • • • • • • • • • • • • • • • • • • • • • •

E

8

Front Suspension Bearing Maintenance Removal of Axle and Hub Assembly

E-Z-GOUi31tt•m iii

6

19000-G I MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

TITLE:

TABLE OF CONTENTS SECTION

F

ACCELERATOR . . . . . . . . . . .

Accelerator Rod Removal

••

F

Accelerator Pedal Adjustment

BRAKES . . . . . . .

PAGE NO.

F

. . . . . .• . . . . . . . . . . . . .

G G

2

G

3

•••••

G

Hil I Brake Release Removal •••••••••

G

Brake Drum and Shoe Removal

G

5 5 6

G

9

General •••••• Brake, Adjuster Brake, Disassembly

• •• • ••

•••

Brake and Hit I Brake Adjustment •••••

H

BATTERIES & CHARGING General ••••••••

H

Battery Installation

H

2

Charging

H

3

A. C.Line Voltage

H

3-

Rotating Cars ••••

H

6

Adding Water • • • • • • • • • . . . . . . . • . . . . . . •

H

6

Water Level ••••

H

6

Cleaning

H

6 7

••.•••

•.•••

H

Testing Batteries

J J J J J

BATTERY CHARGER ; .

General • . • • . . • • .

Charger Installation •• Charger Trouble-Shooting • Component Replacement

MANUAL NO. ISSUE DATE REVISED DATE

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3 4

TITLE:

TABLE OF CONTENTS SECTION

PAGE NO.

Power Circuit

K K K K

6

Testing The Motor •• Forward-Reverse Switch •••••••••••••••

K K

Forward-Reverse Switch Removal & Disassembly Accelerator Switch •••••.•

K K K K

ELECTRICAL . . . . .

General Control Circuit

Accelerator Switch Removal •••••• Resistor Replacement •••••••••.

MOTOR

Motor Removal & Disassembly

L L

Electric Motor Repair •••••• Voltage & Resistance Measurement

L L

Brush Spring Measurement Armature Service

L L

Oil Seal Armature

L L

Bearings & Lubrication ••••• Testing . . . . . . . . • • .

L L

. . . . . . . . . . . . . . .

REAR AXLE . . . . . . . . .

Rear Axle Removal •••

M M

Rear Axle Shaft Repair •

M

BODY AND TRIM . . . . . .

N

Fender Removal ••••

8 8 10 IO 12 12

5 5 5 6

7 7

3

Front Cowl Removal

N N

3

Seat Wrap Removal Floorboard Removal

N N

4 4

PAINT INSTRUCTIONS

p

TROUBLE-SHOOTING

R

E-Z-GOUtlhl•m V

MANUAL NO. 19000-GI ISSUE DATE 10/01/83 REVISED DATE

TITLE:

TABLE OF CONTENTS

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z-GOUDht•J:i vi

OPERATION

& SERVICE MANUAL

MODEL: ELECTRIC ,.GOLF CAR

SECTION TITLE: GENERAL

SECTION The model, serial, and manufacturing numbers are stamped on a plate on the right side of the dash housing of the E-Z-Go vehicle. (Fig. A-I}.

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

Ai

CONTROLS The controls of the new E-Z-Go vehicle consist of a Key Switch, Forward-Reverse Lever, Accelerator Pedal and Combination Service Brake and Hill Brake Pedal.

KEY SWITCH Located on the seat support panel (Fig. A-2), this switch enables you to switch off the basic electrical system of the vehicle by turning the key to the "OFF" position.

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

NOTE: If the vehicle is equipped with E­ Z-Go installed custom accessories, some accessories remain operational with the ignition switch in the "OFF" position, e.g. radio, clock, cigarette lighter.

FORWARD-REVERSE LEVER Located on the seat support panel adjacent to the Key Switch (Fig. A-2), this lever permits the selection of either forward, neutral, or reverse.

FIG. A-I SERIAL NO. PLATE LOCATION

FIG. A-2 CONTROLS (PANEL MOUNTED) A-I

MANUAL NO. 19000-GI 10/01/83 · ISSUE DATE REVISED DATE

TITLE:

GENERAL

CAUTION: WHEN SELECTING DIRECTION DESIRED, BOTH THE VEHICLE AND THE ENGINE MUST BE COMPLETELY STOPPED BEFORE MOVING THE. LEVER. ACCELERATOR PEDAL Depressing the accelerator (Fig. A-3) on an E­ Z-Go vehicle w·ill release the parking (hill) brake (if engaged).

This is a feature to assure that the vehicle is not driven with the parking (hilI) brake engaged.

release when the brake pedal is depressed. Use the BOTTOM . section of the brake pedal· to operate the regular brake system. Depressing the bottom of the brake pedal is the preferred method of releasing the _parking (hill) brake to assure the longest service life of brake components.

BEFORE STARTING

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

COMBINATION BRAKE AND HILL BRAKE PEDAL The brake pedal (Fig. A-3) incorporates a parking (hill) brake feature. To engage, push down on the top section of the pedal until it locks in place. The parking (hill) brake will

Be sure you understand the vehicle, its equipment, and how to use it safely.

Although E-Z-Go �ehicles have been designed to provide you with a safe and reliable vehicle, maintaining its good performance depends to a large extent on the operator.

CAUTION: IMPROPER USE OR OPERATION OF THE VEHICLE OR THE LACK OF PROPER MAINTENANCE MAY RESULT IN DECREASED PERFORMANCE OR DAMAGE TO THE VEHICLE.

FIG. A-3 ACCELERATOR AND BRAKE CONTROLS MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

A-2

TITLE:

GENERAL

CAUTION: BEFORE INITIAL USE, REMOVE CLEAR PLASTIC SEAT COVERINGS.

WARNING: KEEP FEET, LEGS, HANDS, AND ARMS INSIDE THE VEHICLE AT ALL TIMES.

BEFORE ENTERING VEHICLE

WARNING: TERRAIN.

I.

Check for correct tire inflation.

2.

Inspect for fluid leaks.

3.

Be certain that everything is properly stored and secured.

AVOID EXTREMELY ROUGH

WARNING: CHECK THE AREA BEHIND THE VEHICLE BEFORE BACKING UP.

NOTE: Read and understand the following warnings before attempting to operate the vehicle.

WARNING: WHEN THE VEHICLE IS TO BE LEFT UNATTENDED, TURN KEY TO "OFF" POSITION, REMOVE KEY AND ENGAGE HILL BRAKE.

WARNING: MAKE SURE THAT FORWARDREVERSE LEVER IS IN CORRECT POSITION BEFORE ATTEMPTING TO START VEHICLE. WARNING: SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. o

Always bring the vehicle to a complete stop before shifting the forward-reverse control.

WARNING: DRIVE THE VEHICLE ONLY AS FAST AS TERRAIN AND SAFETY CONSIDERATIONS ALLOW. CONSIDER THE TRAFFIC EXISTING AND TERRAIN CONDITIONS. ALSO CONSIDER THE ENVIRONMENTAL FACTORS WHICH AFFECT THE TERRAIN AND YOUR ABILITY TO HANDLE THE VEHICLE.

WARNING: STANDARD VEHICLE IS LIMITED TO 2 OCCUPANTS MAXIMUM.

WARNING: 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.

To start the E-Z-Go electric vehicle; apply the parking (hill) brake; place the forward-reverse lever in neutral; place the key in the ignition switch and turn to the "ON" position; move forward-reverse lever to the direction desired; release parking (hill) brake by depressing the service brake pedal; depress the accelerator pedal to start the motor.

WARNING: USE EXTRA CARE AND REDUCED SPEED WHEN DRIVING ON POOR SURFACES, SUCH AS LOOSE DIRT, WET GRASS, GRAVEL, ETC. WARNING: ALL,. TRAVEL SHOULD DIRECTLY UP OR DOWN HILLS.

BE

WARNING: ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION. STARTING THE E-Z-GO ELECTRIC VEHICLE

NOTE: When the lever is in the reverse position, a warning will sound. This is a device to indicate that the _vehicle is ready to start and run in reverse.

WARNING: USE EXTRA CARE WHEN DRIVING THE VEHICLI; ACROSS AN INCLINE. WARNING: STAY ON DESIGNATED CAR PATHS AND AVOID STEEP SLOPES. USE THE HILL BRAKE WHENEVER THE VEHICLE IS PARKED.

A-3

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

TITLE:

GENERAL

When the accelerator pedal is released, the motor stops. To stop the vehicle more quickly, depress the bottom of the brake pedal.

SERVICING A NEW ELECTRIC VEHICLE Before a new vehicle is put in operation, it is recommended that the owner make a check of the items shown in the INITIAL SERVICE CHART below.

When leaving the vehicle unattended, engage the hill brake by depressing the TOP of the brake pedal until it locks in place. To release the hill brake, depress the BOTTOM part of the brake peda I.

Service operations are described in pertinent sections of the Service Manual. See Table of Contents for location.

To change direction, bring the vehicle to a complete stop. Then shift the forward-reverse lever to the direction desired.

Proceed by depressing the accelerator pedal.

INITIAL SERVICE CHART Item

Service Operation

TO CAUTION: AVOID COMPONENT DAMAGE, THE VEHICLE MUST BE BROUGHT TO A COMPLETE STOP BEFORE SHIFTING THE FORWARD-REVERSE LEVER.

Batteries

Check charge condition.

Seats

Remove covering.

TOWING

Brakes

Check operation necessary.

Tires

Check pressure.

CAUTION:

protective and

ONLY ONE VEHICLE MAY BE TOWED AT A TIME. (Tow bars to fit both 3 and 4 wheel models are available from the E­ Z-Go Service Parts Department.)

.SEATS

CAUTION: MAXIMUM TOWING SPEED IS 12

Preparation of Seats for Service

M.P.H.

CAUTION: IT IS IN THE BEST INTEREST OF

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

plastic adjust

if

Remove protective plastic coverings from seats before placing vehicle in service. The function of the plastic coverings is to protect the seat bottoms and back rests during shipping.

If plastic covering is left on the seats and gets torn, dirt getting under the plastic covering is ground in to the cover material. Water getting under the plastic covering is trapped and eventually will damage the seat assembly.

TIRES Tire condition should be inspected on a daily basis. Recommended pressure for the standard 8.50 x 8 tire is 18-22 psi. Inflation pressures should be checked on a weekly basis wheri the tires are cool.

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z-GOUi3ist•i:t A-4

TITLE:

GENERAL, SERVICING

Tire inflation should be governed by the condition of the golf course. On hard fairways, it is desirable to have a slightly higher inflation pressure. On a very soft fairway, a lower pressure prevents tires from cutting into fairways. All tires should have the same pressure for optimum handling characteristics.

Be careful not to overinflate. Due to the low volume of these small tires, overinflation can occur in a matter of seconds. Be sure to replace the valve dust cap after checking or inflating.

PREVENTATIVE MAINTENANCE

o Assure that all switches are operating normally.

B.

o

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

Clean vehicle.

Wipe seats.

o Clean floormat.

DAILY CHECK LIST

A. Examine vehicle for damage or anything unusual to normal wear and tear.

Make sure that service brakes operate properly.

o

E-Z-Go suggests that preventative maintenance be performed under the following headings: Daily, Weekly, and Semi-Annually.

After the E-Z-Go vehicle has been put into service, it is recommended that the following items be checked daily by the personnel handling the vehicles.

Personnel driving vehicles to and from the storage facility can be an asset to a proper maintenance program if trained 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.

o

o

Remove trash from dash tray.

o

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

o

Wash accumulated dirt from motor compartment and underbody.

SEMI-ANNUAL MAINTENANCE o

Check the differential oil level.

o

Lubricate all moving linkages such as: I. Accelerator rod ball joints.

o

Torn seats.

2. Brake and accelerator linkage bushings.

o

Damaged or missing bag straps.

3. Hill brake pivot pin.

o

Cuts in tires.

o

Mechanical damage, rods, etc.

WARNING: DO NOT LUBRICATE THE HILL BRAKE LATCH ARM OR CATCH BRACKET NOR ANY CABLE CONTROLS.

o

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

o

4. Steering gear and wheel bearings. o

Check the tires for wear and proper air pressure.

Wash batteries, when required, using baking soda and water to r�move corrosion.

E-Z·GOU=Eiut•m A-5

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE:

GENERAL, SERVICING

PERIODIC CHECK LIST

FRONT SUSPENSION

The following inspections should be routinely done on the schedule indicated.

I. Front Axle - 3 Wheel - Inspect for smooth operation.

STEERING I.

Time interval - 3 months.

Gear Box - Assure that all mounting bolts are securely in place. Inspect for abnormal play in steering shaft and/or steering wheel.

Time interval - once every 3 months.

2.

Tie rods and Pitman arms - Inspect for excessive play, bends or loose connections.

Time interval - once very 3 months.

3.

Wheel alignment - Inspect toe-in, toe-out per specification. (See Alignment)

2. Front axle - 4 Wheel - Inspect for damage to the axle and for loose bolts at spring mounts.

Time interval - 3 months.

3. Shock Absorbers - Check for oil leakage or loose connections.

Time interval - every 3 months.

4. Front Springs Leaf Spring - Check for cracks or loose connections around the spring mounting bracket and attaching bolts.

Time interval - once every 6 months or more often if handling is unusual or tire wear is uneven.

4.

King Pins - Check for excessive play.

Coil Spring - Check for cracks in springs and around shock absorber. Check for loose connections around shock mounting bolts.

Time interval - every 6 months.

Time interval

BRAKES I.

Brake Pedal - Check for smooth operation of pedal.

REAR SUSPENSION AND AXLE I. Rear Axle and Housings - Inspect for abnormal noise, loose connections at shocks, and oil leakage around rear cover plate.

Inspect rear leaf springs for damage and loose hardware.

Time interval - once every 3 months.

2.

Hill Brake - Check for proper engagement and release, wear or damage to latch arm or catch brackets. Check for abnormal brake travel that could hinder the proper operation of hill brakes. See Brake Section for brake adjustment· and operation.

Time interval as needed.

3.

Time interval - every 3 months.

WHEELS AND TIRES

- once every 3 months or

Brake Drum and Brake Shoes - Inspect for wear on brake shoes and brake drum.

Inspect for scoring, scratches, or unusual sightings in shoes and drum. (See Brake Section) Time interval - every 6 months.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

- every 3 months.

A-6

I. Wheel - Inspect for proper tire pressure, abnormal wear, cracks or damage to tread area, tightness of lug nuts, dented or damaged wheel rims.

Time interval

- every 3 months.

TITLE:

GENERAL, SERVICING

ELECTRICAL SYSTEM

I.

2.

CARE AND CLEANING OF THE VEHICLE

Batteries - Check for low electrolyte and corrosion build-up.

It is very important that proper techniques and cleaning materials be used.

Time interval - every week.

Ordinary cleaning of vinyl seats and plastic or rubber trim requires 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.

Wiring - Inspect all wiring for loose connections or cracked and/or worn insulation.

Time interval - every month.

3.

Reverse Warning operation.

Check for

proper

Time interval - daily.

4.

Forward-Reverse Switch - Check for wear and lubricate.

Time interval - semi-annually.

5.

Accelerator Switch - Check for wear and lubricate.

Time interval - semi-annually.

6.

Motor Brushes - Check with gauge.

Time interval - semi-annually.

MISCELLANEOUS

I.

Inspect all lubrication areas around pedal shafts, chassis parts, etc.

2.

Check for proper retention of golf bag straps and buckles.

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

The painted surfaces attractive appearance Frequent washing with is the best method of surfaces.

of the vehicle provide and durable protection. lukewarm or cold water preser ving those painted

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

Occasional cleaning and polishing with appropriate materials 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 materials will accelerate corrosion of underbody parts.

It is recommended that the under body be flushed occasionally with plain water.

Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to expedite their removal.

WINDSHIELD

Clean with lots of water and a clean cloth.

DO NOT USE ANY ABRASIVE OR VOLATILE SOL VENTS TO CLEAN PLASTIC PARTS. CAUTION:

E-Z-GOIH3ht•m A-7

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

TITLE:

GENERAL, SERVICING

_ _4 '---- .. - ·-

3-Wheel Front Fork

__

/

Front Wheel Bearing

Steering Unit _ Steering Idler Arm

- ·Lt_- _j: i: .

i

_ j�i .L___ 1 I

-

Ii

-�--�--

:

�

• Pressure Gun Grease Fitting Locations • Fill/Check Plug

FIG. A-4 LUBRICATION CHART MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GO•ltihM:1 A-8

Differential

TITLE:

GENERAL, SERVICING

PERIODIC SERVICE SCHEDULE DAILY BATTERIES A. CHARGE B. CHECK C. CLEAN & INSPECT

*

WEEKLY

MONTHLY

SEMI-AN.

ANNUAL ··-.,

RECHARGE TO FULL CHARGE STA TE AFTER EACH DAY'S lJSE CHECK ELECTROLYTE LEVEL-CORRECT IF REQ'D. AS REQUIRED CHECK (AND ADJUST IF NECESSARY) ON A DAILY BASIS BEFORE CAR IS USED. AS REQUIRED EXAMINE DAILY FOR CUTS AND EXCESSIVE WEAR CHECK PRESSURE. .

*

BRAKES A. CHECK B. ADJUSTMENT TIRES A. CHECK CONTROL LINKAGES CHECK FOR FREE & PROPER OPERATION A. CHECK LUBE BUSHINGS WITH LIGHT OIL B. LUBRICATION MAKE CERTAIN LOCKING DEVICES ARE TIGHT STEERING USE CHEVRON MOLY-GREASE 2 A. CHECK B. LUBRICATION SE.E SERVICE SECTION FOR ALIGNMENT PROCEDURE WHEEL ALIGNMENT 3 & 4 WHEEL CARS RESISTOR ASSY. CHECK CONDITION A. COILS TIGHTEN AS RE<1UIRED B. LEAD CONNECTIONS DO NOT OIL OR GREASE CONTACTS ACCELERATOR SWITCH CHECK CONDITION A. CONTACTS TIGHTEN AS REQ'D. B. LEAD CONNECTIONS USE CHEVRON MOLYC. LUBRICATION GREASE 2 FORWARD/REVERSE SWITCH · USE PETROLEUM JELLY A. CONTACTS TIGHTEN AS REQUIRED B. LEAD CONNECTIONS USE CHEVRON MOLYC. LUBRICATION GREASE 2 USE CHEVRON MOLY-GREASE 2 FRONT WHEEL BRGS. A. ADJUST" .

B. REPACK USE CHEVRON MOLY -GREASE 2 FORK BEARINGS' A. REPACK USE CHEVRON RPM DELO MULTl-SERVICE 200-30 DIFFERENTIAL A. CHECK LUBRICATION CHECK & TIGHTEN WIRE CONNECTIONS AS REQUIRED. CHARGER & CHARGER KEEP RECEPTACLES FREE OF DIRT & FOREIGN MATTER. RECEPTACLE NOTE: INCLUDE ALL DAILY, WEEKLY, MONTHLY, AND SEMI-ANNUAL ITEMS IN THE ANNUAL SERVICE.

*

*

*

*

*

..

* *

*

* *

* * * * *

'

* * * *

-

FIG. A-5 PERIODIC SERVICE SCHEDULE

E-Z-GOU:f!H,t•m A-9

19000-GI MANUAL NO. 10/01/83 ISSUE DATE REVISED DATE

TITLE:

GENERAL, SPECIFICATIONS

SPECIFICATIONS 3 WHEEL

4 WHEEL

521 lbs.

88.5 in.

568 lbs.

93 in.

Width ••••••• Wheel Base ••••

48 in.

60 in.

48 in.

Rear Wheel Tread Clearance Circle

39 in.

