E-Z-GO TXT 48V Repair And Service Manual
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E-Z-GO TXT 48V Repair And Service Manual

Electric powered golf car
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REPAIR AND SERVICE MANUAL
TXT 48V
ELECTRIC POWERED GOLF CAR
614279
ISSUED JANUARY 2010

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Summary of Contents for E-Z-GO TXT 48V

  • Page 1 REPAIR AND SERVICE MANUAL TXT 48V ELECTRIC POWERED GOLF CAR 614279 ISSUED JANUARY 2010...
  • Page 2 SA FE TY 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 TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124 SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 INTERNATIONAL: PHONE: 001-706-798-4311, FAX: 001-706-771-4609 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852 Repair and Service Manual...
  • Page 4 GENERAL INFORMATION To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.
  • Page 5 TABLE OF CONTENTS TITLE PAGE Safety ........................... Inside Covers Model Notes ............................i Safety Information ..........................v TITLE SECTION General Information & Routine Maintenance ...................A Safety ...............................B Body ..............................C Wheels and Tires ..........................D Electronic Speed Control - TCT......................E Front Suspension and Steering ......................F Motor ...............................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with proce- dures developed by the manufacturer.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation.
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page viii Repair and Service Manual...

  • Page 11: Table Of Contents

    GENERAL INFORMATION & ROUTINE MAINTENANCE 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 MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page A-ii Repair and Service Manual...

  • Page 13: Transporting Vehicle

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. SERIAL NUMBER LABEL LOCA- SERVICING THE ELECTRIC TION VEHICLE Two serial number and manufacture date code label are on the vehicle.

  • Page 14: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. It is important that proper techniques and cleaning mate- displaces moisture, sealing against future mois- ture return (P/N 75503-G01).

  • Page 16: Hardware

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. HARDWARE Generally, two grades of hardware are used in the vehi- cle. Grade 5 hardware can be identified by the three marks on the hexagonal head.

  • Page 17: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. PERIODIC SERVICE SCHEDULE Check Clean, Adjust, etc. Replace NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY BEFORE USE: Check service brake general operation...
  • Page 18 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Check for bent/binding linkage rod Check for damage or wear to latch arm or catch bracket PARK BRAKE Lubricate as required, use light oil.

  • Page 19: Table Of Contents

    SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTES, CAUTIONS AND WARNINGS ..............B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE................B - 1 GENERAL MAINTENANCE..................B - 1 BEFORE SERVICING THE VEHICLE............... B - 1 Additional Warnings ..................
  • Page 20 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page B-ii Repair and Service Manual...

  • Page 21: Notes, Cautions And Warnings

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

  • Page 22: Additional Warnings

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Any servicing requiring adjustments to be electrical accessories are turned off before made to the powertrain while the motor is starting work on vehicle.

  • Page 23: Battery Removal & Installation

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. expelled from the battery during the charge cycle. Place batteries into the battery rack. Install the battery Expelled electrolyte may cause damage to the vehicle hold downs and tighten to 45 - 55 in.

  • Page 24: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Some servicing operations may require the vehicle be Center of raised. Front Axle To prevent possible injury or death resulting from a vehicle falling from a jack, be sure the vehicle is on a firm and level surface.
  • Page 25 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Repair and Service Manual Page B-5...
  • Page 26 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page B-6 Repair and Service Manual...
  • Page 27 BODY TABLE OF CONTENTS FOR SECTION ’C’ SECTION TITLE PAGE NO. BODY ..................................C - 1 General ................................C - 1 BODY COMPONENT REPLACEMENT ........................C - 1 Instrument Panel Replacement ........................C - 1 Cowl Replacement ............................C - 4 Front Shield Replacement ..........................
  • Page 28 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 all Notices, Cautions, Dangers and Warnings. BODY Drill Out Rivet Pop Rivet Head Only NOTICE In the following text, there are references to removing/install- ing bolts etc.
  • Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Frame Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...
  • Page 31 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fig. 3 Body Components (Rear) 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 all Notices, Cautions, Dangers and Warnings. Remove the drive rivets (9) securing the ignition switch Front Shield Replacement plate (10) to the instrument panel. Rotate the ignition Tool List Qty.
  • Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Body Replacement Remove the rivets (32) that secure the floor of the bag- well area to the frame underneath. Tool List Qty.
  • Page 34 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page C-6 Repair and Service Manual...

