Cushman HAULER 800 2012 Technician's Repair And Service Manual
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Cushman HAULER 800 2012 Technician's Repair And Service Manual

Electric powered utility vehicles
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TECHNICIAN'S REPAIR AND SERVICE MANUAL
ELECTRIC POWERED UTILITY VEHICLES
625608
ISSUED MAY 2012
REVISED AUGUST 2012

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Summary of Contents for Cushman HAULER 800 2012

  • Page 1 TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLES 625608 ISSUED MAY 2012 REVISED AUGUST 2012...
  • Page 2 SA FE TY SAFETY For any questions on material contained in this manual, contact an authorized representative for clari cation. 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 at 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 SERVICE AND REPAIR MANUAL ELECTRIC POWERED UTILITY VECHICLE HAULER 800 HAULER 1000 STARTING MODEL YEAR 2012 The E-Z-GO Division of Textron Inc. (E-Z-GO) 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 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 SECTION SAFETY ......................... INSIDE COVERS GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ..............................C WHEELS AND TIRES ........................D FRONT SUSPENSION AND STEERING ..................E ELECTRONIC SPEED CONTROL ....................F MOTOR ............................
  • Page 6 TABLE OF CONTENTS 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 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 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. read and observe all warnings and operation instruction labels affixed to the vehicle.
  • 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 TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION ................. A - 1 TRANSPORTING VEHICLE ..................A - 1 Towing ......................A - 1 Hauling......................A - 1 SERVICING THE ELECTRIC VEHICLE..............A - 1 ROUTINE MAINTENANCE ..................
  • 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 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 SERVICING THE ELECTRIC LOCATION VEHICLE Two serial number and manufacture date code label are on the vehicle.

  • 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. REAR AXLE ITEM SERVICE OPERATION The only maintenance required for the first five years is Charge batteries Batteries the periodic inspection of the lubricant level.

  • Page 15: Vehicle Care Products

    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. SUN TOP AND WINDSHIELD cause damage to seals, plastics, the electrical system, body finish or seat material. Do not use pressure in excess of 700 psi (4826 kPa) to wash vehicle.

  • 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 ...
  • 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 TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTICES, CAUTIONS WARNINGS AND DANGERS..........B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE ................B - 1 GENERAL MAINTENANCE ..................B - 1 BEFORE SERVICING THE VEHICLE ...............B - 1 Additional Warnings..................B - 2 BATTERY REMOVAL &...

  • Page 20: Safety

    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. become caught in the moving parts of the collect in the ceiling of buildings powertrain. necessitating proper ventilation. Five air exchanges per hour is considered the Use care not to contact hot objects.

  • 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. should be present. If any corrosion is found, it should be 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 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. Center of Front Axle BL + Front of Vehicle BL - Flat Portion of Frame Fig. 2 Battery Connections (Hauler 1000) LIFTING THE VEHICLE Tool List Qty.
  • Page 25 SAFETY 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 B-5...
  • Page 26 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-6 Repair and Service Manual...

  • Page 27: Body

    BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY ........................C - 1 General ......................C - 1 BODY COMPONENT REPLACEMENT ..............C - 1 PAINTING ........................ C - 8 Minor Scratches ....................C - 8 Larger Scratches....................C - 8 Complete Panel Repair .....................
  • Page 28 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page C-ii Repair and Service Manual...
  • Page 29 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 NOTICE Pop Rivet Head Only In the following text, there are references to removing/installing bolts etc.
  • Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cowl Splash Panel Glove Box Door Instrumental Panel Fender Flare Front Fascia Front Basket Splash Panel Floorpan Brush Guard Fig.
  • Page 31 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Floor Mat Battery Tray Seat Wrap W/Louvers Splash Panel Rocker Panel Side Panel Rear Fender Rear Panel Fig. 3 Rear Body Components (HAULER 800) Repair and Service Manual Page C-3...
  • Page 32 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Floor Mat Battery Tray Seat Wrap W/Louvers Splash Panel Rocker Panel Side Panel Ashtray Rear Fender Rear Panel Fig.
  • Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Back Assembly For Hauler 800 Seat Bottom Assembly Front of Vehicle Seat Back Support Hip Restraint Access Cover Seat Bottom Assembly Seat Back Support Hip Restraint...
  • Page 34 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Plastic Bed Latch Handle Latch Plate Rubber Bumper Fig. 6 Plastic Bed Components (Manual Lift) Repair and Service Manual Page C-6...
  • Page 35 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Plastic Bed Electric Actuator Actuator may be rotated 90° on some models Front of Vehicle ELECTRIC DUMP DOWN WHT from Actuator BLK from Battery RED from Battery...
  • Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING 3. Apply spray touch up paint in light even overlapping strokes. Multiple coats may be applied to provide ade- quate coverage and finish.
  • Page 37 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 C-9...
  • Page 38 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 C-10...
  • Page 39 WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ................... D - 1 TIre Repair ....................... D - 1 Wheel Installation..................... D - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheel and Tire Installation............. D - 2 Repair and Service Manual Page D-i...

