Cushman 632904 Service Manual
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Cushman 632904 Service Manual

48v electric powered utility vehicle
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Repair & Service Manual
48V ELECTRIC POWERED UTILITY VEHICLE
632904
ISSUED MAY 2013
REVISED JANUARY 2014

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Summary of Contents for Cushman 632904

  • Page 1 Repair & Service Manual 48V ELECTRIC POWERED UTILITY VEHICLE 632904 ISSUED MAY 2013 REVISED JANUARY 2014...
  • Page 2 SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLE SHUTTLE 8 STARTING MODEL YEAR 2012 E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.

  • Page 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE SAFETY ........................Inside Covers GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BATTERIES AND CHARGING......................C BODY ...............................D BRAKES............................E ELECTRICAL SYSTEM ........................F ELECTRONIC SPEED CONTROL ....................G FRONT SUSPENSION AND STEERING ..................H MOTOR ............................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.

  • Page 8: Safety

    SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL OPERATION ALWAYS: • Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition. •...
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ALWAYS: • Test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic.
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page viii Repair and Service Manual...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LABEL LOCATION................ A - 1 TRANSPORTING VEHICLE ..................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page A-ii Repair and Service Manual...

  • Page 13: Serial Number Label Location

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERIAL NUMBER LABEL Maximum speed with sun top installed is 50 mph (80 kph). LOCATION If the vehicle is to be transported at highway speeds, the sun top must be removed and the seat bottom...

  • Page 14: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. It is in the best interest of both vehicle owner and servic- ing dealer to carefully follow the procedures recom- mended in this manual.

  • Page 15: Vehicle Cleaning And Care

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE CLEANING AND CARE that will not crack, peel or flake over a wide temperature range (P/N 606312).

  • Page 16: Hardware

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HARDWARE Generally, two grades of hardware are used in the vehicle. Periodically the vehicle should be inspected for loose •...

  • Page 17: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
  • Page 18 GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page A-6 Repair and Service Manual...
  • Page 19 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTICES, CAUTIONS WARNINGS AND DANGERS ..........B - 1 IMPORTANT SAFETY WARNING ................
  • Page 20 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page B-ii Repair and Service Manual...

  • Page 21: Notices, Cautions Warnings And Dangers

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICES, CAUTIONS, WARNINGS Always use the appropriate tools listed in the tool list and wear approved safety equipment. AND DANGERS MODIFICATIONS TO VEHICLE Throughout this manual, the following NOTICES,...

  • Page 22: Additional Warnings

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. powertrain. necessitating proper ventilation. Five air exchanges per hour is considered the Use care not to contact hot objects. minimum requirement.

  • Page 23: Battery Removal & Installation

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. immediately removed with a putty knife and wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion Overfilling batteries may result in electrolyte being...

  • Page 24: Lifting The Vehicle

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE Center of Tool List Qty. Front Axle Floor jack ..............1 Jack stands..............4 Chocks................. 4 Some servicing operations may require the vehicle to be raised.

  • Page 25: Batteries And Charging

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. SAFETY .........................C - 1 BATTERY ........................C - 1 BATTERY MAINTENANCE...................C - 1 At Each Charging Cycle ......................
  • Page 26 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page C-ii...

  • Page 27: Safety

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY the charge cycle. Expelled electrolyte may cause damage to the vehicle and storage Always observe the following warnings when working facility.

  • Page 28: At Each Charging Cycle

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. At Each Charging Cycle Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage. To reduce the possibility of fire, never attach a A battery being charged will ‘gas’...

  • Page 29: Cleaning Batteries

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. maintain the correct electrolyte level within the battery cells. Watering gun similar to the type included in the Battery Maintenance Kit To prevent battery damage, be sure that all battery caps are tightly installed.

  • Page 30: Battery Replacement

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Replacement nals and battery wire terminals with a commercially available protective coating. Front of Vehicle BL+ to Charger BL- to B-...

  • Page 31: Battery Charging

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. to prevent self discharge. The batteries should be • The charger connector/cord set is protected from tested or recharged at thirty day minimum intervals.

  • Page 32: Hydrometer

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. this point there is nothing that can be done to salvage which means that the electrolyte weighs 1.280 times the the battery;...

  • Page 33: Battery Charger

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY CHARGER points of each other. Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should Description be recharged and the test repeated.