  • Page 35: Wheels And Tires

    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 - 1 LIST OF ILLUSTRATIONS Fig 1 Wheels and Tires............................... D - 2 Repair and Service Manual Page D-i...
  • Page 36 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page D-ii Repair and Service Manual...
  • Page 37 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. WHEEL AND TIRE SERVICE ing should be considered. On hard turf, it is desirable to have a slightly higher inflation pressure.
  • Page 38 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. sequence’ pattern (Ref. Fig. 1 on Page D-2). Then, NOTICE tighten lug nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in 20 ft.
  • Page 39 ELECTRONIC SPEED CONTROL - TCT TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. TRUCOURSE TECHNOLOGY (TCT) SYSTEM™ GENERAL .................................. E - 1 TRUCOURSE TECHNOLOGY SYSTEM™ PERFORMANCE OPTIONS & DIAGNOSTICS ........E - 1 Changing Performance Options ........................E - 1 TRUCOURSE TECHNOLOGY (TCT) SYSTEM™...
  • Page 40 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page E-ii Repair and Service Manual...
  • Page 41 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TRUCOURSE TECHNOLOGY SYS- Performance options of the TCT System include: TEM™ • Anti-Roll back to limit backward motion of the vehicle down an incline to less than 2 mph (3 kph) GENERAL •...
  • Page 42 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. At monthly intervals, test the TCT system by allowing a) the vehicle has been stopped for more than one the vehicle to roll down an incline with the accelerator second pedal released.
  • Page 43 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Hill option will slow the vehicle to a stop at a slower rate many other units.
  • Page 44 ELECTRONIC SPEED CONTROL - TCT 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. Required Floor jack ..............1 Battery Jack stands..............2 Reference Wheel chocks ..............
  • Page 45 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. If a power wire (battery, motor or controller) is discon- nected for any reason on the TCT model vehicle, the Run-Tow/Maintenance switch must be left in the ‘Tow/ Maintenance’...

  • Page 46: Troubleshooting Diagrams

    ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 47 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Controller Recover 1311 Display Explanation Tested When Possible Cause Response When High Pedal Disable Controller powers up 1.
  • Page 48 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 49 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fig. 9 Controller Wiring Diagram Repair and Service Manual Page E-9...
  • Page 50 ELECTRONIC SPEED CONTROL - TCT 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 51 ELECTRONIC SPEED CONTROL - TCT 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 7/32"...
  • Page 52 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 2.7 ± 0.5 volts 1.0 ± 0.3 volts Fig. 12 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page E-12...

  • Page 53: Solenoid Replacement

    ELECTRONIC SPEED CONTROL - TCT 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. Required Tool List Qty. Required Socket, 3/8", 3/8" drive ..........1 Socket, 3/8", 3/8"...
  • Page 54 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Red Wire Ring Terminal From Main Wire Harness SOL- From Controller SOL+ Blue Wire Ring Terminal From Main Wire Harness Yellow Wire Ring Terminal From Main Wire Harness...
  • Page 55 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Repair and Service Manual Page E-15...
  • Page 56 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page E-16 Repair and Service Manual...

  • Page 57: Fig. 2 Lubrication Point

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ’F’ SECTION TITLE PAGE NO. MAINTENANCE ................................. F - 2 Lubrication ..............................F - 2 Wheel Bearing and King Pin Bushing Inspection ..................F - 2 Wheel Bearing Packing ..........................F - 2 Wheel Bearing Adjustment ..........................
  • Page 58 FRONT SUSPENSION AND STEERING 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-ii Repair and Service Manual...
  • Page 59 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...
  • Page 60 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. MAINTENANCE Wheel Bearing and King Pin Bushing Inspection NOTICE In the following text, there are references to removing/installing bolts etc.
  • Page 61 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. mended that a bearing packer attached to a grease gun be used; however, manual packing is acceptable if done correctly.
  • Page 62 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. The tie rod has different threads on each end. The end with the groove in the threaded tube has left hand threads while the end without the groove has conventional right hand Rear threads.