  • Page 40: 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. NOTES: Repair and Service Manual Page D-ii...
  • Page 41 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 seconds. Over inflation could cause the tire to separate from the rim or cause the tire to explode, either of which could cause personal injury.
  • Page 42 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Follow all instructions and safety warnings provided by With the valve stem to the outside, mount the wheel onto the mounting/demounting machine manufacturer.
  • Page 43 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 D-3...
  • Page 44 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 D-4...

  • Page 45: 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. Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...

  • Page 46: Fig. 2 Lubrication Points

    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 (3) pumps of grease in any grease fitting at any one time. Excess grease may cause In the following text, there are references to removing/ grease seals to fail or grease migration into areas that installing bolts etc.
  • Page 47 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. Remove hub from spindle and disassemble. See Illus- lated nut must be loosened to align with the closest tration “Seal Installation”...
  • Page 48 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. Measure the distance between the chalk lines at both the front and rear of the tires (Ref Fig. 4). The measure- ment taken at the front of the tires should be 0"...
  • Page 49 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 50 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. Remove the three 1 3/4" long bolts (18), two 1 1/2" long Mounting nuts should be tightened until rubber bushings bolts (28), spring plate (24) and five lock nuts (19) secur- (4) expand to diameter of shock absorber washers (5).
  • Page 51 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. (23). Then pull long bolt and spring plate (24) from axle and spring. Retain above items (20 - 24) for assembly at their original locations.
  • Page 52 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. Install outer wheel bearing (4) and secure hub loosely with castellated nut. Place wheel onto hub and hand View from Underside tighten lug nuts.
  • Page 53 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. of the rollers requires replacement of the bearing. If the roller portion of the bearing is to be replaced, the race must also be replaced.
  • Page 54 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 55 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 install new rack ball joint close to its correct position, Tie Rod Inspection/Replacement measure amount of threads exposed from jam nut (Ref Tool List Qty.
  • Page 56 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. hammer to release tie rod from spindle arm. Remove nut large end loose until rack extension-to-rack and pinion to drop tie rod from spindle arm.
  • Page 57 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 E - 15 Anchor in vice by clamping on the mounting ears of the rack and pinion unit.
  • Page 58 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. Wire Tie, 10" Long ............1 Torque Wrench, in. lbs..........1 Front of Vehicle NOTICE The rack and pinion gears are not serviceable items. If they are found to be damaged or excessively worn, a new rack and pinion unit must be installed.
  • Page 59 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. If rack and pinion pass inspection, clean them, tensioner Remove cotter pin (2) and loosen castellated nut (3) and housing thoroughly and lubricate for assembly.
  • Page 60 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. Check for proper rack extension-to-rack and pinion unit torque. Secure bellows to rack and pinion unit with new clearance by first turning steering wheel fully to the right.
  • Page 61 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. Bearing Separator............1 Gear Puller..............1 Arbor Press..............1 Bearing Driver Set ............1 Torque Wrench, ft. lbs..........1 Torque Wrench, in. lbs..........1 Wheel Bearing Grease ..........AR To remove steering shaft (4) (Ref Fig.
  • Page 62 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. as far as possible using snap ring pliers (Ref Fig. 25). Use fingers to push retaining ring fully into groove. Slide wave washer into base of steering column.
  • Page 63 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. NOTES: Repair and Service Manual Page E-19...
  • Page 64 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. NOTES: Repair and Service Manual Page E-20...