17.5 ft.

39 in.

20.5 ft.

ITEM Weight (without batteries) Length •••••

Tire Pressure •• Front Suspension

18-22 psi CoiI Springs & Shocks

Brakes • • . . . • • •

.

Tires . • • • • • • Electrical System Accelerator Switch Charger Motor •• Drive Train Differential Differential Lubrication

Body • • . . . • • • • . � · · · · · · · · · · Rear Suspension •••••••••• Chassis . . . . . . . . . . . . . . .

Hill Climbing Speed •

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

18-22 psi Leaf Springs

Mechanical Drum Type Wheel Brake With Automatic Hill Brake Release 18 x 8.50 x 8 (18 x 9.50 x 8 optional) 36 Volt D.C. Six 6 Volt Deep Cycle Lead Acid Batteries Four speed with single solenoid, self-adjusting wiper arm contactor 110-120 Volt 60 Cycle A.C. Input, 25 Amp 36 Volt D.C. Output 36 V D.C. High Efficiency Series Wound Direct, Motor Shaft Connected To Differential Pinion Shaft Hypoid Type Ring Gear 12.25: I Ratio RPM Delo Multi Service 200 - 30, 2.0 Pints AlI Steel Replaceable Panels Leaf Springs & Shock Absorbers Rectangular Steel Tubing 40% Grade 12 M.P.H. (maximum) Rack and Pinion

Steering

66 in.

A-IO

OPERATION & SERVICE MANUAL S ECTION TITLE: SAFETY PROCEDURES

MO DEL: ELECTRIC GOLF CAR SECTION

B

USE INSULATED WRENCHES AND BE CAREFUL NOT TO ALLOW WRENCHES TO CONTACT METAL AREAS OF VEHICLE WHILE WORKING ON BATTERY TERMINALS. OBSERVE BATTERY POLARI­ TY WHEN REINSTALLING CABLES.

GENERAL

WARNING:

When performing any inspection or maintenance work on the vehicle, always exercise care to prevent accidental personal injury to yourself or damage to the vehicle.

The following are general precautions which should be closely observed in carrying out any servicing operation. o

Set the hill parking brake.

Using an insulated wrench, remove all wires from the vehicle batteries. Remove the two battery hold downs by removing the hardware and lifting the plastic retainers from the threaded hold down bolts.

0

Do not work on the motor while connected to batteries.

Remove the batteries using a battery carrying tool.

0

When working near batteries, remove any jewelry, such as rings, watch, etc.

· WARNING: BATTERIES ARE HEAVY AND CARE SHOULD BE TAKEN WHEN REMOVING THEM. BE CAREFUL TO LIFT BATTERIES · WITHOUT TIPPING THEM, ELECTROLYTE

0

0

0

o

Never get under the car wh iI e it is supported by a jack. If it is necessary to work under the car, use safety stands.

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

. MAY BE SPILLED WHICH COULD CAUSE : BURNS OR DAMAGE TO VEHICLE AND :. CLOTHING. SHOULD ANY ELECTROLYTE BE SPILLED FLUSH THOROUGHLY WITH

Never connect or disconnect either the batteries or any electrical component while the key is in the ignition switch.

WATER.

Care must be taken to observe the preceding warnings when reinstalling batteries.

When connecting the battery cabl·es, pay particular attention to their polarities.

Never confuse the positive posts with the negative posts.

BATTERY REMOVAL AND INSTALLATION Tools Required:

- 7 I 16" wrench (insulated) - I /2" wrench (insulated) - Battery carrying tool

Quantity Quantity Quantity

E-Z-GC1U:f:H,t•m B-1

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

TITLE:

SAFETY PROCEDURE

LIFTING THE 3 AND 4 WHEEL ELECTRIC POWERED VEHICLE (Fig. B-1)

LIFTING PROCEDURE FOR FRONT OF 3 WHEEL VEHICLE (Fig. B-1)

Tools Required:

To lift the front of the vehicle:

- Hydraulic trolley jack - Jack stands - Chocks or wooden blocks

Quantity I Quantity 4 Quantity 4

WARNING: ALWAYS ENSURE THAT VEHICLE IS ON FIRM AND LEVEL GROUND. NEVER WORK UNDER VEHICLE UNLESS THE VEHICLE IS SUPPORTED ON JACK STANDS. ALWAYS PLACE CHOCKS BOTH IN FRONT OF AND BEHIND WHEELS THAT WILL NOT BE RAISED.

Place the jack under the frame at a point 4"5" in front of the vertical seat panel. Raise the vehicle with the jack and place I jack stand under the most forward flat area of the frame. A second jack stand should be placed on the outboard end of the axle tube.

BE SURE THAT THE BRAKE CABLE AND HANGERS ARE NOT DAMAGED DURING THIS OPERATION. CAUTION:

Slowly lower the jack and move it to the

opposite side of the vehicle and repeat the lifting procedure described above, placing the third and fourth jack stands with corresponding position to those placed on the opposite side.

Tools Required:

Place chocks in front of and behind the rear tires. Place a trolley jack on the left side of vehicle frame. Raise the vehicle, place a jack stand under the front of the frame. Lower the trolley jack. Repeat the procedure on the other side of the vehicle.

WARNING: VEHICLE IS EXTREMELY UN­ STABLE WHILE IN THE POSITION WITH ONE SIDE RAISED.

LIFTING PROCEDURE WHEEL VEHICLE

19000-G I 10/01/83

FOR

REAR

OF 3

WARNING: E-Z-GO DOES NOT RECOMMEND OR ENDORSE ANY PROCEDURE THAT LIFTS THE REAR OF VEHICLE ALONE. USE PROCEDURE FOR LIFTING THE 3 WHEEL ELECTRIC POWERED VEHICLE.

Slowly lower the jack and check that the vehicle is securely supported by the four jack stands. Lower the vehicle using the reverse procedure.

MANUAL NO. ISSUE DATE REVISED DATE

Quantity I Quantity 2 Quantity 2

- Trolley jack - Jack Stands - Chocks of wood

E-Z-GOUDht•m B-2

TITLE:

SAFETY PROCEDURE

o

Jacking Point

<)

Support Point

'---/ __ J -·--·-··---

FIG. B-1 LIFTING AND JACKING POINTS 8-3

19000-G I MANUAL NO. ISSUE DATE I 0/0 I /83 REVISED DATE

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z-GOUtiht•m B-4

OPERATION & SERVICE MANUAL SECTION TITLE: WHEELS and TIES

Tools Required: -

Lug wrench Tire Tool Tire Brush Rubber Mallet

MODEL: ELECTRIC GOLF CAR SECTIONC

the tire over the outside (valve stem side) of the wheel in the direction of the arrow shown.

Quantity Quantity Quantit y Quantity

NOTE: Care must be taken to prevent damage of tire bead. When bead is free of rim, insert tire tool under lower bead and pry tire off.

Tire Repair

Mounting Tire

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

Should a tire repair be necessary, proceed as follows:

Clean both tire beads and wheel rim bead seats with a tire brush. This is important to prevent loss of air around rim.

Install tire on rim (from valve stem side) using a rubber mallet and tire tool. Remove valve core and position bead against narrow flange side.

Apply air pressure through stem while pressing around center of tread. Pressure will build up and snap beads into place. Remove pressure and install valve core.

Overinflate to approximately 30 psi to assure bead seating.

ADJUST to specified pressure (18-22 psi).

If tire is flat, remove wheel and inflate tire to approximately 20 psi. Immerse tire in water to locate air leak and mark the location.

NOTE: Small holes in casing can be plugged with a standard automotive tubeless tire repair kit, available at most automotive supply outlets. To remove tire from rim, deflate by removing valve core, separate both tire beads from rim, push bead from wide side into rim recess.

Using tire tool, carefully remove

Wheel Installation Install wheel as shown by Fig. C-1.

FIG. C-1 WHEELS AND TIRES

E-Z�Ui3ht•m C-1

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

TITLE:

WHEELS AND TIRES

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GOiltihMU C-2

OPERATION & SERVICE MANUAL SECTION TITLE: STEERING

...

GENERAL

Loosen steering nut (4) two to three turns.

Using a mallet placed against the steering nut, apply pressure upwards to steering wheel.

Strike the mallet with a hammer which will cause the steering wheel to break loose from the steering shaft.

The steering assembly is a rack and pinion type.

STEERING ASSEMBLY REMOVAL (Fig. D-2) Tools Required:

-

Phillips screwdriver 1 4/16" socket, I/2" drive Drive ratchet I/2" BalI Peen hammer 2 lb.

Torque wrench 1/2" drive Pulling tool Pliers Mallet

MODEL: ELECTRIC -GOLF CAR SECTION D

Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity

-�:

Turn the steering wheel full travel to the right to position rack end ball joint. (On four wheel vehicles it is necessary to remove the shield to provide access to the steering arm area.)

Remove cotter pin (I) from slotted nut (2) and back nut off approximately halfway. Using a pulling tool as a lever, apply pressure to ball joint and tap nut with a hammer to loosen ball stud. Remove nut and lift stud from arm.

Remove 3 bolts (3) securing steering box to floorboard and lift assembly and lock washers (4) out of vehicle.

ReinstalI in the reverse order of disassembly.

Tighten ball stud slotted nut (2) to 40 ft. lbs. torque. Install new cotter pin.

3

2

FIG. D-1 STEERING WHEEL & SCORECARD HOLDER CAUTION: DO NOT STRIKE THE STEERING NUT OR THE END OF THE STEERING SHAFT DIRECTLY WITH A HAMMER. Reinstall steering wheel as follows: Slide steering wheel onto steering shaft splines.

Apply steering nut and tighten to I 0-15 ft. lbs. torque. Reinstall in the reverse order of disassembly.

DISASSEMBLY Steering Wheel Removal (Fig. D-1)

Remove two screws (I) holding the scorecard assembly (2) located on the back of the steering ·· wheel (3).

NOTE: Reinstall steering wheel correctly relative to steering travel.

CAUTION: TIGHTEN THE SCORECARD ASSEMBLY SCREWS TO 6 IN. LBS. TORQUE MAXIMUM.

E-Z-GOUi3ht•m D-1

MANUAL NO. 19000-G I 10/01/83 ISSUE DATE �EVISED DA TE

TITLE:

STEERING

I

�

!

-\\·-.<.;,/;1 ,--n I /\ ' -

( \..L

.i

--

�-�N

'

G)

�

"

,

-.............

'�

C')

------�-

'\

:

0, Iµ �J ..

� -

I

'�--/4��--/7jl ,,'j ,vi

...I

�

N

FIG. D-2 STEERING MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

D-2 .

TITLE:

STEERING

Steering Shaft Removal (Fig. D-2)

Idler Arm Removal (Fig. D-3)

Remove bolts (5) and lock washers (6) securing the column. Remove column (7) and wheel (8) and slide shaft (9) out through flanged end of column.

Tools Required:

Gear and Rack Removal (Fig. D-2) Remove steering column (7) from gear box ( I 0), remove bolts ( I I ), lock washers (12), and remove cover plate (13) and gasket (14). When removing gears, make note of the position of the spring washers (15), one under the pinion and one top and bottom of the reduction gear (16). Be sure washers are properly positioned when reassembling gears.

Loosen clamp (17) securing the bellows (18).

Slide rack and rod end assembly (19) out. If ball joint or tie rod end is worn or damaged, the rack and rod end assembly must be replaced as a complete unit.

Clean all parts with solvent and check for wear. Replace worn or damaged parts with new parts. Repack gear box with a high quality gear grease. (The factory recommends Moly Grease 2.) Apply grease liberally to gear studs, rack and gears before reassembly.

NOTE: Pins (20) must be lubricated prior to reassembly.

Reassemble alI parts in reverse order of disassembly. Be sure all assembly bolts and nuts are tightened securely to correct torque specifications.

Idler Arm - 4 Wheel Vehicles (Fig. D-3) If the idler arm ass�mbly (I ) is worn or has excessive play, the idier arm bushings (2) must be replaced.

-

Pliers Wrench 11/16" Socket I 5/ I 6 11 Torque wrench

Quantity Quantity Quantity Quantity

To remove the idler arm, disconnect the tie rod ball joint (3) at the bottom of the idler arm and the steering gear ball joint (4) at the top of the idler arm using the procedure outlined under "Steering Assembly Removal".

Lift front of vehicle per procedures in Section B and remove cotter pin (5). Using a pair of pliers or vice grips, rotate idler shaft (6) 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 a high quality gear grease. Reinstall in the reverse order of disassembly. Tighten ball joint nuts to 40 ft. lbs. torque and install new cotter pin.

Tie Rod Inspection Lift front of vehicle (See procedures in Section B) and check for vertical movement of tie rod which would indicate a worn condition.

King Pin Inspection Lift front of vehicle (See procedures in Section B). Hold top and bottom of tire and use a rocking motion to check for king pin movement which would indicate a worn condition.

E-Z-GOU:f3ht•m D-3

MANUAL NO. 19000-GI ISSUE DATE 10/01/83 REVISED DATE

TITLE:

STEERING

FIG. D-4 IDLER ARM REMOVAL MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z-GOUDht•m D-4

OPERATION & SERVICE MANUAL SECTION TITLE: SUSPENSION

MODEL: ELECTRIC GOLF CAR SECTION

FRONT (FOUR WHEEL VEHICLES} (Fig. E-1) Tools Required: - Pliers Quantity I Quantity - Pulling tool Quantity - BalI peen hammer Quantity - Torque wrench Quantity - Box end wrench 15/ 16" Quantity - Socket 15/ 16"

To replace the spindles (17) and (18), king pin bushings (19), or seal (20), proceed as follows:

Removal of the front suspension assembly as a unit is not required for most repair work; however, if removal· is required, proceed as follows: Lift front of vehicle (See procedures in Section B) and place on jack stands. Remove the front wheels. Remove the front bumper, if vehicle is so equipped, and remove the front shield.

Remove the tie rod assembly (7) from the idler arm as follows: Remove the cotter pin (8) from the slotted nut (9) and back off approximately halfway or until the threads are covered. Using a pulling tool lever, apply pressure to the rod end ball joint and tap the nut with a hammer to loosen the ball stud.

Remove the nut and lift the stud from the idler arm.

Remove the nut ( I 0), washers (11 ), and bushings ( 12) from the top of the shock absorber (13). Collapse the shock absorbers. Remove the bolts (14), lock washer (15), and nut (16) and remove the front suspension assembly from the vehicle.

Replace all broken or .worn parts and reinstall in reverse order of disassembly.

Tighten slotted nut on the rod end at idler arm to 40 ft. lbs. torque. Install a new cotter pin.

SPINDLE REPAIR (Fig. E-1) Tools Required: - Pliers - Box end wrench 15/ 16" - Sizing reamer .875" dia.

- Torque wrench - Socket 15/ 16"

E

Quantity Quantity Quantity Quantity Quantity

E-1

Remove the wheel and hub (refer to Bearing Service Procedures). Disconnect the ball joint (21 or 22) from the steering arm (refer to Front Suspension Removal).

Remove the cotter pin (23) and nut (24). Lift the spindle off of the king pin, taking care to note the position of the thrust washers (25 and 26) at top. Clean the spindle with a solvent and inspect for damage or worn bushings or seals.

If bushings are worn larger than .880 inch, press out and replace with new bushings. Press bushings in until flush.

NOTE: Bushing 1.D. will close slightly when pressed into the housing. If a ream operation is required, use a .875 inch sizing reamer.

Reinstall in the reverse order of disassembly.

Tighten the ball joint nut at the steering arm to 40 ft. lbs. torque and install a new cotter pin.

MAINTENANCE FRONT ON WHEEL BEARINGS 3 (FIG. E-4) AND 4 (FIG. E-2) WHEEL When maintenance is performed on either set of these bearings, they must be repacked with grease to assure proper lubrication during operation. Pack bearings as follows. Use a grease packing device or use the following manual procedure ·(See Periodic Service Schedule for grease specification): Place a dab of grease in the palm of the hand.

Using the other hand, take the bearing and dip the bearing into the grease pushing grease up between the rollers of the bearing. This must be done around the complete bearing. Reinstall bearings.

19000-GI MANUAL NO. 10/01/83 ISSUE DATE REVISED DATE

TITLE:

SUSPENSION

FIG. E-1 4 WHEEL FRONT SUSPENSION

MANUAL NO.

ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GO•IDht•m E-2

TITLE:

SUSPENSION

1

FIG. E-2 FRONT SPINDLE FORK REMOVAL AND BEARING SERVICE

the bottom surface to break the bearing loose.

Slide the bearing off the stem. With the fork removed from the vehicle, inspect the bearings and grease seals for damage. If the seal is damaged, the bearing and seal assembly must be repIaced.

(Fig. E-3)

Tools Required: -

Jack stands I I / 16" open end wrench Pliers 2" socket or open end wrench Hammer, Ball Peen 2 lb.

Axle or bearing grease Puller, slide hammer Punch, long tappered Brass bar Torque wrench, 1/2" drive

Quantity 2 Quantity I Quantity I

Clean the bearings with· solvent and dry thoroughly.

Inspect for damage or wear.

Replace with new parts, if necessary. Repack the bearings with grease (see Packing Procedure), making sure rollers are completely covered with grease and making sure that there is grease between the rollers and races (See Maintenance on Front Wheel Bearings).

Quantity Quantity AR Quantity Quantity Quantity Quantity

Lift the front of the vehicle (See procedures in Section B) and place on jack stands, disconnect the steering rack and ball joints, remove the cowl center support of vehicles starting with serid1 .number A8330277238 and remove the console _assembly (See Console Removal Section). Ori earlier vehicles, only the center support need be removed. Lift the dash mat (I) and remove the fork cap (2).

Remove the stem nut (3) and washer (4) from the fork stem (5).

CAUTION:

WHILE REMOVING NUT, SUPPORT FORK SO THAT IT WILL NOT DROP OUT AND DAMAGE FORK STEM AND/OR BEARINGS. The lower bearing (6) will remain on the fork stem. To remove this bearing, tap lightly on

Inspect the outer races (7) and the stem housing for pitting or other damage. If it is necessary to remove and replace the race, proceed as follows: The lower race can be removed using a slide hammer puller.

To remove the top race, use a long tapered punch. Insert the punch through the bottom end of the housing and against the lower edge of the race, strike the punch with a hammer while alternately changing punch position around the edge of the race. InstalI a new race by tapping lightly with a brass bar and hammer. Reinstall the fork and bearings in the reverse order of disassembly.

Tighten the fork stem nut until the fork is snug in the frame, then back off I/4 turn.

Reinstall the dash mat -and fork cap. Reinstall the cowl support and the console, if equipped.

E-Z-GOU:£Hst•m E-3

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

TITLE:

SUSPENSION

FIG. E-3 FRONT FORK REMOVAL MANUAL NO. ISSUE DATE REVISED DATE

I 9000-G I I 0/0 I /83

E-4

TITLE:

SUSPENSl � ON � �----

E-5

MANUAL NO. 19000-GI ISSUE DATE 10/01/83 REVISED DATE

TITLE:

SUSPENSION

REMOVAL OF AXLE AND HUB ASSEMBLY

jam nut to 70-90 ft. lbs. torque. Reinstall the tire and rim assembly on hub and tighten the lug nuts to 50-60 ft. lb. torque and install axle in fork assembly with reverse procedure.

Tighten outside lock nuts to 90-110 ft. lbs. torque.

(Fig. E-4)

Tools Required:

-

II/16" open end wrench I I/8" open end wrench Punch long tappered Hammer, Ball Peen 3/4" socket, 1/2" drive Torque wrench, I/2" drive

Quantity Quantity Quantity Quantity Quantity Quantity

I 2 I I I I

Loosen the shock nut (I) 4 to 5 turns. Slide the retainer, axle nut (2) away from the axle nuts on both sides of the fork.