  • Page 34: Charger Maintenance

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. charging. Polarized Receptacle Fig. 10 Polarized Receptacle The charger will automatically start a few seconds after plug insertion.

  • Page 35: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. BODY ..........................D - 1 General............................ D - 1 BODY COMPONENT REPLACEMENT ................D - 1 Instrument Panel Replacement ....................

  • Page 36: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page D-ii...

  • Page 37: General

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Drill Out Rivet Pop Rivet Head Only NOTICE In the following text, there are references to removing/install- ing bolts etc.
  • Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 2 Body Components (Front) Repair and Service Manual Page D-2...
  • Page 39 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Body Components (Seats and Rear Body) Repair and Service Manual Page D-3...
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Back Support or Seat Bed Frame Fig. 4 Body Components (Cargo Box, Seat, Foot Rest) Repair and Service Manual Page D-4...

  • Page 41: Instrument Panel Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Instrument Panel Replacement Tool List Qty. Phillips Screwdriver ............. 1 Tool List Qty. Rivet Gun ..............1 Electric/air Drill ............1 Duct Tape ..............

  • Page 42: Front Seat Pod Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Seat Pod Replacement Tool List Qty. Wrench, 9/16" ..............1 Tool List Qty. Rivet Gun ..............1 Wrench, 7/16" .............. 2 Phillips Screwdriver............1 Wrench, 1/2"...

  • Page 43: Foot Rest Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. rear body. Repeat procedure on other seat back sup- from rear body. Repeat procedure on other seat back port.

  • Page 44: Front Facing Rear Seat

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To remove the front seat back, remove bolt securing lifting device be used to remove the cargo bed seat back and rear hand hold bar to the back support from the vehicle Install replacement in the reverse order of disassembly.

  • Page 45: Painting

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tool List Qty. Rivet Gun ..............1 Small Pry Bar .............. 1 All painting must be done in an area with ade- Phillips Screwdriver .............

  • Page 46: Complete Panel Repair

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. adequate coverage and finish. Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match.

  • Page 47: Brakes

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL........................E - 1 System Description ......................... E - 1 Wheel Brake..........................
  • Page 48 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page E-ii...

  • Page 49: General

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Pedal Part of Frame Retaining Ring Shaft Master Cylinder Bushing Torsion Bushing Spring Linkage Bellcrank Part of Frame Flexible Brake...

  • Page 50: Maintenance

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE Daily Brake Performance Test Do not allow brake fluid to contact painted surfaces. Wipe off immediately. NOTICE After making any repairs to hydraulic lines, wheel cylin- To assure correct braking performance, all periodic mainte- ders or master cylinder, the brakes must be bled to...

  • Page 51: Master Cylinder Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MASTER CYLINDER REPLACE- Disconnect clevis yoke from upper arm of bellcrank in front of master cylinder. Disconnect linkage rod clevis MENT yoke from lower arm of bellcrank to allow bellcrank to swing out of the way.

  • Page 52: Brake Linkage

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Linkage Master cylinder piston should begin to move immediately upon any activation of the brake pedal. The brake pedal linkage is set at the factory. However, if the master cylinder should have to be replaced, the link- age may require adjustment.

  • Page 53: Brakedrum Removal And Installation

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE DRUM REMOVAL AND Wheel Brake Service INSTALLATION (Continued) Tool List Qty. Dust mask ..............1 Remove cap to gain access to the castellated nut and Safety glasses .............
  • Page 54 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Flexible Hose Clip Flexible Brake Line Banjo Bolt Copper Gaskets Brake Brake Banjo Union Line Line Bolt Brake Cable Wheel Bracket...

  • Page 55: Cleaning And Inspection

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove parking brake strut and lever. Check springs for loss of tension and damage. Replace weak springs and any damaged or badly worn parts. Remove shoe hold-down springs and remove shoes.

  • Page 56: Replacement Of Wear Items

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ROUTINE MAINTENANCE (Con- Actuator Linkage Bushings tinued) Removing the front shield may improve access (See BODY) The brake fluid should be checked at regular intervals The actuator linkage is connected to the lower actuator (as specified in the Periodic Service Schedule) or imme- pivot with a flat washer and cotter pin.
  • Page 57 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cause failure of the braking system. Dispose of in Switch on the park brake lever turns on the warning accordance with Federal, state and local codes.