  • Page 65: Electronic Speed Control

    ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. TRUECOURSE TECHNOLOGY SYSTEM HAULER 800 GENERAL ............................. F - 1 PERFORMANCE OPTIONS & DIAGNOSTICS .................. F - 1 Changing Performance Options ....................F - 1 OPERATION ............................F - 2 Pedal Box ...........................
  • Page 66 ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ (CONT..) SECTION TITLE PAGE NO. 48 VOLT SYSTEM HAULER 1000 48 VOLT SYSTEM VEHICLES GENERAL...................F - 17 OPERATION ............................F - 17 Pedal Box ..........................F - 18 Speed Sensor........................... F - 18 Controller..........................

  • Page 67: General

    ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCOURSE TECHNOLOGY Performance options of the TCT System include: SYSTEM™ • Anti-Roll back to limit backward motion of the vehicle down an incline to less than 2 mph (3 kph).

  • Page 68: Operation

    ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. pedal released. Braking force should be felt at approxi- NOTICE mately 2 mph (3 kph) indicating that the TCT system is functioning.

  • Page 69: Pedal Box

    ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hill option will slow the vehicle to a stop at a slower rate many other units.

  • Page 70: Symptoms

    ELECTRONIC SPEED CONTROL - HAULER 800 - TCT 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..........1 Socket, 3/8" ..............1 Socket, 10mm.............. 1 Battery Ratchet ................

  • Page 71: Testing A Switch For Continuity

    ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Before any electrical service is performed on TCT model vehicles, the Run-Tow/Maintenance switch must be placed in the ‘Tow/Maintenance’...

  • Page 72: Troubleshooting Diagrams

    ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING DIAGRAMS The following diagrams will assist in servicing the vehicle. By utilizing the diagnostic mode Fault Codes, considerable time will be saved in determining the probable vehicle operating malfunction.
  • Page 73 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Controller Recover 1311 Display Explanation Tested When Possible Cause Response When High Pedal Disable Controller powers up 1.
  • Page 74 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 16 PIN Plug from Main Wire Harness to Controller CB- To Battery BL- 10AWG Black Motor Wire 10AWG White Motor Wire A1 - From Motor 4AWG...
  • Page 75 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 9 Controller Wiring Diagram Repair and Service Manual Page F-9...
  • Page 76 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT 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 77 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT 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"...
  • Page 78 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT 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. 12 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page F-12...
  • Page 79 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT 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 List Qty. Tool List Qty. Socket, 3/8" ..............1 Socket, 3/8"...
  • Page 80 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Red Wire Ring Terminal From Main Wire Harness SOL- From Controller SOL+ Blue Wire Ring Terminal From Main Wire Harness...
  • Page 81 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT 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-15...
  • Page 82 ELECTRONIC SPEED CONTROL - HAULER 800 - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page F-16 Repair and Service Manual...
  • Page 83 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 48 VOLT SYSTEM VEHICLES GENERAL NOTICE Performance options of the Precision Drive System 48 volt vehicles operate only in the ‘RUN’...
  • Page 84 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. sound and the vehicle will brake rapidly until it reaches ITS and plunger are accessed by removing the four the speed of approximately 2 mph (3 kph).
  • Page 85 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. GENERAL TROUBLESHOOTING Tool List Qty. Floor jack ..............1 Jack stands..............2 Wheel chocks ..............4 Jumper wire (with alligator clips)........1 DVOM ................1 Socket, 3/8", 3/8"...
  • Page 86 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage. Battery Reference Voltage...
  • Page 87 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Turn the key switch to ‘OFF’ and place the direction If the continuity test indicates that contacts are not “welded”...
  • Page 88 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fault Fault Vehicle Operation Corrective Action Code Change - - - Direction Selector Fault Vehicle Operates in •...
  • Page 89 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 90 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Ground To Hand Speed Input Held MAIN Sensor Diagnostic +15V RUN/ STORE SWITCH (20 A) Charger Interlock...
  • Page 91 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Charger Interlock Switch (Optional) Pot High Logic Enable Pot Low Fuse Sense Pot Wiper Logic Power Ground...
  • Page 92 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 93 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 94 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. MAIN This test will verify secondary circuit voltage. Please reference the chart for probe connections. If not/ Then Probe Connection Voltage...
  • Page 95 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 96 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 17/64"...
  • Page 97 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 1.5 - 1.7 volts 0.4 - 0.6 volts Fig. 29 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page F-31...
  • Page 98 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. CONTROLLER REPLACEMENT SOLENOID REPLACEMENT Tool List Qty. Tool List Qty. Socket, 10mm, 3/8" drive ..........1 Socket, 3/8", 3/8"...
  • Page 99 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. PURPLE Walkaway #10 Black From Walkaway Relay From Motor F2 Relay (Power Harness) To Solenoid Walkaway Fuse...
  • Page 100 ELECTRONIC SPEED CONTROL - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page F-34 Repair and Service Manual...