Loosen the axle nut (3) to permit the flat washer (4) to clear the axle bracket assembly and to permit the axle and hub assembly to drop out of the axle brackets (5 and 6). After the axle and hub assemblies have been removed, slide the ring adjuster (7) off the end of the axle shaft. Loosen the jam nut (8) and unscrew both outside and inside (9) jam nuts from the axle shaft (one side only). After removing the jam nuts from axle shaft, slide the spacers (10) and hub assembly from the end of the axle shaft.

To remove the bearings (11) and grease seals (12) from the hub assembly (13), insert a punch on the opposite side of the bearing to be removed, position it on the bearing cone, tap lightly around the bearing to push bearing and grease seal out of the hub. Clean the bearings with a solvent and dry thoroughly, and check for wear around the rollers and in the races.

Clean the hub assembly with solvent and dry thoroughly and check the outer races· in the hub assembly for damage or wear. Reinstall in the reverse order of disassembly.

-,

NOTE: When installing grease seals into hubs, insert the grease seals, flange side inward (Fig. E:..5), tap lightly and evenly around the seal until the seal is flush with the outer side of the hub assembly. Lubricate seal surface. The hub assembly may be reassembled to the axle assembly using the reverse procedure. When reinstalling the jam nut (9) on the axle shaft, position the inside jam nut against the spacer, tighten the nut until the hub becomes difficult to turn on the axle shaft, back off the jam nut until the hub turns freely. While holding the inner jam nut, tighten the outside MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

FIG. E-5 INSTALLING GREASE SEAL

FIG. E-6 VERTICAL ALIGNMENT

E-Z-GOUi=IM·m E-6

TITLE:

SUSPENSION

FRONT WHEEL ALIGNMENT Tools Required: - I I /16" open end wrench - 611 adjustable wrench - Square

Quantity Quantity Quantity

THREE WHEEL VEHICLE (Fig. E-6)

X2

Should the steering tend to pull to one side, align the wheel as follows: Position the vehicle on a flat level surface and set the wheel in a straight position. Loosen the nut (3) at both ends of the axle (refer to Fig. E-4).

Using a square, check the vertical alignment of the wheel/tire.

Remove the axle nut retainers (2) from the outside axle nut. Loosen the jam nuts on the axle set screws (15). Adjust the set screws to position the wheel/tire ° vertically (90 ) to the floor. Retighten the jam nuts. Reinstall the axle nut retainers (2) and tighten nuts to 90-1IO ft. lbs. torque

WARNING: WHEN ADJUSTING THE FORK, ENSURE THAT A MINIMUM OF ONE FULL AXLE DIAMETER REMAINS IN THE FORK ARM SLOT.· Four Wheel Vehicle (Fig. E-7) To check the front end alignment, lift the front of the vehicle (see procedures in Section B) and rotate each front tire and scribe or chalk a line around the circumference of each tire at approximately the center of the tire. Toe­ in dimensions shall be as follows: (Fi�. E-5) Toe-in front dimension is to be 1/4" - 1/16" smaller than rear dimension, when measured at points XI to XI and .X2 to X2. If toe-in is not within the above range, an adjustment should be made as follows: loosen the nuts or clamps 11811 on the tie rod 11C 11 and rotate tie rod tube as required until the toe-in dimensions are within the acceptable range.

NOTE: After an acceptable range has been achieved, rotate the tie rod tube as required to locate tow pin 11D11 in a vertical position.

Tighten nuts or clamp bolts 11811 securely.

X1 1 -----Front-------1

FIG. E-7 4 WHEEL FRONT END ALIGNMENT FRONT WHEEL BEARINGS Vehicles) (Fig. E-8)

(Four

Wheel

Tools Required: ..,.

-

I I /2" box wrench Jack Jack stand Needle nose pliers Channel lock pliers Punch Hammer 3/4" socket (I /2" drive) 611 extension (1/2" drive) I /2" drive ratchet

Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity

I I 4 I I I I I I I

Lift the front of vehicle (See procedures in Section B) so that wheels are off the floor and install jack stands. Remove the wheel lug nuts and remove the wheels. Remove the dust cap (I ), remove the cotter pin (2), remove the slotted nut (3), pull the hub (4) and the outer bearing (5) off spindle (6).

To remove the inside bearing and seal, insert a punch from the outside and. lightly tap around the bearing cone (7). Clean the bearings, hub, seal and dust cap with a solvent and dry thoroughly.

Inspect for wear or damage.

E-7

MANUAL NO. 19000-GI ISSUE DATE 10/01/83 REVISED DATE

TITLE:

SUSPENSION

2 FIG. E-8 FRONT SPINDLE Worn or damaged parts should be replaced. If the bearing cups (8) are worn or damaged, use a punch to remove and press in new cups.

Repack the bearings with wheel bearing grease, . making sure that grease is forced down between the rollers and race. (See Maintenance on Front Wheel Bearings 3 and 4 Wheel.)

REAR SUSPENSION (3 VEHICLES) (Fig. E-9)

AND

4

WHEEL

REMOVAL OF REAR SHOCK ABSORBERS (Fig. E-9)

Tools Required:

-

9I16" Box wrench 3/4" Box wrench 3/4", 3/8" Drive socket 611 , 3/8" Drive extension 3/8" Drive ratchet Torque wrench Trolley jack

Quantity Quantity Quantity Quantity Quantity Quantity Quantity

I 2 I I I I I

Disconnect the batteries (see procedures in Section B). Remove the wiring from the motor (See Motor Removal and Disassembly). Loosen both rear wheel and tire assemblies by loosening the lug nuts but do not remove. Raise the vehicle (see procedures in Section B).

Remove the rear wheel and tire assemblies.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

Use a 9/ 16" box end wrench on the nut (I) at the top of the shock (2). Rotate the top part of the shock counterclockwise. Lower the body of the shock and retain all hardware. Use a 3/4" wrench to remove the bottom hardware • Remove the shock.

REMOVAL OF REAR LEAF SPRINGS (Fig. E-

9)

Tools Required:

-

Trolley jack Torque wrench 9 I 16" Box end wrench 9/16" Deep socket, 3/8" drive 3/8" Drive ratchet 3/4", 3/8" Drive socket Extension, 3/8" Drive, 6 11 length Needle nose pliers Screwdriver, Standard I /2" Wrench

Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity

READ REMOVING REAR AXLE ASSEMBLY FROM VEHICLE (SECTION M I) BEFORE PROCEEDING.

E-8

TITLE:

SUSPENSION

REMOVAL OF STABILIZER BAR ONLY) (Fig. E-9)

(3 WHEEL

Use the previous procedure for removing the rear springs. Remove 'U' bolt and nut assembly from each side of the vehicle above motor.

Remove the stabilizer spring retainer bracket the reverse order of stabilizer bar 'U' bolt lbs. torque.

bar complete with the assembly. Install using assembly and tighten hardware to 18-25 ft.

REMOVAL OF STABILIZER BAR ONLY) (Fig. E-9)

(3 WHEEL

Use the previous procedure for removing the rear springs. Remove 'U' bolt and nut assembly from each side of the vehicle above motor.

Remove the stabilizer spring retainer bracket the reverse order of stabilizer bar 'U' bolt lbs. torque.

bar complete with the assembly. Install using assembly and tighten hardware to 18-25 ft.

Remove batteries (See Safety Procedures in Section B). Remove the top end of the shock using previous procedures. Place a trolley jack underneath the differential housing and remove the wiring from the motor (See Electric Motor Section). Using needle nose pliers, remove the cotter pin and retaining ring from the brake assembly. Remove the pin from the brake lever. Remove the cable from the shackle.

With the jack elevating_ the rear end, remove the 4 'U' bolts (3) from the rear end. Lower the rear end slowly. Remove the rear end from underneath the vehicle.

Remove the lower nut and bolt assembly (4) from the front of the spring. Remove the nuts and hardware (5) from the shackle (6) and remove the spring (7) from the vehicle.

Install using the reverse order of disassembly.

Tighten all 'U' bolt hardware to 30-35 ft. lbs. torque. Tighten all hardware until the bushings are compressed to the diameter of the retaining washers.

E-9

19000-GI MANUAL NO. 10/01/83 ISSUE DATE REVISED DATE

TITLE:

SUSPENSION

FIG. E-9 REAR SUSPENSION MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-10

OPERATION & SERVICE MANUAL

MODEL: ELECTRIC GOLF CAR

SECTION TITLE: ACCELERATOR

SECTION ACCELERATOR ADJUSTMENT (Fig. F-1 and

F-2)

Tools Required:

- Pliers, needle nose - I /2" Open end wrench

Quantity I Quantity I

DISCONNECT BATTERIES BE­ WARNING: FORE ATTEMPTING THIS ADJUSTMENT. A COMPONENT FAILURE OR INADVERTANTL Y LEAVING THE KEY IN THE "ON" POSITION COULD RESULT IN THE VEHICLE ACCELERATING OUT OF CONTROL.

To determine the need for an accelerator adjustment, observe the accelerator switch assembly (I) with the accelerator pedal (2) in the fully released position. The spring loaded brush should be located on the bottom contact stud (no. I) (3) only and with the contact arm (4) resting against the stop (5).

f

loosen the jam nut (7) at the adjustable yoke (8). Remove the cotter pin (9) and slide the accelerator rod (IO out of the adjustable yoke (8) being careful to note the position of the two flat washers ( I I). Inspect all parts for abnormal wear and replace if required.

Separate the accelerator rod assembly (12) from the accelerator pedal and rotate the adjustable yoke (8) clockwise to shorten, or counterclockwise to lengthen the accelerator rod assembly.

The correct adjustment of the accelerator rod assembly is achieved when the above criteria are met.

Reassemble using the reverse procedure and use a new cotter pin (9) to secure the assembly.

Recheck the adjustments and, with the accelerator in the fully raised position, bend the stop leg (13) to provide I/32" clearance with the accelerator pedal.

Observe the accelerator switch assembly (I) with the accelerator pedal (2) in the fully depressed position.

The spring loaded brush ( 12) should be located in full contact with the top contact stud (no. 5) (6) only.

The accelerator requires adjustment if either of the above conditions are not met.

6

Raise the front of the vehicle (see procedures in Section B) to provide access to the under­ side of the accelerator linkage.

12

1

3

5

FIG. F-1 ACCELERATOR SWITCH ADJUST­ MENT

E-Z-GCiiii3hM:t F-1

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DA TE

TITLE:

ACCELERATOR

I

\,

�----�===='

FIG. F-2 ACCELERATOR LINKAGE REMOVAL MANUAL NO. ISSUE DATE REVISED DATE

I 9000-G I I 0/0 I /83

F-2

TITLE:

ACCELERATOR

ACCELERATOR LINKAGE REMOVAL F-2)

ACCELERATOR PEDAL REMOVAL

(Fig.

Tools Required:

Tools Required: - I /2" Open end wrench - I I /8" Open end wrench - Long screwdriver or alignment punch - Hammer

(Fig. F-3)

- 7/ I 6 11 Box end wrench - Needle no�e pliers - I /2" Open end wrench

Quantity Quantity Quantity Quantity

Quantity Quantity Quantity

Remove the adjustable yoke from the acceler­ ator pedal (see Accelerator Pedal Adjustment Procedure).

Remove the two screws ( I) and the two lock nuts (2) that secure the accelerator pedal assembly (3) to the floor of the vehicle (4).

Lift the accelerator pedal assembly from the vehicle. Should the pivot bearings (5) need to be replaced, they may be removed by removing the pivot pin (6). A new push nut (7) wi 11 be required for reassembly.

Remove the adjustable yoke (8) from the accelerator pedal (2) (see Accelerator Pedal Adjustment Procedure).

At the accelerator switch assembly (I): Slide the barrel of the ball joint socket (14) forward and push the accelerator rod assembly ( 12) away from the pivot arm assembly (I 5). Pull the complete accelerator rod assembly through the cross­ member (16) and out of the vehicle.

NOTE:

If vehicle has been driven under adverse conditions, some difficulty may be encountered when attempting to slide the barrel of the ball joint socket (14).

If such difficulty is en­ countered, tap the barrel using either a straight blade screwdriver or an alignment punch and a hammer.

CAUTION: TAP LIGHTLY TO PREVENT DAMAGE TO THE ACCELERATOR SWITCH ASSEMBLY.

E-Z-GOUiDh(•m F-3

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/0 1/83

\

\ \

\;

\

\\

\�d' �

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

F-4

OPERATION & SERVICE MANUAL

MODEL: ELECTRIC GOLF CAR

SECTI ON TITLE: BRAKES

SECTION HOW THE BRAKE WORKS The brake assembly is a servo action brake.

When the brake pedal is depressed, the cable pulls the brake lever forward which, in turn, pushes the rear brake shoe rearward and against the brake drum. This, in turn, reacts against the lever slide mechanism which forces the front brake shoe to move forward against the drum. At this point, the servo action takes place. For instance, if the vehicle is moving forward when the brakes are applied, the rear brake shoe moves upward applying force against the upper rear portion of the brake drum. The front brake shoe moves downward applying force against the lower front portion of the brake drum.

G

In figure G-3, the brake has been improperly adjusted using the turnbuckle. (Fig. G-4) Each time the brakes are adjusted by the turnbuckle, the angle indicated becomes greater as does the pedal force required to stop the vehicle.

Drum Rotation �

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

Normal brake wear (Fig. G-1) will show wear in quadrants A, B, C, and D with quadrant "A" showing the most wear, 11811 the second most wear, and etc. Quadrants A and D will always be toward the front of the vehicle.

The brake shoes should be replaced when lining thickness (measured at point of greatest wear) becomes approximately .040 thick.

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 adj�sted by the turnbuckle (attached to brake pedal) only, the geometry 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.

Forward. ------

FIG. G-1 BRAKE WEAR Rear Brake Shoe

Front Brake Shoe

Observe the angle of the brake lever in relation to the direction of the cable pull in figures G2 and G-3. In figure G-2, the brake has been properly adjusted using the brake adjusting screw. The angle is less than 90°.

FIG. G-2 CORRECT ADJUSTMENT

G-1

19000-GI MANUAL NO. 10/01/83 ISSUE DATE REVISED DATE

TITLE:

BRAKES

Greater Than 90°

FIG. G-3 INCORRECT ADJUSTMENT

FIG. G-4 BRAKE LINKAGE MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z-GOUtlht•W G-2

TITLE:

BRAKES HOW THE ADJUSTER WORKS

Tools Required

The brake adjusting screw (anchor) has a conical shape with six flats at one end (Fig. G-5).

-

Hydraulic trolley jack Jack stands Chocks 7 mm Open end wrench

Quantity Quantity Quantity Quantity

I 2 2 I

When tightening the adjusting screw, raise the rear of the vehicle (see procedures in Section B), remove the wheel and tire assembly, leave the brake 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. With a wrench, turn the adjusting screw counterclockwise until it will no longer turn. (DO NOT FORCE.) Notice that the screw will turn clockwise easily but will not turn counterclockwise. This means that the brake shoes have expanded against the drum and that the .crowns of the adjusting screw cannot expand the brake shoes any more (Fig. G-7).

Flats (6

FIG. G-5 ADJUSTING SCREW An extension spring holds the front and rear brake shoes against two (2) anchor pistons that ride on the conical end of the adjusting screw (see figure G-6). A ratcheting or indexing effect is encountered when turning the adjusting screw as the two (2) anchor pistons are forced outward by the crowns and pulled back into the flats by the spring.

CAUTION: FORCING OF THE SCREW TO TURN COUNTERCLOCKWISE CAN CAUSE INTERNAL DAMAGE TO THE ADJUSTING MECHANISM. Turn the adjusting screw clockwise to the last flat that was encountered during tightening.

Starting at this flat, turn the adjusting screw clockwise three (3) more flats (or notches).

Replace the adjusting screw boot.

Adjusting Screw

nchor Pistons (2)

Brake Shoe

Extension Spring

FIG. G-6 BRAKE ADJUSTMENT

G-3

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/01 /83

TITLE:

BRAKES

�_;::,,,-Last Flats Encountered X-Brake Drum

TIGHTENED ADJUSTER FIG. G-7 TIGHTENED ADJUSTER ADJUSTING THE BRAKE PEDAL (Fig. G-8) Tools Required

the turnbuckre. Normally, the turnbuckle will only need to be readjusted (from the factory setting) to compensate for wear in the braking system components exclusive of the· brake, i.e., the cables, pins, clevis, etc.

(Fig. G-8)

- 7 mm Open end wrench - Ruler

Quantity I Quantity I

After adjusting both brakes with the brake adjusting screw, the free pedal travel is adjusted with the turnbuckle located directly below the floorboard on the left hand (driver's) side. Free brake pedal travel is the distance the brake pedal travels before engaging the brake. This distance is measured perpendicular to the pedal pads at a point where the hill brake pad and the service brake pad separate.

Place one end of a ruler against the slanted portion of the. floorboard alongside the brake pedal at the point mentioned above. Push the pedal down with your hand; the distance traveled should measure between 3/4" - I" (see figure G-8). If adjustment is required; loosen the nuts on each end of the turnbuckle. Tighten the turnbuckle until the pedal cannot be depressed (no free play)�· l-oosen the turnbuckle until there is between 3/4" - I" of free pedal travel. Tighten the turnbuckle nuts.

NOTE: The turnbuckle should only be used to establish the correct free pedal travel after the brakes are properly adjusted.

When the free pedal travel becomes excessive and braking becomes unacceptable during use, then adjustment is to be made at the brakes.

After adjusting the brakes, check the free pedal travel. If it exceeds I" or less than 3/4", then adjust the free pedal travel with

MANUAL NO.

. ISSUE DATE REVISED DATE

19000-GI 10/01/83

./

\�� � Hill Brake Pad -

« �/> ,;, � \�

' Os '

FIG. G-8 BRAKE PEDAL FREE TRAVEL

E-Z-GOU:f3ht•i:t G-4

1"

3/4-

TITLE:

BRAKES

DISASSEMBLY OF BRAKE PEDAL (Fig. G-9) Tools Required: - Straight bladed screwdriver - Pliers - Ball peen hammer

Quantity Quantity Quantity

To repair or replace damaged or worn brake pedal parts, disassemble as follows:

If the spacers (9) or bearings (IO and (I I) are worn, replace them with new spacers or bearings.

Reassemble by reverse procedure.

NOTE: It may be necessary to remove the indentures on the shaft (4)-caused by the set screws (5).

Unhook the pedal return spring (I). (Insert a thin bladed screwdriver between the small hook end and the pedal bracket, move spring back and away from the bracket.)

Remove the lock nut (2) from the pivot bolt (3) and remove the bolt. Remove the spring, disconnect the cable clevis (4) and lift the pedal out through the floorboard.

To remove the hill brake pedal, note the position of the two springs (5). Remove the "push on" retainer nut (6) (new nut required for reassembly), and remove the hinge pin (7).

Reassemble in the reverse order of disassembly.

REMOVAL OF HILL LINKAGE (Fig. G-1 I)

BRAKE

RELEASE

Tools Required: -

Pliers Hydraulic trolley jack Jack stands 8 mm Open end wrench

Quantity Quantity Quantity Quantity

To remove the hill brake release linkage, raise the front of vehicle (See procedure in Section B) to allow access to underside.

To remove the Iink�ge rod (I), remove the cotter pin (2) and washE:_r (3) from lever arm (4).

Loosen the two set screws (5) in cam (6), and slide the pivot arm shaft (4) out of the pivot bracket (8). The cam and nylon spacer will come out when the pivot arm shaft is removed.