  • Page 58: Parking Brake

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjustment To adjust the parking brake, loosen the screw in the end Adjustment Knob of the lever and turn the knob to tighten or loosen ten- Magnetic sion on the brake cable.

  • Page 59: Electrical System

    ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ..................F - 1 TROUBLESHOOTING....................
  • Page 60 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page F-ii...
  • Page 61 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DIGITAL VOLT OHM METER TROUBLESHOOTING A typical digital volt ohm meter (DVOM) is shown (Ref. In order to effectively troubleshoot the circuits that Fig.
  • Page 62 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Inline Fuse RED/ Passenger Side Driver Side Marker Headlight Headlight Marker Turn Turn DC - DC Converter BLU/WHT Horn + 12V...
  • Page 63 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. POWER SUPPLY NOTICE Tool List Qty. The green wire supplies power to the entire fuse block. DVOM ................. 1 1.
  • Page 64 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. that secures the front part of the light to the rear housing automotive type fuse. Headlight and taillight bulbs and (Ref.
  • Page 65 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle For Models before 2 Oct 2013 Mounting Black Plate DC converter Harness Harness DC converter Washer Washer Screw...
  • Page 66 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page F-6...

  • Page 67: Electronic Speed Control

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. PERFORMANCE ......................G - 1 Speed Control ......................... G - 1 Pedal-Up Features ........................

  • Page 68: Table Of Contents For Section 'G

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘G’ (CONT.) SECTION TITLE PAGE NO. Fig. 16 ITS Adjustment (Sheet 2 of 2) ..................G - 16 Fig.

  • Page 69: Speed Control

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERFORMANCE The pedal-up feature will slow the vehicle (the warning beeper will not sound) until either the vehicle speed is reduced to 8 mph (13 kph), at which it freely coasts NOTICE between 8 and 3 mph (5 kph), or the accelerator pedal...

  • Page 70: High Pedal Disable Feature

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. b) the brake is engaged so as to prevent vehicle NOTICE motion The controller will sense a stalled motor condition and 48 volt vehicles operate only in the ‘RUN’...

  • Page 71: Speed Sensor

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the operator attempts to override the electronic brak- Controller ing feature by moving the direction selector or key The controller is a solid state unit that activates a sole- switch to another position, the warning beeper will noid and controls the function of the vehicle by...

  • Page 72: General Troubleshooting

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL TROUBLESHOOTING To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage. Tool List Qty.

  • Page 73: Testing A Switch For Continuity

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. removing the BL- connection to the battery. Always use insulated wrenches when working on batteries. To check for continuity, set the DVOM to the KW setting Battery and select ‘Continuity’.
  • Page 74 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the continuity test indicates that contacts are not TROUBLESHOOTING DIAGRAMS “welded” and the wiring to the solenoid coil is good, the The following diagrams will assist in servicing the vehi- coil has failed and the solenoid must be replaced.
  • Page 75 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fault Fault Vehicle Operation Corrective Action Code Change - - - Direction selector fault Vehicle operates in •...
  • Page 76 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4 - 3 M- fault Vehicle will not run • Check M- wiring and repair; Replace controller 4 - 4 Auxiliary contact did not Vehicle will not run...
  • Page 77 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Ground To Hand Speed Input Held MAIN Sensor +15V Diagnostic RUN/ STORE SWITCH (20 A) Charger Interlock Throttle Switch (Optional) Pot High...
  • Page 78 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Charger Interlock Switch (Optional) Pot High Logic Enable Pot Low Fuse Sense Pot Wiper Logic Power Ground Main Contactor Brake Light Relay...
  • Page 79 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 80 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Ground SPARE Speed Input SPARE Sensor +15V SPARE All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 81 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAIN This test will verify secondary circuit voltage. Please reference the chart for probe connections. If not/ Then Probe Connection Voltage Positive probe on BL+ and...
  • Page 82 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INDUCTIVE THROTTLE SENSOR (ITS) Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the TESTING AND REPLACEMENT plastic pedal box studs.
  • Page 83 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 7/32" drill bit to measure gap between plunger Micro switch...
  • Page 84 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2.7 ± 0.5 volts 1.0 ± 0.3 volts Fig. 16 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page G-16...
  • Page 85 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTROLLER REPLACEMENT SOLENOID REPLACEMENT Tool ListQty. Tool ListQty. Socket, 10mm ............. 1 Socket, 3/8" ..............1 Socket, 7/16"...
  • Page 86 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Nm) and the 5/16" terminal nuts to 50 - 60 in. lbs (6 - 7 Nm) torque. Reconnect the BL- battery cable and replace the control- ler cover and seat.