  • Page 101: Motor

    MOTOR TABLE OF CONTENTS FOR SECTION ’G’ SECTION TITLE PAGE NO. HAULER 800 GENERAL ............................. G - 1 Motor Removal ........................... G - 1 Motor Disassembly ........................G - 1 Bearing Replacement ........................ G - 3 Brush Replacement ........................G - 3 Motor Assembly .........................
  • Page 102 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page G-ii Repair and Service Manual...
  • Page 103 MOTOR - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Front of Vehicle For Hauler 800 Only Do not hold vehicle on hill by using accelerator and motor.
  • Page 104 MOTOR - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For HAULER 800 only Speed Sensor Fig. 3 Motor Components Repair and Service Manual Page G-2...
  • Page 105 MOTOR - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. On TCT motors, remove the magnet on the end of the armature by carefully removing the snap rings and NOTICE attaching screw.
  • Page 106 MOTOR - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove brushes and replace with new brush replace- Motor Tests ment kit. Locate springs against the side of each brush. The armature and motor housing are not available as Brush Brush...
  • Page 107 MOTOR - HAULER 800 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 G-5...
  • Page 108 MOTOR - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page G-6 Repair and Service Manual...
  • Page 109 MOTOR - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Remove battery cable Do not hold vehicle on hill by using accelerator and from (-) battery terminal motor.
  • Page 110 MOTOR - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For HAULER 1000 ONLY Fig. 9 Motor Components Bearing Replacement To aid disassembly, heat only the commutator end cover before attempting removal of the armature.
  • Page 111 MOTOR - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. against the bearing’s outer race to avoid bearing damage. Brushes should be measured as shown and replaced when the minimum dimension of .62"...
  • Page 112 MOTOR - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Align the commutator end cover with the holes in the quantity of molybdenum grease to the male portion of motor housing and assemble (Ref.
  • Page 113 MOTOR - HAULER 1000 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 G-11...
  • Page 114 MOTOR - HAULER 1000 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 G-12...

  • Page 115: Batteries And Charging

    BATTERIES AND CHARGING TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. SAFETY ........................H - 1 BATTERY .........................H - 1 BATTERY MAINTENANCE ..................H - 1 At Each Charging Cycle ..................H - 2 Monthly ......................H - 2 Electrolyte Level and Water ................H - 2 Cleaning Batteries ...................H - 3 Battery Replacement ..................H - 3 Prolonged Storage ...................H - 5...
  • Page 116 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: Page H-ii Repair and Service Manual...
  • Page 117 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 Overfilling batteries may result in electro- lyte being expelled from the battery during NOTICE the charge cycle. Expelled electrolyte may cause damage to the vehicle and storage Always observe the following warnings when working on or facility.
  • Page 118 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 119 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. should also be sprayed with the sodium bicarbonate Watering gun similar to the type included in the (baking soda) solution.
  • Page 120 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint. The batteries should be placed into the battery racks For HAULER 800 Only and the battery hold downs tightened to 45 - 55 in.
  • Page 121 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Prolonged Storage Battery charger, controller and other electronic devices need to be disconnected since they will contribute to the premature discharge of batteries.
  • Page 122 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. that may result from personnel running over or trip- Hydrometer ping over the cord set. A hydrometer (P/N 50900-G1) is used to test the state of •...
  • Page 123 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. and replaced with a good battery of the same brand, NOTICE type and approximate age. Do not perform a hydrometer test on a battery that has just been watered.
  • Page 124 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 H-8...
  • Page 125 ELECTRICAL SYSTEM TABLE OF CONTENTS FOR SECTION ’J’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ....................... J - 1 TROUBLESHOOTING ........................... J - 1 POWER SUPPLY ..........................J - 5 MAIN & ACCESSORY WIRING ......................J - 5 LIST OF ILLUSTRATIONS Fig.