FIG. G-9 BRAKE PEDAL SPRING REMOVAL

E-Z�UtUU•m G-5

MANUAL NO. 1 9000-G I 10/01/ 83 ISSUE DATE REVISED DATE

TITLE:

BRAKES

" .(§:IH--6

FIG. G-10 BRAKE "KICK OFF" LINKAGE BRAKE DRUM AND SHOE REMOVAL

impossible due to its eccentric action. A drum that is i:nore than .0 IO inch out-of-round on the inside diameter should be replaced with a new drum.

Tools Required: - Hydraulic trolley jack - Plastic tipped hammer - Jack stands

Quantity I Quantity I Quantity 4

Drum Removal

Lift the rear of the vehicle ($ee procedures in Section B). Remove the wheel. Tap the brake drum 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

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

WARNING: DO NOT REBORE DRUMS IN ORDER TO TRUE UP THE BRAKING SURFACE. Cleaning It is recommended that a suitable greaseless type solvent be used to clean the braking surface of brake drums before they are placed in service to assure the cleanest possible surface.

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

E-Z-GOU:f=lh<•m G-6

TITLE:

BRAKES

1 2 3

FIG. G-11 WHEEL BRAKE Shaded Areas To Be Lubricated

FIG. G-12 BRAKE LUBRICATION AREAS

E-Z·G(nitiisM:t G-7

MANUAL NO. 19000-G I 10/01/83 ISSUE DATE REVISED DATE

TITLE:

BRAKES

Shoe Removal (Fig. G-1 I)

the flats on the tension pin.

Tools Required:

CAUTION:

DO NOT TURN THE PINS AS THEIR SEAL MAY BE BROKEN.

Quantity I

- Pliers

Remove the brake shoe retainer springs.

Using a pair of pliers, compress the brake shoe spring retainer (I) at the open end of spring.

While holding the tension pin (2) with the pliers, turn the retainer spring 1/4 turn to align the slot in the spring retainer with

Grasp the brake shoes (3) in the center and tilt them outward and away from the back mounting plate. This wiII release the tension on the brake springs (4). Remove the brake springs and remove the brake shoes.

?

I II FIG. G-13 WHEEL BRAKE COMPONENTS Brake Removal (Fig. G-13)

Clean the axle shaft to remove grease, dirt and all foreign matter. Apply small amount of lubricant (Neverseize) to the spline. Install the hub and tighten the axle nut to 70 ft. lbs. torque minimum.

Tools Required: -

Drum puller 1/2" Socket I /2" Drive ratchet Torque wrench 7/16" Socket

Quantity Quantity Quantity Quantity Quantity

If the slot in the axle nut and hole in the axle do not line up, continue to tighten axle nut until alignment is made.

NOTE: Minimum torque is 70 ft. lbs. Up to

To remove the brake assembly for axle bearing and seal replacement, the hub must be removed as follows: Remove the cotter pin and remove the axle end nut and the. washer.

Install a new cotter pin •.

Install an automotive type ·drum puller to the hub with at least 2 lug nuts finger tight. Pull the hub off the axle shaft with the puller.

RECOMMENDED PROCEDURE

140 ft. lbs. torque is satisfactory.

Remove the cotter pin and clevis pin attaching the brake cable to the brake lever. Using 1/2" socket wrenches, remove the 4 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.

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

G-8

I. 2.

3.

BRAKE

ADJUSTING

Lift the vehicle so that the rear tire is off the ground (see procedures in Section B).

Remove the wheel and tire assembly (See Maintenance Tip b. below).

Face the brake· assembly from the side of the vehicle, reach over the top of the brake and remove the brake adjusting screw boot (Fig. G-14).

TITLE: 4.

5.

6.

7.

8.

9.

10.

I I. 12.

13.

14.

BRAKES

While holding the drum in place, turn the adjusting screw counterclockwise until the adjusting screw will no longer turn. Do not force.

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

Starting at this flat, turn the adjusting screw clockwise three (3) more flats (or notches).

Replace the rubber boot and wheel and tire assembly.

Lower the vehicle.

Repeat steps I - 8 for other side.

After adjusting the brake with the brake adjusting screw, check the free pedal travel. If it is in excess of I" or less than 3/4", adjust as follows: Loosen the nuts on both ends of the turnbuckle.

Tighten the turnbuckle unti I all free play is removed from the pedal.

Loosen the turnbuckle until 3/4" - I" of free pedal travel is obtained.

Tighten the nuts on the turnbuckle.

NOTE: This procedure will eliminate any high

braking effort and/or dragging brakes.

MAINTENANCE TIP: (Fig. G-13) a.

The brake manufacturer recommends that the surfaces of the brake lever slide mechanism be lubricated with grease every three (3) to four (4) months of normal operating conditions.

CAUTION: MAKE SURE THAT NO GREASE COMES IN CONTACT WITH THE BRAKE DRUM OR SHOE SURFACES. b.

FIG. G-14 REMOVING SCREW BOOT HILL BRAKE ADJUSTMENT (Fig. G-15) The hill brake engagement and holding force should be properly adjusted if the brakes have been adjusted per the "recommended brake adjusting procedure".

HILL BRAKE FUNCTION: I.

To check for proper hill brake function, lift the rear of the vehicle (see procedures in Section B) so that both rear tires are clear of the ground and there are no objects near the tires.

2.

Remove the seat, reverse switch in turn the ignition position, and fully

If there is my dovbt 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 turnbuckle be loosened to allow plenty of slack in the cable system. This will allow the brake lever to return to its proper position. Then proceed with step 3 above.

WARNING: TO TEST FOR THE AUDIBLE "CLICK" OF THE MICRO SWITCH, THE VEHICLE FORWARD AND REVERSE SWITCH MUST BE IN THE NEUTRAL POSITION OR HAVE THE REAR WHEELS RAISED TO PREVENT POSSIBILITY OF INJURY IF VEHICLE IS ACTIVATED.

E-Z-GOUtlh(•m G-9

place the forward and the "forward" position, switch to the "on" engage the hill brake.

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE: 3.

4.

BRAKES

Slowly depress the accelerator pedal until the "click" of the accelerator switch is detected (the limit switch on the accelerator switch assembly activates the solenoid). If the solenoid is activated (clicked) after the hill brake is released, the hill brake is functioning properly.

If the accelerator switch solenoid is activated prior to complete hill brake disengagement, the cause may be one or a combination of the following: a. An improperly adjusted hill brake kick­ off cam. b. The catch bracket and/or latch arm is worn or damaged.

5.

To check the above items (a, b), lower the rear wheels to the ground. Lift the front of the vehicle (see procedures in Section B). If the vehicle has four wheels, remove the left front wheel (driver's side) for better access to the hill brake kick-off mechanism, and proceed as follows: a. Inspect the catch bracket (I) and latch arm (2) for any damage or wear. b. If the hill brake latch arm needs replacing, see section on "Disassembly of Brake Pedal".

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

c. If the catch bracket needs replacing, proceed as follows: I) Be sure that the hi11 brake has been released.

2) Roll the floormat back from the brake area to provide access to the 1/4" catch bracket mounting nuts (5) (7 I 16" wrench).

3) Remove the 1/4" x 3/4" long bolts (3), lock washers (4), and the nuts (5) which retain the catch bracket ( I) to the brake bracket.

4) Remove the catch bracket and install a new catch bracket in the reverse order of disassembly. d. Check the cam (6) for proper adjustment.

When the latch arm is engaging the catch bracket, there must not be any gap between the top of the cam and the latch arm (Fig. G-15). e. If the cam requires adjustment, proceed as follows: I) Engage the hill brake.

2) Loosen the two cam set screws (7).

3) Rotate the pivot arm assembly (I, Fig. G-16) upward (clockwise when viewed from the driver's side of the vehicle) to remove the free play in the Ii nkage.

4) Rotate the cam counterclockwise so that the top of the cam is contacting the latch arm.

5) While holding the cam and the pivot arm assembly in proper position, tighten the cam set screws.

E-Z-GOUDht•m G-IO

TITLE:

BRAKES

Cam Must Be Against Latch Arm At This Point

114• f!t'ax Gap At This Point

FIG. G-15 CATCH BRACKET ADJUSTMENT

1

FIG. G-16 PIVOT ARM ASSEMBLY G-11

19000-G I MANUAL NO. I 0/0 I /83 ISSUE DATE REVISED DATE

MANUAL NO. ISSUE DATE REVISED DATE

I 9000-G I I 0/0 I /83

E-Z-GCJUtlhMU G-12

OPERATION & SERVICE MANUAL SECTION TITLE: BATTERIES AND CHARGING

MODEL: ELECTRIC GOLF CAR SECTION

H

GENERAL

o

Electric vehicle batteries require careful maintenance to maximize their useful service life.

Inspect all terminations to assure that they are both clean (corrosion free) and securely fastened to battery posts.

o

When adding water, do not overfill (Fig. H-1). Overfilling will cause a loss of acid from the electrolyte. Use distilled water when adding water to batteries. E-Z-Go strongly recommends that other water sources not be used since impurities can reduce the useful life of the batteries.

The following table indicates the maximum allowable impurities in water to be used for batteries. If it is suspected that a suitable water source other than distilled be available, a water analysis will indicate if the water is detrimental to battery operation.

WARNING: THE ELECTROLYTE IN A STORAGE BATTERY IS A DILUTE ACID WHICH CAN CAUSE SEVERE BURNS. ALWAYS WEAR SAFETY GOGGLES WHEN ADDING WATER, CHARGING BATTERIES, OR CLEANING BATTERIES. TREAT ALL ELECTROLYTE SPILLS BY EXTENDED FLUSHING WITH CLEAR WATER. WARNING: HYDROGEN GAS IS FORMED WHEN CHARGING BATTERIES. DO NOT CHARGE BATTERIES WITHOUT ADEQUATE VENTILATION. DO NOT SMOKE IN AN AREA BEING USED FOR CHARGING BATTERIES. CONCENTRATIONS OF 4% HYDROGEN GAS OR MORE IS EXPLOSIVE. PREVENTATIVE MAINTENANCE o

Check the electrolyte level at least once · a week.

o

Inspect all wmng for breaks deterioration of the insulation.

o

Inspect all terminations ·for frayed con­ ductors and loose or damaged connectors.

Impurity

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

or

Battery Cap · Electrolyte Level at . Least 1 /2" Above Plates or To Level1 ,.,_........,.....,..........,.,,.,.,.,.,......,., Indicator Plates

FIG. H-1 BATTERY ELECTROLYTE LEVEL

Calculated As

100 & MgO CaO ..

FE NH4 NO 3 NO 2 CL

Ports Per Million Clear & White Trace 40 5.0 8.0 50 10 5.0 5.0

TABLE H-1 RECOMMENDED ALLOWABLE IMPURITIES IN WATER TABLE H-1

19000-G I MANUAL NO. I 0/0 I /83 ISSUE DATE REVISED DATE

TITLE: 0

BATTERIES AND CHARGING

Batteries should be recharged after everyday's use. Charge batteries between rounds if possible.

SHOULD THE OPPOSING TERMINALS BE "SHORTED OUT" OR CONTACTED TO THE FRAME. A SHORT CIRCUT COULD RESULT IN AN EXPLOSION AND SEVERE PERSONAL INJURY.

CAUTION: DO NOT SEND A VEHICLE OUT UNLESS IT'S BATTERIES ARE IN A GOOD STATE OF CHARGE. DISCHARGING A BATTERY COMPLETE­ LY BEFORE RECHARGING (DEEP CYCL­ ING) IS DETRIMENTAL TO BATTERY LIFE. 0

WARNING: BE SURE THAT THE FORWARD AND REVERSE SWITCH IS IN THE NEUTRAL POSITION AND THE KEY SWITCH IS IN THE "OFF" POSITION.

Keep batteries clean. Wash batteries with a stiff bristle brush using water and bicarbonate of soda. Rinse with water after cleaning.

WARNING: WEAR GLOVES AND EYE PROTECTION WHEN WORKING WITH BATTERIES. ACID IN THE ELECTRO­ LYTE CAN CAUSE BURNS TO THE EYES, SKIN AND CLOTHING. 0

Batteries should be checked frequently to be sure that they are in a good state of charge. Full charge for a new battery should yield a hydrometer reading of 1.280 specific gravity while an older battery may give a reading of 1.250 specfic gravity and still be fully charged.

0

In the "off season", the batteries should be fully charged and stored in an unheated covered area. Check the batteries during the "off season" and recharge if a hydrometer shows a reading of less than 1.220 specific gravity.

Inspect the battery racks for corrosion and clean if required using a putty knife and a wire brush. Remove all corrosion before priming and painting with a corrosion resistant paint.

Before returning batteries to service, perform all of the preceding preventative maintenance.

o

To prevent unnecessar·y drag on the vehicle which will result in poor performance and a higher amperage draw, inspect for improperly adjusted wheel bearings, dragging brakes, and underinflated tires.

BATTERY INSTALLATION WARNING: BEFORE PROCEEDING, REMOVE ALL JEWELRY, RINGS, WATCHES, ETC., AND WRAP ALL WRENCHES IN VINYL INSULATING TAPE (FIG. H-2) TO ELIMINATE THE POSSIBILITY OF A SHORT CIRCUIT 19000-G I 10/01/83

Remove the wiring from each battery using an INSULATED WRENCH (Fig. H-2) and remove the two battery hold downs.

Remove the batteries using a battery removal tool.

WARNING: BATTERIES ARE HEAVY AND CARE SHOULD BE TAKEN WHEN REMOVING THEM. BE CAREFUL TO LIFT BATTERIES WITHOUT TIPPING THEM, ELECTROLYTE MAY BE SPILLED WHICH COULD CAUSE BURNS OR DAMAGE TO VEHICLE AND CLOTHING. SHOULD ANY ELECTROLYTE BE SPILLED, FLUSH THOROUGHLY WITH WATER.

o

MANUAL NO. ISSUE DATE REVISED DATE

See Safety Procedures in Section B. Carefully note the manner in which the old set of batteries were installed.

Pay particular attention to the polarity of the wiring (Fig. H3).

Inspect all batteries visually for damaged containers, covers or terminals that may have been damaged or broken during transit. Inspect each cell (a dry cell would indicate a possible crack in the battery case).

Inspect all cables and terminations for any defects and replace as required. If they are to be reused, clean in a solution of water and bicarbonate of soda ( I bucket water to I cup of bicarbonate of soda). Rinse thoroughly and clean and dry. Remove any remaining corrosion from the wire terminations using a wire brush.

Clean the battery terminals with a wire brush until all corrosion is removed.

E-Z·G<.nlDhl•W H-2

TITLE:

BATTERIES AND CHARGING

Install the batteries and the battery hold downs.

Tighten the hold down hardware snugly (25-30 in. lbs.) to prevent battery bounce but do not overtighten since the battery case could be distorted.

Insulated Wrap

01 \ \ \ \ \ \ d1 \ \ \ 'C] FIG. H-2 INSULATED WRENCH Use an insulated wrench to install the battery wiring and tighten nuts to provide a tight connection between the wire terminations and the battery posts.

Apply a coat of petroleum jelly to the outside of the connection to retard corrosion of the joint.

Before the vehicle is put into service for the first time with new batteries, a 12 hour charge is required fo charge all batteries to a common level of charge.

When electric golf cars are used for 36 holes or more, the batteries become deeply dis­ charged, which is reflected in a low specific gravity reading.

Batteries in this state of discharge require longer charge cycles to restore their full capacity.

If this lengthy charge time is prematurely terminated because the car is returned to service, the balance· of the charge should be made up. This make· up or catch up charge should be accomplished at the earliest possible time.

If the recharge is not made up, the batteries become more and more discharged as they are used. When batteries are allowed to remain deeply discharged, their life is shortened.

CHARGING

(Fig. H-4)

It is most important to follow the following steps when charging batteries. o

Check that electrolyte covers the plates in all cells.

o

Charging must be performed in a well ventilated area.

o

Inspect the charger D. C.• plug for loose, bent, arced or dirty contacts.

o

Inspect the vehicle receptacle for loose wires or damage.

o

Insert plug into receptacle and check that the connection is tight.

o

Be careful not to pull on the D. C. cord or place it in a position where it can be driven over or present a hazard to personnel working in the area.

WARNING: ALWAYS TURN CHARGER OFF BEFORE UNPLUGGING. UNPLUGGING WITH CHARGER CONNECTED COULD RESULT IN AN ARC. UNPLUG ·BY PULLING ON THE HANDLE, NOT THE CORD. Observe the ambient temperature in the charging area.

A battery requires a longer charge time than normal when the ambient temperature falls below 60° F. The time required increases as the ambient temperature decreases.

A. C. LINE VOLTAGE The E-Z-Go battery charger's initial output is directly proportional to the input voltage. If a problem is encountered with several vehicles that indicates an insufficient initial (start) charge, it is suggested that the batteries be tested, and if found satisfactory, then the input A. C. voltage should be checked by the power company and their recommendations be followed. For additional information pertaining to the battery charger, see the BATTERY CHARGER SECTION in this manual.

E-Z-GOU\f:ihM:t H-3

19000-G I MANUAL NO. I 0/0 I /83 ISSUE DATE REVISED DATE

TITLE:

BATTERIES AND CHARGING

FIG. H-3 POWER WIRING DIAGRAM MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GOUtUst•m H-4

TITLE:

BATTERIES AND CHARGING

DO!

2

DONT!

FIG. H-4 CHARGING BATTERIES

E-Z-GOUtiht•W H-5

19000-G I MANUAL NO. ISSUE DATE I 0/0 I /83 REVISED DATE

TITLE:

BATTERIES AND CHARGING

ROTATING CARS

filled the gassing will force a portion of the electrolyte out through the vent holes in the vent caps. The result of this electrolyte loss will additionally result in corrosion of the wire and connections and the corrosion of the battery support members.

It is important to charge each car fully after each day of play. With this in mind, the fleet should be "rotated" such that the first car on charge should be the first car to be used the following day.

In this way, batteries will receive the maximum charge available and the wear on the vehicles will be evenly distributed.

ADDING WATER (Table H-1) The electrolyte in the vehicle's batteries is a solution of sulfuric acid and water. The water portion of this solution evaporates or is lost in the charging cycle but the acid is retained.

In the life of a battery, it is only necessary to replenish water and not the acid.

WARNING: IF A CONSIDERABLE AMOUNT OF BATTERY ELECTROLYTE IS SPILLED, IT MAY BE REPLACED. BE SURE TO OBSERVE

ALL PROCEDURES, CAUTIONS, AND WARN­ INGS PROVIDED BY THE ELECTROLYTE MANUFACTURER. When replenishing water, use only distilled water or water that has been tested and found to meet the requirement of table H-1.

In the life of an average battery, the water usage will be approximately 2 1/2 times the original electrolyte quantity, or approximately 16 quarts.

CAUTION: USE OF NON DISTILLED WATER CONTAINING VARIOUS MINERALS BECOMES SIGNIFICANT IN THIS QUANTITY AND WILL HAVE A DETRIMENTAL EFFECT ON THE LIFE OF THE BATTERY. WATER LEVEL (Fig. H-5) Add water to the indicator ·ring if equipped or to 1/2" above the top of the separators. Filling above this level will cause the loss of electrolyte during the charging cycle. The charging cycle causes bubbles to occur which will cause the electrolyte to fill the cavity above the plates. If the electrolyte is over-

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

CAUTION: BEFORE CHARGING, BE SURE THAT ELECTROLYTE IS ABOVE THE SEPARATORS. NEVER ALLOW THE ELEC­ TROLYTE TO FALL BELOW THE TOP OF THE PLATES SINCE PERMANENT DAMAGE CAN RESULT TO THE UNCOVERED PORTION OF THE PLATES. NOTE: It is recommended that any additional water required be added at the end of the charging cycle.