  • Page 87: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. MAINTENANCE......................H - 2 Lubrication..........................H - 2 Wheel Bearing and King Pin Bushing Inspection ..............
  • Page 88 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘H’ (CONT.) SECTION TITLE PAGE NO. Fig. 15 Bellows Replacement......................H - 12 Fig.
  • Page 89 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...
  • Page 90 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE NOTICE Do not use more than three pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that In the following text, there are references to removing/installing bolts etc.
  • Page 91 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Bearing Packing Rotate the wheel 2 - 3 more turns to displace excess grease. If required, tighten castellated nut (3) again Tool List Qty.
  • Page 92 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lift the front of the vehicle and support on jack stands as per SAFETY section. Confirm the alignment of the front Remove Bolt springs.

  • Page 93: Front Suspension

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.
  • Page 94 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installation of shock absorber is reverse of disassembly. prevent pulling apart intermediate shaft. Mounting nuts should be tightened until rubber bushings Remove the three 1 3/4"...
  • Page 95 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (19) securing driver side spring to axle and discard lock nuts (19). Hold nut (21) with wrench and loosen long bolt (20). Note location of washer (22) and thread long bolt out as far as possible to remove the washer, nut and spacer (23).
  • Page 96 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. apply a light coating to the outer bearing race. Install outer wheel bearing (4) and secure hub loosely View from Underside of Vehicle with castellated nut.
  • Page 97 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. hub and dust cap (7) in solvent and dry thoroughly. Inspect for signs of damage. Pitting or a blue coloration of the rollers requires replacement of the bearing.
  • Page 98 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STEERING Front of Vehicle Flat Section Fig. 12 Steering Components Rack Ball Joint Replacement To remove rack ball joint (1), loosen passenger side front wheel and lift and support front of vehicle per Tool List Qty.
  • Page 99 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tie Rod Inspection/Replacement To install new rack ball joint close to its correct position, measure amount of threads exposed from jam nut (Ref. Tool List Qty.
  • Page 100 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. faced hammer to release tie rod from spindle arm. large end loose until rack extension-to-rack and pinion Remove nut to drop tie rod from spindle arm.
  • Page 101 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To access the pinion seal, remove rack and pinion unit from vehicle. “Rack and Pinion Unit Replacement” on page H-15 Anchor in vice by clamping on the mounting ears of the rack and pinion unit.
  • Page 102 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE The rack and pinion gears are not serviceable items. If they Front of Vehicle are found to be damaged or excessively worn, a new rack and pinion unit must be installed.
  • Page 103 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. seal lip prior to installing seal. “Pinion Seal Replace- from ball joint and ball joint from spindle arm. ment”...
  • Page 104 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. wrench to thread shaft of rack extension (7) further into Steering Wheel Replacement rack ball joint. This will provide more travel for the steer- Tool List Qty.
  • Page 105 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Shaft and Column Replacement Loosen the steering wheel retaining nut (6) two to three turns (Ref.
  • Page 106 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Slide wave washer (10) out bottom end of steering col- umn and keep for reuse. Remove small retaining ring (11) and press bearing from steering shaft.

  • Page 107: Motor

    MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL........................J - 1 Motor Removal ......................... J - 1 Motor Disassembly ........................
  • Page 108 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page J-ii...
  • Page 109 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Mark both the axle and motor housings to permit realignment during reassembly of motor to rear axle (Ref.
  • Page 110 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Motor Components Bearing Replacement Push back each brush until its spring (15) is resting against the side of the brush (Ref. Fig. 3). This keeps Tool List Qty.
  • Page 111 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove brush terminal hardware (12) at A1 and A2 (Ref. Fig. 3). When installing armature into the bearing/end cover Remove screws (13) securing brush plate (14).
  • Page 112 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Motor Tests The motor housing is not available as an individual part. No testing is recommended to determine the specific area of failure.