  • Page 126: 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. Notes: Page J- ii Repair and Service Manual...
  • Page 127 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 In order to effectively troubleshoot the circuits that A typical DVOM (digital volt ohm meter) is shown (Ref. include the horn, lighting, brake/turn signals and Fig.
  • Page 128 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Turn Marker Headlight Headlight Marker Turn Inline Fuse DC - DC Driver Side Passenger Side converter Turn Marker Headlight Headlight...
  • Page 129 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTE: Connectors are viewed from rear of the connector GRAY GRAY GREEN WHITE GREEN WHITE ORANGE/RED ORANGE/RED BLACK BLACK BLUE...
  • Page 130 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driver Side Passenger Side Marker Headlight Headlight Marker Turn Turn BLU/WHT Horn + 12V ORN /WHT 15 AMP Fuse 15 AMP Brake...
  • Page 131 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 3. Check Converter Supply Firmly attach the black probe (-) to the most negative Tool List Qty.
  • Page 132 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVERSE BUZZER GRN/ Control Harness DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER, LABEL AND PLATE Fig. 5 Electrical Accessories Repair and Service Manual Page J-6...
  • Page 133 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. KEY SWITCH AND KEY SET HOUR METER DETAIL TURN SIGNALS HORN BUTTON Floorboard Fig. 6 Electrical Accessories Repair and Service Manual Page J-7...
  • Page 134 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURN SIGNAL HEAD LIGHT & Rear Fender TAILLIGHT Fig. 7 Electrical Accessories Repair and Service Manual Page J-8...
  • Page 135 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 J-9...
  • Page 136 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Page J-10 Repair and Service Manual...

  • Page 137: Brakes

    BRAKES TABLE OF CONTENTS FOR SECTION ’K’ SECTION TITLE PAGE NO. MECHANICAL BRAKES BRAKE SYSTEM OVERVIEW ......................K - 1 General Description ........................K - 1 How the Service Brake Works ....................K - 2 Equalizer Link ..........................K - 2 Automatic Adjuster Mechanism ....................K - 2 How the Parking Brake Works ....................K - 2 Compensator Assembly ......................K - 3 Kick-Off Actuating Linkage ......................K - 3...
  • Page 138 BRAKES TABLE OF CONTENTS FOR SECTION ’K’ SECTION TITLE PAGE NO. Fig. 10 Equalizer and Compensator ......................K - 9 Fig. 11 Parking Brake Pedal Hinge Inspection ..................K - 10 Fig. 12 Kick-Off Cam Inspection ......................K - 10 Fig. 13 Periodic Brake Performance Test ...................K - 11 Fig.

  • Page 139: Mechanical Brakes

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Pedal Torsion Springs Push Nut Hinge Pin Identification Hole* Service Brake Pedal Pedal Latch Spacer Kick Off Catch Bracket Cap Screw...

  • Page 140: Automatic Adjuster Mechanism

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. How the Service Brake Works Depressing the service brake pedal pulls the compensa- tor assembly and equalizer link, which are connected to the brake cables (Ref.

  • Page 141: Compensator Assembly

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Compensator Assembly The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref.

  • Page 142: Troubleshooting Flowchart

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace Condition of: Includes...
  • Page 143 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjuster Tries Disassemble Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.

  • Page 144: Troubleshooting Table

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING TABLE Test (PBPT), and Aggressive Stop Test is performed (Ref. Fig. 6 on Page K-6). Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Condition Possible Cause...
  • Page 145 MECHANICAL BRAKES 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 Neither wheel locks when park brake Incorrect compensator spring adjust- Return to factory specification ment is latched.