E-Z-Go recommends that all vent caps be removed and immersed in a container of water while watering the batteries. This will prevent loss of the caps and dilute any acid residue that could result in burned fingers. After replacing vent caps, rinse off batteries with a hose to eliminate any spilled electrolyte that may have been splashed during the watering operation.

CLEANING A coating of acid impregnated dirt on the top surface of a battery will create an electrical path between the terminals of the battery.

This electrical path will cause a "current leakage" which will both reduce the operating efficiency of the battery and reduce its useful life.

CAUTION: BE SURE ALL VENT CAPS ARE SECURELY IN PLACE BEFORE CLEANING BATTERIES. THIS WILL.PREVENT CONTAM­ INANTS FROM ENTERING BATTERIES. WARNING: USE EYE PROTECTION AND GLOVES DURING THE FOLLOWING CLEAN­ ING OPERATION. Wash with a hose and remove any remaining foreign matter using a stiff bristle brush and a solution of water and bicarbonate of soda ( I cup of bicarbonate of soda to I bucket of water). Hose off batteries after cleaning.

E-Z-GOUtllst•m H-6

TITLE:

BATTERIES AND CHARGING

If the batteries in the vehicle have been on charge and are to be tested with a voltmeter, drive the vehicle around for approximately 30 seconds, then let it stand idle for three or more minutes before testing. This stabilizes the voltage. In this instance, it removes a "surface charge" from the plates which would give a false high voltage reading.

TESTING BATTERIES What To Check: If a vehicle fails to perform satisfactorily and it is suspected there is a battery failure, each battery should first be checked individually and then all batteries in the vehicle should be checked as a set.

Test With Hydrometer: Using a battery hydrometer, test each battery individually, comparing the three cell readings of each battery. If the variation between the highest and lowest cell readings in any one battery is .050 (SO gravity points) or more, there is reason to suspect a weak or failing cell. This test is best accomplished with the batteries in a partially discharged state; after the car has been used for at least 9 holes of golf.

LOAD TEST

This test is designed to simulate the demands imposed on batteries supplying power to electric vehicles.

Batteries fully charged and with the electrolyte ° ° temperature @ 80 °F ! s F (26, 7 c ! 3°C) are discharged at the constant rate specified for the type battery being tested to a terminal voltage equivalent to I. 75 volts per cell. The discharge time in minutes is the battery capacity. The full charge electrolyte specific gravity is to be the same as specified by the battery manufacturer.

Instructions For Using Hydrometer: (Fig. H-6)

I.

Draw the minimum of electrolyte into the test tube to permit the float to float freely without contacting the top or bottom of the test tube.

2.

Hold hydrometer in a vertical position and take a reading at your eye level.

3.

Always correct hydrometer Specific Gravity reading to 80° F. For each ten degrees temperature above 80 ° F, add 4 points to reading. Example: 90 ° F 1.250 Sp. Gr. = 1.254. For each ten degrees ° below 80 F, subtract 4 points from reading. Example: 70 ° F 1.250 Sp. Gr. = 1.246.

4.

Test each cell, record readings (corrected to 80° F).

A variation of SO points between any two cell readings (example 1.250 = 1.200):· i.ndicates a defect in the low reading cells�

VOLTMETER CHECK

If the voltage of each cell cannot be measured, test the terminal voltage of each battery (if a set of batteries is being checked). Compare the voltage of the batteries against one another. If the battery voltage readings vary by 0.5 volts or more, there is probably a weak or failing battery. As stated under "Hydro­ meter Check", the Voltmeter check is more effective if the batteries are partially charged.

Golf car batteries shall be tested as indicated + above at a rate of 75- I ampere. There are load testers on the market that are capable of testing batteries in the vehicle. l(the Hydrometer or Voltmeter check indicates a battery, or one battery in a set of batteries is failing, fully charge it and conduct the above Load Test.

Record the discharge time in minutes for the cell voltage to reach I. 75 volts (5.25 volts for a 6-volt battery. A battery which delivers 50% or less of its rated capacity in minutes should be replaced.

The life of an electric vehicle battery is determined not only by the number of cycles (a discharge and a recharge) it receives but also by the depth of each cycle. Suppose batteries are used to operate a golf car for 18 holes per day. Let us call that one life cycle. If they are used for 36 holes, this is a much deeper discharge and would be equivalent to approximately three life cycles.

A battery used 36 holes per day will have a life span approximately one-third that of one used 18 holes per day.

H-7

19000-GI MANUAL NO. 10/01/83 ISSUE DATE REVISED DATE

TITLE:

BATTERIES AND CHARGING

Battery Cap Electrolyte Level at Least 1 /2" Above l Plate s or To Level-£ Indicator Plates

�-n II rf - I

.-n

I

1 I 1

� . I

FIG. H-5 BATTERY ELECTROLYTE LEVEL

Rubber Bulb

Se e Text

Hollow Tube

FIG. H-6 USING HYDROMETER MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

H-8

OPERATION & SERVICE MANUAL

MODEL: ELECTRIC GOLF CAR SECTION

SECTION TITLE: BATTERY CHARGER

J

GENERAL (Fig. J-1)

WARNING: CHARGERS SHOULD BE MOUNTED ON A PLATFORM ABOVE THE The E�Z-Go battery charger is semi-automatic GROUND, OR IN SUCH A MANNER AS TO and is designed specifically for charging . PERMIT THE MAXIMUM AIR FLOW UNDER­ electric vehicle batteries.

NEATH AND AROUND THE CHARGER. IF THE CHARGER IS MOUNTED SUCH THAT The charger type is known as a ferro-resonant.

INSUFFICIENT AIR FLOW IS PREVENTED The term ferro-resonant is applied to a charger FROM ENTERING UNDERNEATH THE CASE, that starts the charge at a relatively high rate OVERHEATING WILL RESULT WHICH MAY of charge and continuously reduces the rate as CAUSE SERIOUS DAMAGE TO THE CHARGER the battery or batteries become nearer the full AND THE POTENTIAL FOR FIRE. charge condition.

If the charger is operated in an outdoor The charger can be connected to a vehicle that location, rain and sun . protection must be has been driven any number of holes and set provided. to the ON or 12 Hour timer position without overcharging or undercharging the batteries. See paragraph in BATTERIES SECTION of this If the charger is connected to a vehicle that manual for symptoms that may indicate a low has been operated for 36 holes and the timer input voltage (A.C.) condition. is set to the 12 Hour position, the charger will The charging (D.C.) cord is equipped with a operate at a "charge rate" as long as the battery voltage indicates that the battery polarized connector which fits into a matching receptacle on the vehicle. requires charging.

The power (A.C.) cord is equipped with a standard three prong U. L. listed grounded type plug. Electrical outlet receptacles installed for use at the battery charging locations must be of the three prong grounded type, which will ground the charger and vehicle to eliminate any electrical hazard.

When the battery voltage indicates a fully charged condition, the charger automatically reduces the rate of charge and continues to operate at a "trickle rate" until the 12 Hour time setting has expired and shuts the charger off. If the vehicle has been operated for 9 holes and the charger is set for 12 Hours, the charger will respond in the same way.

Provide Protection From Elements.

Under certain. conditions, it may be better to reduce the charge time rather than let the charger operate for a 12 hour period. If prolonged daily usage.of a vehicle is for only 9 holes and the batteries are near the end of their useful life, it is recommended that they be charged for a shorter period of time.

Consult your E-Z-Go's representative's service manager for proper procedures when these conditions exist.

CHARGER INSTALLATION

Grounded A.C. Receptacle

/fTI\\ � �,.....,---,�

�

110-120 VAC. Dedicated 1S amp Circuit

(Fig. J-2)

Each charger requires an input of a dedicated I I 0-120 Volt A.C. 60 cycle 15 Amp circuit.

FIG. J-2 CHARGER INSTALLATION

E-Z-GOUtlhl•i:t J-1

19000-G I MANUAL NO. 10/01/83 ISSUE DATE REVISED DATE

TITLE:

BATTERY CHARGER

1 --2·

FIG. J-1 BATTERY CHARGER MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GOU:f:U,t•m J-2

TITLE:

BATTERY CHARGER

WARNING: AN UNGROUNDED ELECTRICAL DEVICE MAY BECOME A PHYSICAL HAZARD THAT COULD RESULT IN AN ELECTRICAL SHOCK OR ELECTROCUTION. WARNING: WHEN CONNECTING OR DISCONNECTING THE CHARGER TO A

VEHICLE, ALWAYS MAKE SURE THAT THE TIMER OR POWER SWITCH IS SET IN THE OFF POSITION. IF IT IS NOT, AN ELECTRICAL ARC WILL OCCUR AND MAY CAUSE AN EXPLOSION OR FIRE.

3.

To test the fuses (6), place a probe on one side of a fuse and the other probe on the other side of the same fuse, the needle should deflect on the ohm meter. If it does not move, a bad fuse is indicated.

Repeat procedure on the other fuse.

4.

To test the negative side of the charger (8), touch either probe to the tip of the negative wire at the D.C. plug and the other to the terminal on the ammeter (9) which has 2 wires that connect to the transformer (I 0).

If a full needle deflection does not take place, an open circuit somewhere in the negative or black wire is indicated. This may be a broken wire, a loose terminal, or a defective ammeter. If the needle does not deflect, probe each component in the circuit until the open circuit is found. When the probe crosses the "open", it will deflect full scale.

5.

Touch the red (+) probe to one blade of the A.C. plug (11) (not the ground pin) and the black (-) probe to the black wire from the A.C. cord to the timer (12). If the needle of the Ohm Meter does not deflect, switch the red (+) probe to the other blade of the A.C. plug. It should deflect to indicate a complete circuit. If the needle does not deflect, it indicates a broken A.C. input wire. If the black wire is sound, repeat the same test to the white wire and the other blade of the A.C. plug.

6.

Disconnect the wires at the top contact that joins the timer motor (12) and the transformer (I 0) (a). Touch the red (+) probe to the timer motor wire and turn the timer on. Touch the black probe to the contact from which the transformer and timer motor wires were removed. The Ohm Meter should deflect. All circuitry from the A.C. plug to the primary coil of the transformer is functioning. The Ohm Meter will check the tranformer correctly only for an open circuit and not for a short. Touch one probe to the primary wire at one end (a) and the other at the opposite end (b). The meter will indicate if the circuit is complete. Touch one probe to each joint at the diode, the meter will indicate if the circuit is complete.

Remove one black wire from the capacitor.

CHARGER TROUBLE-SHOOTING (Fig. J-1 &

J-3)

A simple but effective method of trouble­ shooting a battery charger that does not operate is as follows. Use Fig. J-1 & J-3 for reference. Follow the sequenced procedures.

WARNING: DISCONNECT THE BATTERY CHARGER FROM BOTH THE A.C. POWER AND THE BATTERIES BEFORE PROCEEDING.

I.

2.

Remove the top cover (I) by removing the Phillips head screws (2) from the flanges.

Set VOM meter to the XI ohms scale.

Examine the D.C. plug (3) that connects to the vehicle carefully for loose terminals or broken wires. If everything is in good condition, use the Ohm Meter. Touch the red probe to the tip in the D.C. plug on the positive side (4) , touch the black probe to the heat sink (5) of the diode. The ohm meter's needle should deflect. If the needle does not move there is an open circuit between the D.C. plug and the diode which indicates a break in the white wire.

Touch the red ;(+) probe to the heat sink (5) and the black (-) probe to the joint of the wire and silicon diode (7). If the needle moves, it indicates a bad diode. If the needle does not move, reverse the leads, touch the black (-) probe on the heat sink and the red (+) probe on the joint, the needle of the ohm meter should deflect. If it does not move, a bad diode is indicated (7).

Conformance to this procedure indicates that all circuitry between the tip of the positive wire at the D.C. plug to the joint at the wires coming from the diodes is functioning correctly.

E·Z·GCnlttht•m J-3

19000-GI MANUAL NO. I 0/01 /83 ISSUE DATE REVISED DATE

TITLE: 7.

BATTERY CHARGER

Set the Ohm Meter to I K ohms. Touch one probe to each terminal of the capacitor, reverse the probes. The needles should deflect and then return to neutral.

Repeat this procedure; as the capacitor charges and discharges, the needle will deflect and return each time the probes are reversed. If the needle does not deflect at all, it indicates an open circuit.

If the needle deflects full scale and remains at full scale with the probes in either position, the capacitor is shorted.

An Ohm Meter is unable to test for a transformer with a short circuit. Should the charger fail to work after the above tests have been completed, the transformer should be exchanged for one that is known to be good.

WARNING: BE SURE TO DISCHARGE THE CAPACITOR ( 13) BEFORE TOUCHING EITHER WIRE OR TERMINAL THIS IS DONE BY SHORTING OR TOUCHING BOTH CAPACITOR WIRES OR TERMINALS WITH AN INSULATED SCREWDRIVER WHILE HOLDING THE INSULATED HANDLE. With one wire removed, touch one probe to each end of the black wire (c & d). The meter will deflect to indicate a complete circuit.

COMPONENT REPLACEMENT In general, component replacement within the battery charger · requires no explanation; however, diode replacement must be done with extreme care.

CAUTION: TO PREVENT DAMAGE AND PREMATURE FAILURE OF DIODES, THE FOLLOWING PROCEDURES MUST BE FOLLOWED. Diodes are semi-conductor components and should not be subjected to severe shock such as might be encountered by dropping the component or using electric or air tools to tighten mounting hardware.

Excessive heat applied to the diode during the soldering operation may result in damage to the diode.

When soldering a wire to a diode, use a heat sink such as a pair of pliers placed between the solder joint and the body of the diode to prevent excessive heat transfer to the diode.

Touch but do not press heavily on the diode post with the soldering iron or gun. Make a firm mechanical connection between the wire and the diode, and heat both the wire and the diode post until the solder (60/40 tin/lead 14 to 16 gauge) flows into the joint. Remove the solder and the iron and. allow to cool slowly before disturbing the joint.

Before installing the diode to the heat sink, clean the heat sink and apply a thin layer of heat sink compound (available at any electronics supply house) between the body of the diode and the heat sink. Tighten the diode hardware to I 5-20 in. lbs. torque. Remove any excess heat sink compound.

Grounded To Capacitor Mounting Bolt

FIG. J-3 WIRING DIAGRAM MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

E-Z-GOU£Ust•m J-4

OPERATION & S�RVICE MANUAL SECTION TITLE: ELECTRICAL

GENERAL There are two distinct circuits used in the operation of an electric vehicle. These circuits are the control and the power circuits.

The control circuits 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 MS-I is actuated by the forward and reverse switch, and micro switch MS-2 is actuated by the accelerator switch.

MODEL: ELECTRIC GOLF CAR SECTION K

RI, R2, and R3,through the forward and reverse switch which directs power in the correct orientation through the armature and field windings of the motor.

As the accelerator pedal is depressed further, the wiper advances to position (2) which bypasses resistor RI. Position (3) bypasses resistors RI and R2. The final position (4) bypasses all resistors and unrestricted battery power is transmitted to the motor which yields the maximum speed and power.

CIRCUIT TESTING (Fig. K-2)

CONTROL CIRCUIT (Fig. K-1)

Tools Required:

Forward Operation

- Volt meter with 0-50 volt range - Ohm meter

With the key switch in the "ON" position and the forward and reverse switch in the "FORWARD" (F) position, micro switch MS-I is closed which provides an electrical path to the solenoid. Depressing the accelerator pedal moves the "wiper" side of the accelerator switch from the "OFF" position (0) to the (I) position, and also activates micro switch MS2. The closure of MS-2 completes the control circuit and activates the coil of the solenoid which causes the solenoid contacts to close which in turn activates the power circuit.

Reverse Operation The reverse operation is identical to forward operation except that'· a. reverse warning device is activated by the forword and reverse switch that is placed in the "REVERSE" (R) position.

This warning device is in continuous operation while the forward and reverse switch is in the "REVERSE" (R) position.

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

Depressing the accelerator pedal moves the "wiper" side of the accelerator switch from the "OFF" position (0) to the (I) position. Power now flows through the resistor

Quantity Quantity

If the car fails to operate or operates poorly, the following test sequence should be followed.

WARNING: TO PREVENT THE 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 (see procedures in Section B) before proceeding.

To test the control circuit, turn the key switch (I) to the "ON" position. Set the volt meter to the 50 VDC range.· Touch the black probe to the negative (-) contact of the vehicle D.C. receptacle and the red (+) probe to the positive (+) contact of the vehicle D.C. receptacle.

(Fig. K-3) A meter reading of 36 VDC � 3V indicates that batteries are satisfactory. A reading of below 36 VDC indicates that one or all batteries are defective (See Batteries Section for testing procedures). No reading indicates an "open" condition and the power transmission circuit should be inspected for a broken or disconnected conductor.

E-Z·GCnH=iht•m K-1

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

TITLE:

ELECTRICAL Accelerator Switch ,------7 1 oO

Solenoid

----t------------�

1

1

"

3

'-- 4

I I

I

'-'-- - - - _j

F&R Switch See Note 1

See Note 3

A1

I-

- - - F1 -�....,._.____,

iO

Resistors r-----, I I I R1

I I 1Motor I

_)-

Charger Receptacle

NOTES I. FORWARD & REVERSE SWITCH (F & R) - FORWARD POSITION SHOWN WITH SOLID LINE - REVERSE POSITION SHOWN WITH DASHED LINE - NEUTRAL POSITION IS BETWEEN CONTACTS 2. MS I IS ACTIVATED BY THE FORWARD REVERSE (F & R SWITCH) - NORMALLY CLOSED - CLOSED IN THE FORWARD OR REVERSE POSITION - OPEN IN THE NEUTRAL POSITION 3. MS2 IS ACTIVATED BY THE ACCELERATOR - NORMALLY CLOSED - OPEN WHEN ACCELERATOR SWITCH IS IN '0' POSITION - CLOSED WHEN ACCELERATOR SWITCH IS IN I, 2, 3, OR 4 POSITION LEGEND MS C NC NO

MICROSWITCH COMMON NORMALLY CLOSED NORMALLY OPEN

-- POWER WIRE -- CONTROL CIRCUIT WIRE WIRE REFERENCES IN TEXT

0

FIG. K-1 ELECTRIC CAR WIRING DIAGRAM MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z�U:£iht•W K-2

I

R2 I I I R3 I L ___I

F2

-

I

TITLE:

ELECTRICAL

FIG. K-2 POWER WIRING DIAGRAM

E-Z-GOUtllst•m K-3

19000-G I MANUAL NO. I 0/0 I /83 ISSUE DATE REVISED DATE

TITLE:

ELECTRICAL Depress the accelerator pedal. Locate the red (+) probe on the small terminal of the solenoid (2) with the black wire attached. A meter reading of 36 VDC ! 3V indicates that the black wire from the solenoid to MS-2 is in good condition. Move the red (+) probe to the other small terminal located on the solenoid.

If the meter needle deflects; the solenoid coil is working. A meter reading of "0" indicates that the solenoid should be replaced.

Locate the red (+) probe to the key switch (I), terminal 4. A meter reading of 36 VDC ! 3V indicates that the yellow wire from the solenoid to the key switch is in good condition. Locate the red (+) probe to the key switch, terminal 3. Turn key on. A meter reading of 36 VDC ! 3V indicates that the key switch is in satisfactory condition. No reading indicates that the key switch should be replaced.