  • Page 113: Rear Axle

    REAR AXLE REAR AXLERead all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE ..................K - 1 Checking the Lubricant Level ....................K - 1 REAR AXLE DISASSEMBLY ..................K - 1 Axle Shaft Removal and Disassembly ...................
  • Page 114 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page K-ii Repair and Service Manual...
  • Page 115 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For further axle information, see Electric Rear Axle NOTICE Manual P/N 28148G01. Refer to REAR SUSPENSION section for axle removal. It is recommended that whenever a bearing, seal or ‘O’...
  • Page 116 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Removal and Disassembly (Continued) Use care to prevent damage to the inner surface of the Attach a slide hammer to the axle shaft thread and axle tube at the sealing area.
  • Page 117 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Replacement NOTICE Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with Tighten the castellated axle nut to 70 ft.
  • Page 118 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page K-4 Repair and Service Manual...

  • Page 119: Rear Suspension

    REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................L - 1 General............................. L - 1 Shock Absorber Removal......................
  • Page 120 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page L-ii...
  • Page 121 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of disassembly except that the shock absorber nuts (1,3) NOTICE must be tightened until the shock absorber bushings (4) expand to the diameter of the shock absorber washer...
  • Page 122 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of the Vehicle Fig. 1 Rear Suspension Repair and Service Manual Page L-2...

  • Page 123: Weather Protection

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD ....................M - 1 Trailering ..........................
  • Page 124 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page M-ii...
  • Page 125 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP AND WINDSHIELD Rear Support Installation Using a plastic faced hammer, tap end caps (5) into the top of the rear struts (3, 4) (Ref.
  • Page 126 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Of Vehicle Rear of Vehicle (Driver Side Shown) Front Strut Front of Vehicle Fig. 1 Shuttle 8 Sun Top Repair and Service Manual Page M-2...
  • Page 127 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPILT WINDSHIELD Insert bolt (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.
  • Page 128 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FULL WINDSHIELD Insert screw (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.

  • Page 129: Wheels And Tires

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ..................N - 1 Tire Repair..........................
  • Page 130 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page N-ii...
  • Page 131 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEEL AND TIRE SERVICE Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section Tools List Qty.

  • Page 132: Wheel Installation

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation With the valve stem to the outside, mount the wheel onto the hub with lug nuts (1). Finger tighten lug nuts (1) as shown.

  • Page 133: Troubleshooting

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. ELECTRICAL SYSTEM....................P - 1 Basic Electrical Power System Troubleshooting ..............P - 2 Basic Electrical Troubleshooting for Accessories..............
  • Page 134 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page P-ii...
  • Page 135 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM For non-PDS vehicles, see Electronic Speed Control Section. For PDS vehicles, see Electronic Speed Control (PDS) Section. For PDS vehicles, also use Diagnostic Mode, PDS Fault Codes and Troubleshooting Diagrams.
  • Page 136 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction BATTERIES WILL NOT CHARGE Vehicle/charger connector damaged Replace connector (Continued) Battery case damage Replace battery Low electrolyte level Maintain correct electrolyte level Battery capacity deficient...
  • Page 137 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUSPENSION AND STEERING Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment (Incorrect toe in) Align front tires STIFF STEERING Bent rack...
  • Page 138 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page P-4...

  • Page 139: Lightning Protection And Grounding

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. Grounding Requirements ....................... Q - 1 Ground Systems ..........................
  • Page 140 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page Q-ii...
  • Page 141 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 1.
  • Page 142 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 6.
  • Page 143 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 from penetrating or structurally damaging the building.
  • Page 144 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page Q-4...

  • Page 145: General Specifications

    GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. SHUTTLE 8........................R - 1 LIST OF ILLUSTRATIONS Fig.
  • Page 146 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page R-ii...
  • Page 147 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE™ 8 TYPE: ELECTRIC POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 626500 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Precision Drive System™...
  • Page 148 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lowest Clearance at Differential 3.00 in. (7.6 cm) 123.5 in. (313.7 cm) 149.0 in. (3178.5 cm) 167.5 in. (425.5 cm) 46.0 in.
  • Page 149 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING CLEARANCE DIAMETER 33 ft (10.1 m) RECOMMENDED MAX SIDE TILT 25% or 14° MAX RECOMMENDED MAX RAMP GRADE 25% or 14°...
  • Page 150 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page R-4...
  • Page 151 NOTICE NOTICE Read the following warnings before attempting to operate the Read and understand the following text and warnings before vehicle: attempting to service vehicle: In any product, components will eventually fail to per- form properly as the result of normal use, age, wear or abuse.
  • Page 152 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...

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