  • Page 146: Troubleshooting And Inspection

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING AND INSPEC- TION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes. In this break-in period, it is not uncommon for the brake pedal free travel (and the effort required to latch the parking 1/4"...
  • Page 147 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cables and linkages or initial break-in of components. brake lever. They must be loose when the brake pedal Not enough pedal free travel may indicate improper has been released (Ref.

  • Page 148: Periodic Brake Performance Test (Pbpt)

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point 0.0" Gap Push (0.0 mm) Catch...

  • Page 149: Aggressive Stop Test

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ping location or measure the vehicle stopping distance from the point at which the brakes were latched. The vehicle should stop within the “normal”...

  • Page 150: Wheel Brake Inspection

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. found, the drum must be replaced. NOTICE 3. Remove any accumulated brake dust from the wheel The brake adjuster mechanism must expand and release fully brake assembly with a brush.
  • Page 151 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 7. Check the condition and operation of the moving The pattern of normal brake shoe wear is anchor assembly (Ref.

  • Page 152: Maintenance And Repairs

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE AND REPAIRS essential to proper brake function. Too much pedal free travel will limit braking capability. Too little pedal free Tool List Qty.

  • Page 153: Brake Drum Removal And Installation

    MECHANICAL 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 Installation Repeat the previous step(s) until the pedal free travel does not change during the aggressive braking. Remove the dust cap (1) to gain access to the castel- Check to see that the clevis pins attaching the brake lated nut (2) and the cotter pin (3) (Ref.

  • Page 154: Wheel Brake Service

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. entire brake has been disassembled. NOTICE Remove any accumulated brake dust with a brush. Pay particular attention to the location of the inner brake drum Remove the brake shoes.

  • Page 155: Backing Plate/Entire Wheel Brake Assembly Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Shoe Removal Be sure that the adjusting screw is screwed into the star wheel nut until only 1 - 2 threads are exposed. If the brake shoes are replaced, replace the brake springs and NOTICE the adjuster components.

  • Page 156: Brake Shoe Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Shoe Installation The brake shoe end is pointed and engages the back- side of the adjuster.There is a 17L stamped into brake shoe (Ref.

  • Page 157: Brake Cable And Equalizer Assembly Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP PULL ADJUSTER ASSEMBLY Fig. 26 Brake Shoes &Springs Brake Cable and Equalizer Assembly axle brackets. Install new retaining rings. Connect the cables to the brake levers using new clevis pins and Removal and Installation new cotter pins.

  • Page 158: Compensator Assembly, Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Compensator Assembly, Removal and Installation Disconnect the compensator assembly from the brake pedal by removing the cotter pin and clevis pin (Ref. Fig. 27 on Page K-19).

  • Page 159: Parking Brake Pedal Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the two bolts (1) and nuts (2) which secure the setscrew heads in the kick-off cam should be approxi- catch bracket.

  • Page 160: Parking Brake Kick-Off Cam Removal, Replacement And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Kick-Off Cam Removal, Replacement and Installation. Disconnect the parking brake release linkage as described above. Loosen the two setscrews (5) from the cam (6) and remove the cam pivot (7), cam and spacer (8) (Ref.
  • Page 161 MECHANICAL 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 K-23...
  • Page 162 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Page K-24 Repair and Service Manual...
  • Page 163 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SYSTEM DESCRIPTION washers securing the master cylinder to the brake actu- ator assembly housing. Install new master cylinder, and tighten nuts to 12 - 14 ft.
  • Page 164 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ROUTINE MAINTENANCE NOTE: Unless fluid is lost or a brake line is discon- nected, there is no need to bleed the system. Tool List Qty.
  • Page 165 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. actuator pivot and the linkage rod (See Actuator linkage Attach a short length of clear hose to the caliper bleed bushings).
  • Page 166 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Page K-28 Repair and Service Manual...