FIG. K-3 VEHICLE RECEPTACLE (VIEWED FROM FRONT)

With the forward and reverse switch in the forward position, remove the red(+) probe from the positive contact of the receptacle and relocate it to the positive (+) terminal of the solenoid (2). The positive terminal may be identified by the heavy gauge wire and the green wire that are attached to it. A meter reading of 36 VDC ! 3V will indicate that the heavy gauge wire (BR+) and terminations between the battery and solenoid positive (+) terminal are in good condition.

With the forward and reverse switch in the neutral position, locate the red (+) probe on the common terminal (3) of MS-2 (located on the accelerator switch). The common terminal may be identified by the RED/WHITE wire attached to it. A meter reading of 36 VDC !

3V indicates that the RED/WHITE wire and termination between the micro switch MS-2 and the forward and reverse switch are in good condition.

Depress the accelerator pedal. Locate the red (+) probe on the normally closed (NC) terminal of micro switch MS-2. This terminal may be identified by the black wire attached between it and the solenoid. A meter reading of 36 VDC ! 3V indicates that the micro switch is functioning. If the meter fails to move from the "0" position, check that the accelerator pedal is depressed, it if is and there is no reading, the micro switch MS-2 must be replaced.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

Locate the red (+) probe on the common (c) terminal of micro switch (4) MS-I situated on the forward-reverse switch assembly (6). The terminal may be identified by the blue wire attached to it. A meter reading of 36 VDC !

3V will indicate that the wire from the key switch to micro switch MS-I is in good condition.

Place the red (+) probe to the positive (+) contact of the vehicle receptacle. Locate the black (-) probe to the normally closed (NC) position of micro switch MS-I. This terminal may be identified by the black wire attached to it. A meter reading of 36 VDC ! 3V will indicate that the micro switch (4) is in good condition.

The completion of this test procedure will have checked all wiring and components in the control circuit.

The reverse warning device does not affect the operation of the vehicle, however, E-Z-Go strongly recommends that it's operation be checked and maintained since the correct functioning of this safety device may prevent an accident.

The warning device (I) should sound whenever the key switch is in the "ON" position and the forward reverse switch is in the "REVERSE" (R) position. Should the warning device fail to sound, the following procedure should be used to trouble-shoot the circuit (Fig. K-4).

K-4

TITLE:

ELECTRICAL

Set the volt meter to the 50 voe range, check that the key switch in "ON" and the forward­ reverse switch is in the "REVERSE" (R) position. Locate the black probe (-) in the negative side of the vehicle receptacle (Fig. K-3) and place the red (+) probe to the warning devices terminal with the green wire (3) attaching the solenoid (2) to the warning device. A meter reading of 36 voe ±' 3V indicates that the green wire joining the solenoid and the warning device is in good condition.

Locate the red (+) probe on the other terminal of the warning device. A reading of 36 voe � 3V will indicate that the wire joining the micro switch MS-2 to the warning device is in good condition. If both green wires are in good condition and the warning device does not sound, the warning device must be replaced.

3

FIG. K-4 WARNING DEVICE

E-Z-GOU:f3h(•i:i K-5

19000-GI MANUAL NO. 10/01/83 ISSUE DATE REVISED DA TE

TITLE:

ELECTRICAL

POWER CIRCUIT

(Fig. K-5)

Tools Required:

Quantity I

- V. O. M. If The Vehicle Does Not Run:

WARNING: TO PREVENT THE 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 (see procedures in Section B) before proceeding.

Place key switch (I) in the 'ON' position and the forward-reverse switch (6) to the forward 'F' position.

Set the volt meter to the 50 VDC range. Touch the black (-) probe to the negative (-) contact of the vehicle D.C. receptacle and the red (+) probe to the positive (+) contact of the vehicle D.C. receptacle (Fig. ).

A meter reading of 36 VDC � 3 VDC indicates that the batteries are satisfactory. A reading below 36 voe indicates that one or all batteries are defective. (See Batteries Section for testing procedures.) No reading indicates an "open" condition and the following procedure should be followed.

Locate the black (-) probe on each of the four motor (8) terminals and the number I contact of the accelerator switch (5). A reading of of 36 voe .:!:" 3 voe at each terminal will indicate that the wiring and resistors are good. A reading of O VDC indicates an "open" condition that may be located by visual inspection, or using an ohm meter, perform a "continuity" test between the terminals of each wire.

CAUTION: REMOVE BATTERY (+) CONNEC­ TIONS BEFORE USING OHM METER. (SEE SAFETY PROCEDURES IN SECTION B.) No reading indicates a broken wire, a poor connection, or corrosion at either of the wire terminations.

If The Vehicle Runs But Performs Erratically:

WARNING: TO PREVENT THE 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 (see procedures in Section B) before proceeding.

Place key switch (I) in the 'ON' position and the forward-reverse switch (6) to the forward 'F' position.

Locate the red (+) probe on the positive (+) post of the battery (7) that has two heavy gauge wires attached to it. Locate the black (­ ) probe on motor (8) terminal S2. A meter reading of 36 voe .:!:" 3 voe indicates that the wire joining the motor (S2) and the battery (BR-) is satisfactory.

Visually inspect all components for burned or broken wires, loose connections at each of the accelerator switch (5) contacts, resistor coils (9) and the forward and reverse switch. Inspect all terminations for corrosion and clean if re­ quired. If a visual inspection fails to yield the cause of the problem, an ohm meter may be used to perform a "continuity" test at each component.

A reading of less than 36 2'3 VDC indicates a broken wire, a poor connection, or corrosion at either the battery or motor termination.

CAUTION: REMOVE BATTERY (+) CONNEC­ TIONS BEFORE USING AN OHM METER. (SEE SAFETY PROCEDURES IN SECTION B.)

Locate the black (-) probe to the motor (8) terminal SI. A reading of 36 VDC 2" 3 VDC indicates that the field coils are satisfactory.

A meter reading of O VDC indicates that the field coil is "open", which will require the repair or replacement of the motor. Locate the black (-) probe to the motor (8) terminal A I. A meter reading of 36 VDC .:!:" 3 VDC indicates that the armature is satisfactory.

NOTE: A test light may be substituted for an

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

ohm meter.

If the vehicle continues to run with the accelerator switch (5) in the released position, either the accelerator linkage is out of adjustment (See Accelerator Adjustment in Section F) or the solenoid (2) contacts are stuck

E-z.Goii£Hi1•1:t K-6

TITLE:

ELECTRICAL

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LI.

co

FIG. K-5 POWER WIRING DIAGRAM

K-7

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

TITLE:

ELECTRICAL

in the 'ON' position. If the vehicle continues to operate after determining that the accelerator linkage is in correct adjustment, the soleno id (2) must be replaced.

TESTING THE MOTOR

(Fig. K-5)

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

Tools Required:

- v.o.M.

Quantity I

WARNING: TO PREVENT THE 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 (see procedures in Section B) before proceeding.

Place key switch (I) in the 1 ON 1 position and the forward-reverse switch (6) to the forward 'F' position.

NOTE: Use the following test ONLY IF THE MOTOR WILL NOT RUN. This check is for open circuits in field co ils, brushes, or brush rigging. To check for a short circuit, refer to the Motor Section.

Set the volt meter to the 50 VDC range.

Locate the black (-) probe to the negative (-) contact of the vehicle D.C. receptacle and the red (+) probe to the motor terminal 52.

A meter reading of O VDC indicates a good condition. Locate the:- red (+) probe on the motor (8) terminal SI. A meter reading of 0 voe indicates that the· field coils are satisfactory. A meter reading of 36 VDC :: 3 voe indicates that the field co ils are open and the motor must be repaired or replaced.

Locate the red (+) probe on the motor terminal A2. A reading other than O VDC indicates that the power wiring should be rechecked.

Locate the red (+) probe to the motor terminal AI. A meter reading of O VDC indicates that the brushes, brush holder, and all connections

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

are satisfactory. A meter reading of 36 VDC

±" 3 voe indicates a problem with the brushes,

brush holder, or connections.

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

WARNING: REMOVE BATTERY {+) CONNEC­ TIONS BEFORE CONTINUING WITH THIS TEST. SHORTING OF MOTOR WIRES COULD RESULT IN AN EXPLOSION. Remove wires from motor terminals AI and 52. Set the ohm meter to the RX I scale.

Using the ohm meter, place probes on motor terminals SI and 52. A meter reading of 11011 indicates a satisfactory condition at the field co ils. No needle deflection indicates an "open" condition that will require the motor to be repaired or replaced.

Place the probes on motor terminals AI and A2.

A meter reading of "0" indicates a satisfactory condition at the brushes and No needle deflection indicates a rigging. 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 SI and 52 to the motor shell indicates a short circuit between the field co ils and the case.

Continuity between terminals AI 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.

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

FORWARD-REVERSE SWITCH (Fig. K-6) The Forward-Reverse switch operation is described in Power Circuit at the beginning of this section.

Switch Lubrication During the servicing of the vehicle, the forward-reverse switch shaft should be removed, cleaned, and lubricated with bearing grease. The contact surfaces may also be lubricated with a thin coat of petroleum jelly to permit smooth operation of the switch.

E-Z·GOUi3UN:i K-8

TITLE:

ELECTRICAL

FIG. K-6 FORWARD AND REVERSE SWITCH ASSEMBLY K-9

19000-G I MANUAL NO. I 0/0 I /83 ISSUE DATE REVISED DATE

TITLE:

ELECTRICAL

Forward and Reverse Switch Inspection and Repair: WARNING: DISCONNECT THE BATTERY LEAD (114) (FIG. K-1) FROM THE BATTERY BEFORE ATTEMPTING SERVICE OF THE FORWARD-REVERSE SWITCH. Periodic inspection of the switch should include the following: I.

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 pressure.

3.

Rotate the switch lever 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 lubricated, if required, with a very thin coat of petroleum jelly.

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

Inspect the micro switch for adjustment and dirt that might inhibit it's operation.

Reassemble in the reverse order of disassembly.

FORWARD AND REVERSE SWITCH REMOVAL AND DISASSEMBLY (Fig. K.:.6)

Reinstall the forward-reverse switch in the vehicle and adjust the switch to align with the hole in the vertical support panel. Tighten the hardware that secures the forward-reverse switch to the vehicle to 10-12 ft. lbs. torque.

ACCELERATOR SWITCH (Fig. K-7) The accelerator switch is a rheostat type, mechanically controlled by a push-rod linkage connected to the accelerator foot pedal.

Switch operation is described in the Power Circuit, Forward Operation, at the beginning of this section.

Switch Lubrication DO NOT lubricate the five copper contact studs or the spring loaded brush contact.

Quantity

Switch Inspection and Repair (Fig. K-7)

Disconnect the wiring connections on the rear of the switch, disconnect one push-on connec­ tion from the solenoid and one from the warning device. Disconnect the wire from the micro switch to the key switch at the key switch.

19000-GI 10/01/83

Reassemble the switch in the reverse order of disassembly. Rotate the cam from stop to stop and check the operation of the micro switch (7) roller. The switch roller must be positioned as shown in Figure K-6, when the cam is located in the reverse stop position.

Loosen the mounting screws (8) and adjust the position of the micro switch to achieve the position shown.

Quantity

Remove lever and knob (I) from shaft (2).

MANUAL NO. ISSUE DATE REVISED DATE

Remove the nut (5) from the switch shaft (2), remove the cam (6) complete with the shaft (2) from the bushing, and remove the shaft (2) from the cam assembly (6).

The contact arm shaft (2) is the only part on the switch assembly (I) .requiring lubrication.

This part should be removed (semi-annually), cleaned and lubricated with wheel bearing grease.

Tools Required: - 7 /I 6 11-I /2" Box combination wrench - 9I16" Box wrench

Loosen the two screws (3) which secure the switch bracket to the seat support frame (4) and slide the switch assembly from the slotted bracket.

WARNING; DISCONNECT THE BATTERY LEAD (//4) (FIG. K-1) FROM THE BATTERY

BEFORE PROCEEDING WITH INSPECTION.

H-GOUtlht•W K-IO

TITLE:

ELECTRICAL

NOTE: To assure efficient operation, the accelerator switch must be kept in good repair.

Periodic inspection of wiring harness connections, board mounted contact studs, and the spring loaded sliding brush contact should be made as follows:

3.

Observe badly pitted or worn contact studs (5).

If a contact is burned or melted (resulting from a stuck or misadjusted accelerator linkage), the contact board assembly (6) (includes contacts and hardware) must be replaced.

I.

Inspect and tighten (if required) the nuts (3), lock washers (4), securing contact studs (5) to 30-35 in. lbs. torque.

4.

Inspect the spring loaded brush contact (7) for firm spring pressure and a free action in the bushing.

2.

Inspect and tighten (if required) all wire connections. to 30-35 in. lbs. torque.

5.

Inspect the brush (7) for a burned tip and abnormal wear. When the brush is worn to approximately I/2" in length, the brush must be replaced. To check the length, remove the brush by removing the shaft and arm assembly (2) and sliding the brush from it's carrier.

2

FIG. K-7 ACCELERATOR SWITCH ASSEMBLY

E-Z-GO••tihl·W K-11

MANUAL NO. 19000-GI I 0/01/83 ISSUE DATE REVISED DATE

TITLE:

ELECTRICAL

ACCELERATOR SWITCH REMOVAL (Fig. K-8)

RESISTOR REPLACEMENT (Fig. K-10)

Tools Required:

Tools Required:

-

I I /8" Open end wrench Long standard screwdriver SmalI hammer I /2" Box end wrench

Quantity Quantity Quantity Quantity

- I /2" Box wrench - 7I 16" Box wrench

To remove the accelerator switch assembly (I) from the vehicle, disconnect the wire 1/4 (Fig. K-1) at the batteries. (See Safety Procedures in Section B.) Disconnect the wire /15 (Fig. K-9) at the forward-reverse switch.

Disconnect the red/white wire at the micro switch, the yellow wire at the solenoid and the wire from motor terminal A I (Fig. K-9).

Disconnect the accelerator linkage (2) from the accelerator switch arm (3) (See Section F).

Loosen nut (4) and lift assembly (I) to gain access to hardware (5 and 6) securing power wiring to the switch. Remove wiring.

Quantity I Quantity I

WARNING: TO PREVENT THE VEHICLE FROM INADVERTENTLY ACCELERATING, WHICH COULD CAUSE BODILY INJURY, THE VEHICLE MUST BE LIFTED TO RAISE BOTH DRIVE WHEELS ABOVE THE GROUND. WARNING: REMOVE BATTERY(+) CONNEC­ TIONS BEFORE PROCEEDING. Raise the vehicle (See procedures in Section B).

Remove the hardware (I) (2) (3) retaining the resistor board (4) to the heat shield (5). Inspect the resistor coil assembly (6) for a defective resistor. Remove the lock washer (7) and nut (8) from the either end of the defective resistor and remove the power wiring (9). Remove the second set of hardware, bolt (I 0), lock washer (11), and nut ( 12) and replace defective resistor

(13).

Tighten hardware attaching resistor and wiring to 15-20 ft. lbs. torque.

Reinstall resistor board assembly to heat shield and tighten hardware to 40-50 ft. lbs. torque.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

K-12

TITLE:

ELECTRICAL

1

J

FIG. K-8 ACCELERATOR & HILL BRAKE LINKAGE (ELECTRIC CAR) K-13

19000-G I MANUAL NO. I 0/0 I /83 ISSUE DATE REVISED DATE

TITLE:

ELECTRICAL

--------�

Solenoid

Accelerator Switch ,----- 7 i oO I

1

I

I

Resistors r - - -, I

I

R1

I I

R2

''

'----

F&R Switch See Note 1

__ __,,

Grn MS2

I I

______ ..J

h

'

I

'- 4

Blk

C See Note 3

3

I

R3

''-- - - - _j

0--......----' I

I

1

Motor

I

F2

-

...J-

Charger Receptacle

NOTES I. FORWARD & REVERSE SWITCH (F & R) · - FORWARD POSITION SHOWN WITH SOLID LINE - REVERSE POSITION SHOWN WITH DASHED LINE - NEUTRAL POSITION IS BETWEEN CONTACTS 2. MSI IS ACTIVATED BY THE FORWARD REVERSE (F & R SWITCH) - NORMALLY CLOSED - CLOSED IN THE FORWARD OR REVERSE POSITION - OPEN IN THE NEUTRAL POSITION 3 . MS2 IS ACTIVATED BY THE ACCELERATOR - NORMALLY CLOSED - OPEN WHEN ACCELERATOR SWITCH IS IN '0' POSITION - CLOSED WHEN ACCELERATOR SWITCH IS IN I, 2, 3, OR 4 POSITION LEGEND MS C NC NO

MICROSWITCH COMMON NORMALLY CLOSED NORMALLY OPEN

-- POWER WIRE -- CONTROL CIRCUIT WIRE WIRE REFERENCES IN TEXT

0

FIG. K-9 ELECTRIC CAR WIRING DIAGRAM MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GO•h3hM:• K-14

I

L ___I

r -A1 - - -F1-

lO

I I

TITLE:

ELECTRICAL

13 6

.

AdJacent Coils Must Not Touch Each Other 63 Min./.93 Max. Shield Must Not Be Distorted Wire #1 5

FIG. K-10 RESISTOR ASSEMBLy

E-Z-GOU½=ihM:t K-15

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE:

ELECTRICAL

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z-GOUtlls(•m K-16

OPERATION & SERVICE MANUAL SECTION TITLE: �LECTRIC MOTOR

MODEL: ELECTRIC GOLF CAR SECTION

MOTOR REMOVAL AND DISASSEMBLY (Fig.

do not require specialized tools or knowledge that may be attempted.

Replacement of brushes and field coils may be attempted; however, major repairs, such as armature turning or bearing replacement, should only be attempted by a qualified motor technician.

L-1 and L-2)

Tools Required:

-

I/2" Box wrench Phillips screwdriver 9I16" Box wrench 7I16" Box wrench

Quantity Quantity Quantity Quantity

VOLTAGE AND RESISTANCE MEASUREMENT

WARNING: REMOVE BATTERY(+) CONNEC­ TION BEFORE PROCEEDING (SEE SAFETY PROCEDURES IN SECTION B). SHORTING OF MOTOR WIRES COULD RESULT IN AN EXPLOSION. Remove alI wires from the motor.

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

WARNING: REMOVE BATTERY (+) CONNEC­ TIONS BEFORE CONTINUING WITH THIS TEST. SHORTING OF MOTOR WIRES COULD RESULT IN AN EXPLOSION. Remove wires from motor terminals AI and S2. Set the ohm meter to the RXI scale.

Using the ohm meter, place probes on motor terminals SI and S2. A meter reading of 11011 indicates a satisfactory condition at the field coils. No needle deflection indicates an "open" condition that will require the motor to be repaired or replaced.

Remove the two clamp bolts (I) that secure the motor (2) to the end shield (3). Slide the motor housing straight out from the end shield (3) to remove it from the axle assembly.

Loosen the nuts (4) attaching terminals SI and S2. Remove the two clamp bolts (5) that secure the front end shield (6) to the motor (2). Slide the front end shield (6) and armature (7) out of the motor frame.

Remove the four screws (8) (Fig. L-2) from the rear end shield (3). Remove the brushes (9) (See Brush Spring Measurement). Remove the front end shield (6) from the armature (7).

Reassemble in the reverse order of disassembly and torque bolts (I) :· to I 00-120 in. lbs.

ELECTRIC MOTOR REPAIR (Fig. L-2) Tools Required:

- Gauge assembly E-Z-Go P/N A-17219-GI - Ohm meter

L.

Quantity

Place the probes on motor terminals AI and A2.

A meter reading of 11011 indicates a satisfactory condition at the brushes and No needle deflection indicates a rigging. 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 SI and S2 to the motor shell indicates a short circuit between the field coils and the case.