  • Page 167: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................L - 1 PORTABLE CHARGER INSTALLATION ..............L - 1 UNDERSTANDING THE CHARGER ................ L - 2 LED DISPLAY INFORMATION................. L - 2 LED Operation Codes ..................L - 2 LED Fault Codes....................L - 2 MAINTENANCE INSTRUCTIONS ................
  • Page 168 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page L-ii Repair and Service Manual...
  • Page 169 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CHARGER DESCRIPTION supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way –...
  • Page 170 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers LED Fault Code: NOTICE RED FLASH: Light turns on briefly, but does not Looping the DC cord through the steering wheel when charg- flash after that - check for valid AC voltage.
  • Page 171 BATTERY CHARGER 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-3...
  • Page 172 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page L-4 Repair and Service Manual...

  • Page 173: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................M - 1 General ......................M - 1 Shock Absorber Removal.................M - 1 Shock Absorber Installation................M - 1 Rear Spring Removal ..................M - 1 Rear Spring Installation ..................M - 1 REAR AXLE REMOVAL ...................M - 3 Rear Axle Installation ..................M - 3 LIST OF ILLUSTRATIONS...
  • Page 174 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 M-ii...
  • Page 175 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 dis- assembly 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 176 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 M-2...
  • Page 177 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers REAR AXLE REMOVAL the governor and remove the cable. See SPEED CON- TROL section. Remove the linkage rod off of the gover- Tool List nor.
  • Page 178 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 M-4...
  • Page 179 REAR AXLE TABLE OF CONTENTS FOR SECTION ’N’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE .......................N - 1 Checking the Lubricant Level ....................N - 1 REAR AXLE DISASSEMBLY .......................N - 1 Axle Shaft Removal and Disassembly ..................N - 1 Axle Shaft Seal Removal and Replacement ................N - 2 Axle Shaft Replacement ......................N - 3 LIST OF ILLUSTRATIONS Fig.

  • Page 180: Rear Axle

    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 N-ii Repair and Service Manual...
  • Page 181 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 28148-G01. Refer to REAR SUSPENSION section for axle removal. It is recommended that whenever a bearing, seal or ‘O’...
  • Page 182 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Removing/Installing Axle Shaft Remove the bearing by supporting the inner race of the bearing on an arbor press bed and apply pressure to the threaded end of the axle shaft (Ref.
  • Page 183 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 184 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 N-4 Repair and Service Manual...

  • Page 185: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD................... P - 1 Trailering ......................P - 1 SUN TOP ........................P - 1 Rear Support Installation.................. P - 1 Front Strut ......................P - 1 Sun Top ......................
  • Page 186 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page P-ii Repair and Service Manual...
  • Page 187 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 Repeat procedure with rear strut at passenger side of vehicle. Front Struts Remove and discard the four bolts from the front cowl The top does not provide protection from roll (See Detail C).
  • Page 188 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 Front of Vehicle CANOPY STRUT KIT includes item 3 - 8 HARDWARE KIT includes item 9 - 16 seat back support Bumper Front of...
  • Page 189 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPLIT WINDSHIELD Insert bolt (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.
  • Page 190 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 Install sash (3) on each side of the windshield. Using a plastic faced mallet, gently tap sash to ensure wind- Tool List Qty.
  • Page 191 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 P-5...
  • Page 192 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page P-6 Repair and Service Manual...
  • Page 193 HANDHELD DIAGNOSTICS TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. HOW TO USE THE HANDHELD PROGRAMMER ...........Q - 1 Primary Connections: 4 PIN TYCO ..............Q - 1 Alternate Connection: 4 PIN MOLEX ...............Q - 1 Navigation ......................Q - 1 Changing Data Value ..................Q - 2 Book Mark ......................Q - 2 Repair and Service Manual...

  • Page 194: Handheld Diagnostics

    HANDHELD DIAGNOSTICS 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 195 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HOW TO USE THE HANDHELD PRO- GRAMMER The Curtis handheld Programmer is used for program- ming, testing, troubleshooting, tuning, diagnosing and parameter adjsutments for speed controller and auxiliary devices.
  • Page 196 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Press down the left arrow once or more on the naviga- MAIN MENU DEFINITIONS tion key to display the main menu. •...
  • Page 197 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value Profile Selection 1 - 5 Freedom Enable ON/OFF Speed...
  • Page 198 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value Main Welded 0 - 255 Speed Sensor Fault 0 - 255 Main Driver On...
  • Page 199 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value LCD Contrast -150 - 150 Program Language English...
  • Page 200 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page Q-6 Repair and Service Manual...

  • Page 201: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ’R’ SECTION TITLE PAGE NO. TROUBLESHOOTING HAULER 800 1206HB-5201 Controller Faults and Troubleshooting ................R - 1 TROUBLESHOOTING HAULER 1000 ELECTRICAL SYSTEM .........................R - 5 Basic Electrical Power System Troubleshooting .................R - 5 Basic Electrical Troubleshooting for Accessories ................R - 5 SUSPENSION AND STEERING ......................R - 6 Repair and Service Manual Page R-i...
  • Page 202 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page R-ii Repair and Service Manual...
  • Page 203 TROUBLESHOOTING - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 1206HB-5201 Controller Faults and Troubleshooting Controller Recover 1311 Display Explanation Tested When Possible Cause Response When Throttle applied to Hardware Failsafe...
  • Page 204 TROUBLESHOOTING - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Controller Recover 1311 Display Explanation Tested When Possible Cause Response When High Pedal Disable Controller powers up 1.
  • Page 205 TROUBLESHOOTING - HAULER 800 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-3...
  • Page 206 TROUBLESHOOTING - HAULER 800 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page R-4 Repair and Service Manual...
  • Page 207 TROUBLESHOOTING - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM Condition Possible Cause Correction VEHICLE WILL NOT MOVE Refer to Section F (Electronic Speed Control - HAULER 1000) for HAULER 1000 vehicle.
  • Page 208 TROUBLESHOOTING - HAULER 1000 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...
  • Page 209 TROUBLESHOOTING - HAULER 1000 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-7...
  • Page 210 TROUBLESHOOTING - HAULER 1000 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page R-8 Repair and Service Manual...

  • Page 211: Lightning Protection And Grounding

    LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. GROUNDING REQUIREMENTS................S - 1 GROUND SYSTEMS ....................S - 1 LIGHTINIG PROTECTION REQUIREMENTS............S - 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM ........S - 1 GROUND NETWORK REQUIREMENTS..............
  • Page 212 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: Page S-ii Repair and Service Manual...
  • Page 213 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 : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 1.
  • Page 214 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: EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding Rev -, ECN 027194 10/19/92 6.
  • Page 215 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 : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 trating or structurally damaging the building.
  • Page 216 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: Page S-4 Repair and Service Manual...

  • Page 217: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. HAULER 800 ......................T - 1 HAULER 1000 ......................T - 2 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions ..................T - 3 Fig. 2 Incline Specifications and Turning Clearance Diameter ........T - 4 FIg.
  • Page 218 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 T-ii...
  • Page 219 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: HAULER 800 TYPE: ELECTRIC 48V POWERED TRUCK MODEL YEAR: 2012 Part No:. 618840 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS TrueCourse Technology: Programmable to any golf course terrain, with expanded regenerative braking function, and vehicle charger lockout z Solid State continuously variable seperately excited speed controller...
  • Page 220 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: HAULER 1000 TYPE: ELECTRIC 48V POWERED TRUCK MODEL YEAR: 2012 Part No:. 618842 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Precision Drive System™...
  • Page 221 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 48.6 in (123.0 cm) 7.5 in (19.0 cm) (Front) 65.5 in (166.0 cm) 37.0in (94.0 cm) 103.5 in (262.0 cm) (Rear) 38.0 in (97.0 cm) 44.5 in...
  • Page 222 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 ◦ MAX 25% or 14 ◦ MAX TURNING CLEARANCE DIA.
  • Page 223 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 11.4" (28.9 cm) 7.8" (19.8 cm) 1.8" (4.5 cm) 6.3" (16 cm) 1.4" 3.5cm 2.5" (6.3 cm) 10.5"...
  • Page 224 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 T-6...
  • Page 225 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 perform properly as the result of normal use, age, wear or abuse. It is virtually impossible to anticipate all possible compo- To prevent personal injury or death, nent failures or the manner in which each component...
  • Page 226 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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Hauler 1000 2012

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