Continuity between terminals AI 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.

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

Quantity

Major motor repair should not be attempted by golf course maintenance staff. There are some maintenance and repair procedures that

Check the motor brushes for wear using gauge assembly, E-Z-Go part number A-17219-GI. (Fig. L-3) If the gauge length is more than I 1/2", the brushes must be replaced.

E-Z-GOUDl,t•m L-1

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE:

ELECTRIC MOTOR 4.

FIG. L-1 MOTOR REMOVAL MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

H-GCJll:£1hl•m L-2

TITLE:

ELECTRIC MOTOR

-

><

...

FIG. L-2 ELECTRIC MOTOR

E-Z-GOU:f:Jhl•W L-3

19000-G I MANUAL NO. I 0/0 I /83 ISSUE DATE REVISED DATE

TITLE:

ELECTRIC MOTOR

Brush Gauge Hole

Brush

Motor Gauge Rod

FIG. L-3 BRUSH WEAR MEASUREMENT MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GO•itlist•i:t L-4

TITLE:

ELECTRIC MOTOR

NOTE: To inspect or remove brushes requires the disassembly of the motor.

Brushes and rigging should be inspected annually for adequate length and free movement. Inspect for broken, cracked, or chipped brushes or wear that has left the brush less than 9/ 16" long (Fig. L-4).

E-Z-Go recommends that if a defective brush is found, the entire set should be replaced. To remove the brush requires that the pigtail be removed from the rigging, and that the brush tensioning spring be removed from the brush by "hooking" the spring with a piece of wire with a small right angled bend in the end. Moving the spring rearwards and to the side which will permit the brush to be slid out.

10

r-----i,1,.....---1 : :?::: 1 : i*1 9

7

5

3

1

FIG. L-5 BRUSH SPRING TENSION ARMATURE SERVICE The armature inspection can only be accomplished by disassembly of the motor.

If the armature appears to be rough, pitted, scored, or has signs of burning or heavy arcing between the armature bars, the armature should be removed for servicing.

After replacing the brush set, the brush springs should be checked for tension.

OIL SEAL (Fig. L-2) -if upon inspection, the armature or field coils appear oily, a faulty oil seal is suspect, allowing· the differential lubrication to poss into the . motor.

Oil or grease on a armature will - introduce sparking, resulting in rapid armature and brush wear.

9/ 16" Min.

- ---- ----

To replace oil seal:

FIG. L-4 MINIMUM BRUSH LENGTH

Remove the motor and end shield (Refer to Removing and Installing Motor).

Disassemble the motor.

BRUSH SPRING TENSION MEASUREMENT (Fi$). L-5)

Clean any oil or grease from armature or field coils by wiping with contact cleaner or alcohol.

Use a spring scale on a line directly opposite the line of force exerted by the brush spring.

The reading should be taken at the point where the spring loses contact with the brush.

Drive the seal ( I 0). from the rear end shield (3) with suitable punch and hammer.

Carefully check the seal seat on the armature shaft for grooves and scars.

The spring scale should read between I and 2 lbs. Deviation from the above figure requires that the spring be replaced.

Measurement of the spring force will require the removal of the brush mechanism from the end shield or the use of a spring scale with a right angled hook.

Apply "Hanna oil sealer" or equivalent to the mating surface before placement of the oil seal. (Use /170957 Oil Seal Compound - Hanna Paint Company, Columbus, Ohio.) Do not allow to dry before assembly.

E-Z-GOU:f:iht•m L-5

19000-G l MANUAL NO. I 0/01/83 ISSUE DATE REVISED DATE

TITLE:

ELECTRIC MOTOR

Press the seal into position with an arbor press.

Locate the seal into the end shield with the seal lip spring facing away from the armature side.

Limit the depth of cut to 0.005 inch or less and repeat cut as often as required. Do not reduce the diameter to less than 2 5/8 inches.

Reassemble the end shield to the differential housing and install the motor per installation procedure.

If turning eliminates undercut of mica insulation between armature bars, undercut approximately I /32 inch. Finish turn armature after undercut.

Slight roughness of an armature can be polished away with grade 4/0 or finer sandpaper (Fig. L-6). Never use emery cloth as the particles of emery are conducting and may short circuit the armature bars. Do not use oil or lubricants on the armature or brushes.

After refinishing an armature, check it for eccentricity. It should not exceed 0.001 inch runout with a 0.0002 inch maximum bar-to-bar difference.

If an armature is sparking badly and the cause of the sparking is not corrected, the armature and brushes wiII deteriorate rapidly and soon become inoperative.

If deep burned sections are evident, either in the brush track or on the riser ends of the armature bars, this a symptom of an open circuit in the armature winding.

If such evidence is noted, the armature should be checked for adjacent bar-to-bar resistance which should be .00258 plus or minus .00026 ohm. To measure armature resistance, select any two bars of the armature with exactly 16 bar span between the bars selected.

The resistance measured should be .021 or minus .002 ohm.

If armature bars are deeply pitted or grooved in the brush track, the armature must be refinished.

To refinish the armature: Disassemble Procedure.

the

motor

per

Disassembly

Mount armature in a lathe and diamond turn the armature.

Use Protective Sheeting Between Core and Vise

ARMATURE

If one or more armature conductors are abnormally black or appear burned compared with the other armature conductors, this is an indication of a shorted and/or grounded armature winding. If such evidence is detected, the armature should be checked by high potential tests (not exceeding 600 VAC - I minute) and a growler coupled with the above resistance checks.

NOTE: The above checks must be performed by a qualified repair station.

t

The armature is not normally rewound due to the difficulty encountered in the process of removing the copper conductors which are bonded to the armature core. If the armature is grounded, shorted, or has open coils, replace with a new armature.

Clean and assemble in reverse order.

FIG. L-6 ARMATURE SERVICE

MANUAL NO.

ISSUE DATE

REVISED DATE

19000-GI 10/01/83

L-6

TITLE:

ELECTRIC MOTOR

BEARINGS AND LUBRICATION

To replace armature end bearings:

No provision is made for relubricating the ball bearings. The bearings are a shielded, sealed type of bearing to protect against dirt or other foreign matter entering the bearing, and to prevent loss of grease.

The bearings are prelubricated by the bearing manufacturer for its service life and are not to be regreased.

Disassemble motor per Disassembly Procedure.

To determine the serviceability of the bearings, it is necessary to completely disassemble the motor. Check bearings by turning them with your fingers. Feel for binding or gritty effects and for "excessive" looseness or wobble. If any defect is apparent, or if there is any doubt at all as to serviceability of the bearings, replace them with new ones.

NOTE: Without extensive specialized equipment that is not generally found in motor repair shops, the term "excessive" cannot be established.

A good motor technician can determine if any looseness is "excessive" from experience.

Remove the armature end bearings by means of a suitable bearing puller (Fig. L-7). Press new armature end bearings into place by means of an arbor press that exerts pressure on only the inner ring. Assemble with the metallic shield towards the shaft shoulder.

CAUTION: DO NOT USE A HAMMER FOR BEARING RELACEMENT. IT WILL DAMAGE THE BEARING. Clean and assemble in reverse order.

TESTING (Fig. L-8) To test the motor out of the vehicles, assemble to a differential assembly and clamp the motor in a fixture or to a bench and wire as per Fig. L-8.

Reassemble motor in the reverse order of disassembly. Reconnect all motor wires and tighten to 35-40 in. lbs. torque.

PuUer Bearing Adapter (Sprrtter)

FIG. L-7 BEARING REMOVAL L-7

MANUAL NO. 19000-G I ISSUE DATE 10/01/83 REVISED DATE

TITLE:

ELECTRIC MOTOR

4 Terminal Motor

+

A1

A2 S1

S2

FIG. L-8 MOTOR TEST WIRING

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I 0/0 I /83

E-Z-GO•i:f=llst•m L-8

Line 36V. D.C.

OPERATION & SER-VICE MANUAL SECTION TITLE: REAR AXLE

MODEL: ELECTRIC GOLF CAR SECTIONM

GENERAL The vehicle's rear axle is a conventional automotive, semi-floating, hypoid gear, carrier­ type design.

The vehicle is equipped with expanding shoe drum brakes on the rear wheels.

Brake service instructions are covered in the Brake Section of this manual.

Differential Lubrication The lubricant level should be checked at intervals specified in the Periodic Service Schedule. With the vehicle on a level surface, the lubricant level should be to the bottom level of the filler plug hole. If the lubricant is low, make reference to the periodic service schedule for recommended lubricant.

The axle shaft wheel bearings receive their lubrication from grease packed in the bearings when assembled.

Axle Adjustments NOTE: Considering the precise nature and the special tools required for proper adjustment, the performance of a new axle is seldom if ever improved by readjustment in the field, consequently, the practice is discouraged.

However, due to conditions beyond normal control, such as replacing worn or damaged parts, etc., a few cases will require repair in the field.

All repair work done to the differential case and drive pinion must be performed by an :· experienced automotive differential repair shop •..

REMOVING REAR AXLE ASSEMBLY FROM VEHICLE (Fig. M-1) Tools Required:

-

Pliers, needle nose I /2" Open end wrench 9 I 16" Open end wrench Jack stands

Quantity Quantity Quantity Quantity

I I I 2

Disconnect the batteries (see procedures in Section B). Remove the wiring from the motor (See Motor Removal and Disassembly).

Loosen both rear wheel and tire assemblies by loosening the lug nuts but do not remove.

Raise the vehicle (see procedures in Section B). Remove the rear wheel and tire assemblies.

Place the jack under the center of the rear bumper and elevate until the rear axle is clear of the jack stands. Remove the jack stands and relocate them under the outboard ends of the rear bumper. lower the vehicle onto the jack stands that are adjusted such that the rear axle assembly is as low as possible but still remains clear of the shop floor.

WARNING: BEFORE PROCEEDING, BE SURE THAT THE VEHICLE IS SECURELY SUP­ PORTED ON THE JACK STANDS. Remove the- trunk lid (see Body and Trim Section) to gain access to the upper mounting hardware of the rear shock absorbers. (I ) (2) (3) Remove the upper mounting hardware of the rear shock absorbers.

Disconnect the brake cables from the actuating lever.

NOTE: It is suggested that an additional person support the motor during the following procedure. Use the jack to support the motor and axle assembly before removing the nuts (4) and washers (5) from the four "U" bolts (6).

WARNING: DUE TO THE WEIGHT AND LOCATON OF THE MOTOR, CARE MUST BE TAKEN NOT TO ALLOW THE AXLE ASSEMBLY TO ROTATE OR FALL DURING THE FOLLOWING OPERATION. Slowly lower the jack before pulling the complete motor and axle assembly through the vehicle's wheel well.

WARNING: CARE MUST BE TAKEN TO PREVENT THE MOTOR AND AXLE ASSEMBLY FROM STRIKING THE VEHICLE OR THE JACK STANDS WHILE REMOVING IT FROM THE VEHICLE. Reassemble the motor and axle assembly using the reverse order of disassembly.

E-Z-GOU:flht•m M-1

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE:

REAR AXLE

Tighten the nuts (4) fastening the "U" bolts (6) to 30-35 ft. lbs. torque. Tighten the nuts (I) retaining the shock absorber until the top rubber bushing (3) is compressed to the same diameter as the washer (2).

Tighten the nuts fastening the motor terminals to 35-40 in. lbs. torque.

NOTE:

For motor removal, see Section L.

FIG. M-1 REAR SUSPENSION MANUAL NO. ISSUE DATE REVISED DATE

19000-G I I0/0I/83

M-2

wire

TITLE:

REAR AXLE

f

FIG. M-2 REAR AXLE Torque Requirements for Rear Axle Assembly

AXLE SHAFT REMOVAL AND REPAIR

Differential Cover Screw

18-23 ft. lbs.

Tools Required:

Differential Bearing Cap Bolt

35-45 ft. lbs.

Drive Pinion Nut

50-80 ft. lbs.

Drive Gear Bolt (Ring Gear)

45-65 ft. lbs.

-

Axle Nut

70 ft. lbs. min.

NOTE: Removal of brake assemblies are not necessary for rear axle assembly repair.

Arbor press Needle nose pliers I 1/16" Hex socket-1/2" drive Snap ring pliers (internal) Slide hammer (E-Z-Go P/N 18753-GI) - 1/2" Drive pull handle or ratchet - Anti-seize compound (E-Z-Go P/N 12719-GI)

E-Z-GOUtiht•m M-3

Quantity Quantity Quantity Quantity Quantity Quantity Quantity

MANUAL NO. 19000-G I 10/01/83 ISSUE DATE REVISED DATE

TITLE:

REAR AXLE

FIG. M-3

FIG. M-5

After removing wheel, remove cotter pin, axle nut and washer. Fig. M-3.

Attach slide hammer on· axle shaft thread and remove axle and bearing assembly. Fig. M-5.

FIG. M-4

FIG. M-6

Remove brake drum, slide hub assembly off axle shaft and remove outer snap ring (Fig. M7, item I). Fig. M-4.

Bearing removal is accomplished by supporting bearing inner race on press bed and applying pressure to threaded end of axle shaft. Fig. M-6.

MANUAL NO.

ISSUE DATE REVISED DATE

19000-GI 10/01/83

H-GC-•li3ht•m M-4

TITLE:

REAR AXLE

Assemble new bearing by pressing onto shaft untiI firmly seated against shoulder.

INSPECTION OF AXLE SHAFT COMPONENTS BEARINGS It is recommended that whenever bearings are removed, they (regardless of mileage) be replaced with new ones.

OIL SEALS

•

Inspect axle tube for any signs of leakage past, seals. (See Axle Shaft Seal Removal.)

AXLE SHAFT SEAL SURFACE Inspect the sealing surface for nicks or grooves.

Replace shaft if seal has damaged this surface.

SHAFT SEAL REMOVAL AND REPLACE­ MENT

FIG. M-6

Tools Required: - Snap ring pliers (internal) - Seal puller or screwdriver - Seal Installation tool (E-Z-Go P /N 18739-G I) - Ba 11 peen hammer

Quantity Quantity Quantity Quantity

Remove inner snap ring (2), pull out seal (3) with puller or pry out with screwdriver. Care should be taken not to damage inner surface of axle tube (4) at sealing area. Fig. M-7.

Install seal (3) to proper depth with installation tool. Install inner snap ring (2). Wipe seal surface with motor oil. Fig. M-7.

AXLE SHAFT REPLACEMENT Carefully insert axle shaft and bearing assembly through oil seal. Rotate shaft until spline engages with differential side gear.

Install outer snap ring (I). Fig. M-6.

Coat spline of axle shaft with anti-seize compound. InstalI hub assembly, brake drum, washer, nut, and cotter pin in reverse order.

NOTE: Tighten axle nut to 70 ft. lbs. torque minimum. Increase torque as required to align slot in nut with cotter pin hole.

E-Z-GOUJ:iht•m M-5

19000-GI MANUAL NO. ISSUE DATE 10/0 1/83 REVISED DATE

TITLE:

REAR AXLE

DIFFERENTIAL CASE ASSEMBLY REMOVAL AND REPAIR Tools Required:

- I /2" Drive pulI handle or ratchet - I /2" Hex socket - I /2" drive - 9/16" Hex socket - 1/2" drive - Pry bars - Gear puller - Adjustable wrench (gear puller) - Step plate adapter - 11/16" Hex socket - I /2" drive - Plastic tip or ball peen hammer - 5/ 16" or 3/8" dia. drift punch - 5/32" dia. drive pin punch - Torque wrench - Arbor press

Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity

I I 2 I I I I I

Quantity Quantity Quantity Quantity

FIG. M-9 Bearing caps are marked for identification.

Letters or numbers are in the horizontal and vertical position. When reassembling, replace them in the same position. Remove the· 4 bearing cap screws and remove the caps. Place caps in a safe place to avoid damaging their machined surface. Fig. M-9.

FIG. M-8 Remove the right and left hand axle shaft assemblies as previously stated. Remove the ten cover plate screws and remove the rear cover. Fig. M-8.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

M-6

TITLE:

REAR AXLE

Do not remove the bearing from differential case unless a bearing failure is evident.· Before reinstalling bearings, inspect for any sign of damage. If damage is evident, replace with new bearings. Insert a jaw pu IIer into the indentations provided in the differential case.

Take care not to damage shims between bearing and differential case. Fig. M-11.

NOTE: The original shims may be reused if undamaged and must be replaced on the same side as removed.

FIG. M-10 Pry the differential case from the carrier with two pry bars. If new bearings are not required, the old bearings and shims are to be replaced on the same side as removed. Fig. M-9.

FIG. M-12 Remove the gear cap bolts.

Fig. M-12.

FIG. M-11

E-Z�UtHst•m M-7

MANUAL NO. 19000-GI ISSUE DATE 10/01/83 REVISED DATE

TITLE:

REAR AXLE

FIG. M-13 Use plastic tip hammer or a hard wooden block and a ball peen hammer to drive the ring gear off the differential case.

NOTE: Be careful not to damage ring gear teeth. Fig. M-13.

FIG. M-15 Supporting the differential case, drive the pinion shaft from the differential case. Fig. M-15.

FIG. M-14 Drive the lock pin out of pinion shaft.

M-14.

MANUAL NO.

ISSUE DATE REVISED DATE

19000-GI 10/01/83

FIG. M-16 Fig.

Remove the pinion gears and the thrust washers by rotating both gears 90° to the opening in the differential case. Fig. M-16.

M-8

TITLE:

REAR AXLE

FIG. M-18 FIG. M-17

Install thrust washers behind the axle side gears and install in differential case. Install the thrust washers behind differential pinion mates.

Fig. M-17.

Install the c:Pinion gear and thrust washers by rotating 90 into differential case until pinion shaft can be installed. Hole in pinion shaft must align with lock pin hole in differential case. Fig. M-18.

FIG. M-19

Assemble the lock pin. Drive the pin to the approximate center location of the pinion mate shaft. Fig. M-19.

M-9

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

TITLE:

REAR AXLE

FIG. M-20

FIG. M-21 NOTE: When installing new differential bearings, reuse the original shims or use new shims, if required, making sure that the shims are installed on the same side of the case from which they were removed. Fig. M-20. Position the ring gear on the differential case and start MANUAL NO. ISSUE DATE REVISED ft:

o:.,_

19000-GI 10/01/83

the drive gear bolts into the gear. Tighten the screws, alternating back and forth across gear to allow the gear to be pulled evenly into place. Tighten the screws to 45-65 ft. lbs. torque Fig. M-21.

M-IO

TITLE:

REAR AXLE

PINION REMOVAL AND REPAIR Tools Required: - Pin removal tool kit (E-Z-Go P/N 1873 8-G I) - I I/16" Hex socket - I /2" drive - I /2" drive pull handle or impact wrench (recommended) - 5/16" or 3/8" dia. drift punch - Arbor press - Ball peen hammer - Center punch - Adhesive metal bonding (E-Z-Go P/N I 2572-G2)

Quantity Quantity Quantity Quantity Quantity Quantity Quantity Quantity

FIG. M-23 Remove the front bearing cup by locating punch on back edge of the cup (in carrier slots) and tapping with a hammer. Invert carrier and repeat for rear bearing cup removal. Fig. M23.

CAUTION: DO NOT NICK CARRIER BORE. CAUTION: SHIMS ARE LOCATED BETWEEN THE REAR BEARING CUP AND CARRIER BORE. WHEN CAUTION EXERCISE REMOVING BEARING CUP. IF SHIMS ARE DAMAGED, REPLACE.

FIG. M-22 To remove the pinion: I.

Remove right and left hand axle shafts (as previously shown).

2.

Remove differential case previously shown).

3.

Install pinion nut holder and secure with cap screws provided.

4.

Slip adapter over spline.

5.

Use I I/16" hex socket and rotate spline clockwise (Fig. M- 25 for pinion components).

assembly (as

M-11

MANUAL NO. 19000-G I ISSUE DATE 10/01/83 REVISED DATE

TITLE:

REAR AXLE

FIG. M-24

FIG. M-26

Replace the previously removed shims or use a new shim pack of the same thickness, if required, in the inner bearing bore. Seat the bearing cup into the carrier. Invert carrier and seat outer bearing cup. Fig. M-24.

Insert pinion into the carrier. Assemble outer bearing cone and oil slinger.

Apply small amount of metal bonding adhesive to pinion nut thread. Assemble pinion nut finger tight.

Install pinion nut kit per Fig. 21 information.

Tighten pinion nut to 50-80 ft. lbs. torque by rotating pinion shaft counterclockwise.

Rotation of pinion should read 2-13 in. lbs. torque. Fig. M-26.

FIG. M-25 Install inner bearing cone, spacer, and shims on pinion (use original shims if undamaged or replace with new shims). Fig. M-25.

MANUAL NO.

ISSUE DATE REVISED DATE

19000-GI 10/01/83

FIG. M-27 Stake pinion nut 4 places in spline grooves ° approximately 90 apart. Fig. M-27.

E-Z-GO••tii,t•m M-12

TITLE:

REAR AXLE

ASSEMBLY OF CARRIER Tools Required: -

Torque wrench 9I 16" Hex socket - I /2" drive I /2" Hex socket - I /2" drive Gasket forming sealant Dial indicator Plastic tip hammer

Quantity Quantity Quantity Quantity Quantity Quantity

FIG. M-29 Reassemble the bearing caps making sure the letter stamped on the caps corresponds with those on the carrier. Tighten the bearing cap screws to 35-45 ft. lbs. torque. Fig. M-29.

FIG. M-28 Install the differential assembly into the carrier, aligning the ring gear and pinion teeth to avoid nicking the teeth. Tap lightly if necessary. Fig. M-28.

E-Z-GOIIUh(•m M-13

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE:

REAR AXLE

FIG. M-30 Check the ring gear and pinion backlash in three equally spaced locations, using a dial indicator. Backlash should be from .004" to .008". High backlash is corrected by moving the ring gear closer to the pinion.

Low backlash is corrected by moving the ring gear away from the pinion. These corrections are made by switching the shims from one side of the differential case to the other. Fig. M-30.

FIG. M-31 Properly clean cover plate and carrier surfaces, apply sealant, and install the cover plate.

Tighten screws 18-23 ft. lbs. torque. Fig. M-31.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

E-Z�Utlist•m M-14

OPERATION & SERVICE MANUAL SECTION TITLE: BODY AND TRIM

MODEL: ELECTRIC GOLF CAR SECTION

BODY TRIM

To remove the fender cap, drill out the 2 rivets from the retainer strip.

Drill out I rivet through the fender cap in the bagwell. Remove the 3 hex head screws and lock nuts attaching the fender cap to the fender and remove the fender cap. Reinstall in the reverse order of disassembly.

Tools Required: - Electric drill - I /811 OriII bit - I /4" Drill bit

Quantity Quantity Quantity

The body trim consists of a vinyl extrusion installed around the lower edge of the body assembly and across the rear edge of the dash tray and the front cow I.

TRIM REMOVAL AND INSTALLATION To remove the fender trim, drill out the rivet where the trim meets the fender cap. Remove 5 nuts securing trim retainer at floorboard (both sides of car) and remove retainers. Grasp loose end and pull out and down.

REMOVING AND INSTALLING REAR FENDER

(Fig. N-2)

Tools Required: - Phillips screwdriver - Electric drill - I /811 drill bit

Installation When installing trim, it is best to heat the material to a working flexibility. This can be done under field conditions by submerging the part to be installed in a container of hot water (I I o0 to 120 ° F) for approximately ten minutes.

Hook the trim lip over the flange on the outside of the fender, press down with thumb and push lower edge of trim over the lower flange.

After the trim is installed, replace the retainer strips at the rear bumper with new rivets or screws.

Mark the hole locations for the retainer strip assemblies at the floorboard by pushing an awl through from the opposite side under floorboard, then drill through the trim with a 1/4" drill and install the retainer in the reverse order of disassembly.

FENDER CAP REMOVAL

N

Quantity Quantity Quantity

Remove the 5 screws ( I) securing the armrest (2) and remove the armrest. (Fig. N-2) Remove the trim from the fender only.

It is not necessary to remove retainer strips at floorboard, but the rivet through the trim where the trim meets the fender cap must be removed.

Remove the fender cap and trunk Iid. Remove the 2 nuts (3) (Fig. N-2), remove the 3 screws (Fig. N-2) securing the fender to the seat compartment frame. Remove the 3 screws (5) (Fig. N-2) in the bagwell area. Lift the fender up and to the rear to remove. Reinstall in the reverse order of disassembly.

NOTE: Screws (4 and 5) are the self drill and tap type and may require the use of an impact driver for removal.

(Fig. N-1}

Tools Required: - Electric dril I - 1/8" Drill bit - 7/16" Open end wrench

Quantity Quantity Quantity FIG. N-1 FENDER CAP REMOVAL

E-Z�UDl«•m N-1

19000-GI MANUAL NO. I 0/01 /83 ISSUE DATE REVISED DATE

TITLE:

BODY AND TRIM

FIG. N-2 BODY PARTS MANUAL NO. ISSUE DATE REVISED DATE

I 9000-G I 10/01/83

N-2

TITLE:

BODY AND TRIM

REMOVING AND INSTALLING FRONT COWL

REMOVAL OF DASH TRAY

Tools Required:

Tools Required:

- 7/16" Open end wrench - Phillips screwdriver Three Wheel Car

Quantity Quantity

- 2 lb. Ball Peen hammer - 5/8" chisel (flat, thin) or pneumatic chisel

(Fig. N-3)

Remove the trim by peeling off at the lower corner of the cowl. The cowl is secured to the frame with twelve flanged nuts ( I and 5).

To gain access to eight of these nuts, two splash panels (3) must be removed. Remove screws (2) (two each panel). Remove two nuts (4) and two nuts (5) on each panel. Remove four nuts (1) each side of cowI. PuII out on each side of cowl to clear mounting studs from the frame, lift to the front and off. Reinstall in the reverse order of disassembly.

Four Wheel Car Removal procedure for the four wheel vehicle front cowl is the same as for three wheel vehicle except for the removal of five nuts under the front.

Quantity Quantity

Remove the cowI, cowI support, dash rubber, and dash mat.

Remove the two hex head screws located on either side of the cowl support.

The dash tray is secured by four welds located along the front edge. To remove the dash tray, a hammer and 5/8" chisel or a pneumatic air chisel may be used to break all four welds (to break a weld, the chisel must be forced through the weld). Once the four welds are broken, the dash tray can be removed.

The dash tray is reinstalled or replaced using 10-24 x 3/4" Lg. self drilling and tapping screws.

5

FIG. N-3 REMOVING THE COWL

E-Z-GOUJ:§ht•i:i N-3

MANUAL NO. 19000-GI 1.SSUE DATE 10/01/83 REVISED DATE

TITLE:

BODY AND TRIM

REMOVAL OF SEAT WRAP

REMOVAL OF FLOORBOARD (Fig. N-2)

Tools Required:

Tools Required:

- 2 lb. Ball Peen hammer - 5/8" chisel (flat, thin) or pneumatic chisel - I /4" wrench - Phillips screwdriver

Quantit y Quantity

- 2 lb. BalI P een hammer - 5/8" chisel or pneumatic chisel - 7/ 16" wrench - Phillips screwdriver

Quantity Quantity

Quantity Quantity Quantity Quantity

DISCONNECT BATTERY OR WARNING: BATTERIES BEFORE PROCEEDING. SEE PROCEDURE IN SECTION B.

Remove the accelerator pedal assembly, brake pedal assembly, steering column, armrests and floormat.

Remove the armrests, seat bottom, Forward and Reverse switch assembly, charger plug (elec tric vehicle only), choke (gas vehicle only), and ignition switch.

Remove the two hex head screws which are located on each side of the cowl support.

Remove one screw located on the floorboard under the Forward and Reverse knob (Fig. N-

2).

Remove two I /4" nuts from the weld studs located on each side of the seat wrap (Fig. N-

2).

The seat wrap is retained by four spot welds located along its top edge.

To remove the seat wrap, all four welds must be broken (to break the welds, either a 5/8" chisel and hammer or a pneumatic air chisel gun may be used). The weld will be broken when the chisel is forced into the weld.

The seat wrap is now ready for removal.

Pu 11ing the top of the seat wrap forward wi 11 cause the lip to move out from under the floorboard.

Remove one screw located at the rear of the floorboard where the seat wrap meets the floorboard.

The floorboard is secured by 22 spot welds as shown in Figure N-2.

To remove the floorboard, all 22 welds must be broken with either a hammer and 5/8" chisel or a pneumatic air chisel. The weld will be broken when the chisel is forced through the weld. Do this for all 22 welds. It is recommended that they be broken from the underside of the vehicle whenever possible since it is easier to reach the welds from this location.

Remove the floorboard.

The floorboard is reinstalled or replaced using 10-24 x 3/4" Lg. self d�illing and tapping screws.

The seat wrap is reinstalled or replaced by using No. 10-24 x 3/4",- �g. self drilling and tapping screws.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

E-Z-GOUiDht•m N-4

TITLE:

BODY AND TRIM

REMOVING CONSOLE

TRUNK LID AND BAGWELL REMOVAL

The console is held in place by 6 plastic fasteners.

Tools Required:

Tools Required:

- Stubby screwdriver - Screwdriver, 13" length

Quantity I Quantity I

Place the screwdriver on the center pin of the fastener underneath and behind the front wheels.

Push the center of the fastener towards the rear of the vehicle. To remove fasteners in the dash area, reach behind the console with the stubby screwdriver and push the center pin of the fastener out and remove from the dash. To install, use the reverse procedure.

- Phillips screwdriver - Chisel - Hammer

Quantity Quantity Quantity

The hammer and chisel may be substituted with an air chisel. Remove the 4 screws from the trunk lid and remove the trunk lid. Remove the 6 screws from each side of the bagwell.

Take a hammer and chisel and remove the weld on the underside of the back bumper. Install using the reverse procedure, substituting self­ drilling and tapping screws for welds.

E-Z-GOU:£11,t•m N-5

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE:

BODY AND TRIM

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

N-6

OPERATION & SERVICE MANUAL SECTION TITLE:. PAINT INSTRUCTIONS

MODEL: ELECTRIC GOLF CAR SECTION

RETOPCOAT VEHICLES

INSTRUCTIONS

p

E-Z-GO

Step I - Lightly sand with water using //320 paper until all gloss is removed and the desired finish obtained. Do not remove the galvanneal surface from the metal. Silver chips in sanding dust will indicate galvanneal removal.

Step 2 - Clean surface with solvent - mineral spirits or naptha.

Step 3 - Mix Polane catalyst //V66-V29 at a ratio of I to 8 (16 oz. per gallon of paint).

Reduce with thinner /IR7K2 I 2 to a viscosity Add of 24-26 Saybolt Universal Seconds. retarder R7K625 I as necessary to slow drying time.

Viscosity should be measured by NOTE: standard cup such as a Zahn or Ford. The cup can be purchased at most paint supply outlets.

A cup filled with paint mixture should flow through the bottom orifice at 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 (I) mil thickness is the normal NOTE: coverage required to hide primer or bare metal.

Step 5 - Allow 4-6 hours drying time for finished coat. Most Polane topcoats have small transparent bubbles dt .initial application. Most will disappear after a cyre of 2-3 days.

P-1

19000-GI MANUAL NO. ISSUE DATE 10/01/83 REVISED DATE

MANUAL NO. ISSUE DATE REVISED DATE

19000-G I 10/01/83

E-Z-GO••Dm•m P-2

OPERATION & SER.VICE MANUAL SECTION TITLE: TROUBLESHOOTING

MODEL: ELECTRIC GOLF CAR SECTION

R

SUSPENSION AND STEERING POSSIBLE CAUSE

CONDITION Hard Or Erratic Steering

Abnormal Play Or Looseness In Steering

CORRECTION

I. Incorrect tire pressure.

2. Insufficient or incorrect lubri­ cation.

3. Suspension, steering or linkage 3. Repair or replace parts as parts damaged. required.

4. Improper front wheel alignment. 4. Adjust wheel alignment.

5. Deformed springs.

5. Replace springs.

I. Steering wheel loose.

2. Steering linkage or attaching parts loose or worn.

3. Steering box attaching hardware loose.

4. Adjust or replace bearings.

5. Replace worn parts.

I. Improper tire pressure.

I. Inflate tires to recommended pressures.

2. Inspect parts and replace out of specification parts.

3. Replace shocks or mounting and hardware.

Steering gear parts badly worn.

2. Wheels, tires, or brake drums out-of-round.

3. Defective, worn, or loose shock absorbers or mounting parts.

4. Loose or worn steering or ,. . suspension parts.

5. Loose or worn wheel bearings.

6. Incorrect front wheel alignment.

Tire Wear

I. Inspect splines. Remove scorecard holder and tighten steering wheel nut.

2. Tighten, adjust, or replace worn parts.

3. Tighten hardware.

4. Loose or worn wheel bearings.

5.

Wheel Vibration

I. Inflate tires to recommended pressure.

2. Lubricate as required.

4. Tighten or replace as required.

5. Adjust or replace bearings.

6. Adjust front wheel alignment.

I. Improper tire pressure.

2.

3.

4.

5.

I. Inflate tires to recommended pressure.

Brakes grabbing.

2. Adjust or repair brakes.

Incorrect front wheel alignment. 3. Align front wheels.

Broken or damaged steering 4. Repair or replace defective parts. and suspension parts.

Whee I runout.

5. Replace faulty wheel.

R-1

MANUAL NO. 19000-GI ISSUE DATE 10/01/83 REVISED DATE

TROUBLE-SHOOTING

TITLE:

POSSIBLE CAUSE

CONDITION Car Pulls To One Side

I. Improper tire pressure.

CORRECTION I. Inflate tires to recommended pressures.

2. Install tires of same construction and tread depth and design.

2. Front tires with uneven tread depth, wear pattern, or different tread design.

3. Incorrect front wheel alignment. 3. Align front wheels.

4. Adjust or repair brakes.

4. Brakes dragging.

5. Replace defective tire.

5. Defective tire.

CHECK ITEMS I. Batteries discharge much faster than normal after a correct charge.

A. Batteries, charger and charging circuit. o Inspect battery terminals for tightness or corrosion. o Inspect the battery electrolyte level. o Inspect the specific gravity of battery electrolyte. o Inspect battery case for damage. o Inspect the charging circuit for loose connections, broken wires, or connections. o Check the A.C. voltage (115 Volts, 15 Amp) at the battery charger A.C. connection. o Check that the charging plug is firmly connected to the charger receptacle. o Inspect the D.C. cord and plug for damage.

B. Traction motor and power transmission circuit.

Inspect the power transmission circuit and motor circuit for loose connections. (Check for loose connectors at the accelerator switch, solenoid, and motor.) o Inspect the accelerator switch for dirty, burned or worn contacts, and for full arm travel. o Inspect the motor for worn brushes or damaged brushes, or dirty armature. o

C. Mechanical o o o o o o

Inspect the brakes.

Inspect the accelerator switch and linkage for adjustment.

Check the tire pressures.

Check for excessive wheel bearing drag.

Inspect the differential for oil leakage or defective action.

Check the operation of all controls. The vehicle should be run with the accelerator pedal fully depressed unless safety conditions require reduced speed. This will minimize power consumption.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

R-2

TROUBLE-SHOOTING

TITLE:

2. If the vehicle does not move in either direction. o o o

o o o

Check if the batteries are discharged.

Check the battery posts and terminals for corroded, loose, or broken connections.

Hold down brake pedal and be sure the area is clear. Place the forward-reverse switch in the forward position and depress the accelerator pedal and listen for a click. If no click is produced, check operation and connections of the solenoids, the key switch, accelerator switch, and charging receptacle.

Inspect the motor, accelerator switch, and resistor for loose or broken connections.

Inspect the accelerator switch for worn contact points and correct operation.

Inspect the motor for worn or defective brushes, or dirty armature. Also check the armature for broken wires or a short circuit.

3. If the acceleration becomes rough and uneven. o o o o

Inspect Inspect points.

Inspect Inspect

for loose or broken connections between the accelerator switch and resistor. the accelerator switch for dirty, burned, corroded, shorted, or worn contact the resistors for damage. for loose terminals.

4. If car starts immediately when the forward-reverse switch is set in the forward or reverse position. o o o o

Check the accelerator linkage adjustment.

Inspect the accelerator switch for jammed contact points.

Inspect for stuck accelerator pedal.

Inspect for stuck solenoid contacts.

5. The vehicle stops suddenly - refer to procedures 2 and 3.

6. The vehicle speed slows. o o o o

Check the battery electrolyte level and charged condition.

Check the batteries, accelerator switch, resistors, and motor for loose connections.

Inspect the accelerator switch for dirty or worn contact points, particularly the upper contacts. Also check for wires shorted or broken at connections and for full arm movement-.

Inspect the · motor for worn or damaged brushes or dirty armature.

7. If the accelerator switch contacts are burned abnormally. o

Check that the wiper contact is in contact with the fixed contacts.

8. If the motor does not stop even when the accelerator pedal is released.

If the motor stops when the forward-reverse switch is placed in the "N" position: o Check the accelerator switch micro switch. o Check the solenoid for stuck contacts.

R-3

MANUAL NO. 19000-GI 10/01/83 ISSUE DATE REVISED DATE

TITLE:

TROUBLE-SHOOTING

MOTOR POSSIBLE CAUSE

CONDITION Motor Does Not Turn

I. Brushes are not contacting armature.

2. Motor terminals are loose or corroded.

3. Power transmission wires are broken.

4. Field coil is "open".

5. Armature is broken.

CORRECTION

I.

Adjust properly.

2. Tighten or clean.

3. Check for breaks at joints.

Replace leads.

4. Repair or replace.

5. Repair or replace.

Motor Turns Slowly

I. Terminals are loose or corroded. I. Tighten or clean.

2. Wires are defective or 2. Check for any defect of leads, particularly at joints. Replace connections are faulty. wires.

3. Accelerator wiper movement 3. Adjust. is incomplete.

4. Batteries may need charging.

Noisy Motor

I. Bolts are loose.

2. Motor has foreign matter

I. Retighten.

2. Clean interior of motor.

inside.

3. Bearings are defective.

4. Bearings are dirty.

4.

Bearing Heat Excessive

I. Bearings are defective.

2. Improperly installed.

2. Adjust.

Erratic Operation

I. Load exceeds specification.

2. Armature is out of round.

3. Brushes are worn beyond spec.

4. Armature is excessively rough.

5.;- High mica at armature.

6. Armature is dirty.

7. Armature coil is shorted or broken.

3. Replace.

Replace.

I. Replace.

I. Reduce load.

2. Repair or replace at service shop.

3. Replace.

4. Smooth with sandpaper (/1500600).

5. Recondition� 6. Clean with a cleaner, dry thoroughly.

7. Replace.

Vibration

I. Motor loose.

2. Motor turns erratically.

I. Tighten.

2. Repair or replace.

Motor Operates at Excessive Speed

I. Field coil winding is shorted in motor.

I. Repair or replace field coils.

MANUAL NO. ISSUE DATE REVISED DATE

19000-GI 10/01/83

E-Z-GOUDhl•m R-4

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