  • Page 63: Front Suspension

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. FRONT SUSPENSION Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.
  • Page 64 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Front Axle Replacement At the 3 1/2" long bolt (20) securing front of left spring, note location of washer (22) and remove it from end of Tool List Qty.
  • Page 65 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ware (25 - 27) securing rear of spring (17) to vehicle NOTICE frame and discard lock nuts (27). Using new lock nuts (19, 27), install passenger side Failure of a single spring will result in overstressing the other spring;...
  • Page 66 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Loosen front wheel(s). Lift and support front of vehicle Lower vehicle per SAFETY section and tighten front per SAFETY section and remove front wheel(s).
  • Page 67 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. STEERING Front of Vehicle Flat Section Fig. 11 Steering Components Rack Ball Joint Replacement Remove the cotter pin (2) and loosen the castellated nut (3) until rack ball joint (1) threads are protected.
  • Page 68 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Grasp the tie rod (8) at ball joints (6) and check for any vertical motion which would indicate a worn condition and require replacement (Ref.
  • Page 69 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Cut wire ties (5,6) and slide bellows off rack extension. NOTICE Install new bellows aligning small end over groove in rack extension and secure with new wire tie (5).
  • Page 70 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Remove cotter pin (1) and loosen castellated nut (2) until tie rod ball joint (3) threads are protected (Ref. Fig. 16 on Page F-12).
  • Page 71 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Rack and Pinion Unit Disassembly and Inspection Tool List Qty. Required Vice ................1 Socket, 3/8", 3/8"...
  • Page 72 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Rack and Pinion Unit Replacement Set proper rack extension-to-rack and pinion unit clear- ance. “Checking/Adjusting Rack Extension-to-Rack and Tool List Qty.
  • Page 73 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. hex of rack extension. An 1/8" gap should exist between the large hex and the end of the rack and pinion unit. Approximately 1/8"...
  • Page 74 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ahead position, align the steering wheel on the steering Remove the four bolts (5) and washers (6) that secure shaft and slide wheel on shaft.
  • Page 75 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Repair and Service Manual Page F-17...
  • Page 76 FRONT SUSPENSION AND STEERING 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-18 Repair and Service Manual...
  • Page 77 MOTOR TABLE OF CONTENTS FOR SECTION ’G’ SECTION TITLE PAGE NO. GENERAL .................................. G - 1 Motor Removal .............................. G - 1 Motor Disassembly ............................G - 1 Bearing Replacement ............................ G - 3 Brush Replacement ............................G - 3 Motor Assembly .............................
  • Page 78 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page G-ii Repair and Service Manual...
  • Page 79 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. GENERAL Front of Vehicle Do not hold vehicle on hill by using accelerator and motor. Leaving the motor in a stalled condition for more than 3-4 seconds will raise the commutator bars result- Remove BL- ing in unacceptable noise and accelerated brush wear...
  • Page 80 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Speed Sensor Fig. 3 Motor Components Repair and Service Manual Page G-2...
  • Page 81 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. On TCT motors, remove the magnet on the end of the NOTICE armature by carefully removing the snap rings and attaching screw.
  • Page 82 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 83 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Repair and Service Manual Page G-5...
  • Page 84 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page G-6 Repair and Service Manual...

  • Page 85: 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 ..........................
  • Page 86 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page H-ii Repair and Service Manual...

  • Page 87: Battery Maintenance

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. SAFETY Overfilling batteries may result in electro- lyte being expelled from the battery during NOTICE the charge cycle.
  • Page 88 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 89 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. batteries which should also be sprayed with the sodium Watering gun similar to the type included in the bicarbonate (baking soda) solution.
  • Page 90 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. (baking soda) and water and thoroughly dried before Prolonged Storage priming and painting with a corrosion resistant paint. The batteries should be placed into the battery racks Battery charger, controller and other electronic devices and the battery hold downs tightened to 45 - 55 in.

  • Page 91: Troubleshooting

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. that may result from personnel running over or trip- ping over the cord set. • The charger is automatically turned off during the connect/disconnect cycle and therefore no electri- cal arc is generated at the DC plug/receptacle con-...
  • Page 92 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Hydrometer NOTICE A hydrometer (P/N 50900-G1) is used to test the state of charge of a battery cell (Ref. Fig. 7 on Page H-6). This is Do not perform a hydrometer test on a battery that has just performed by measuring the density of the electrolyte, been watered.
  • Page 93 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should be recharged and the test repeated.
  • Page 94 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page H-8 Repair and Service Manual...

  • Page 95: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................J - 1 PORTABLE CHARGER INSTALLATION ..............J - 1 UNDERSTANDING THE CHARGER .................J - 2 LED DISPLAY INFORMATION..................J - 2 LED Operation Codes ..................J - 2 LED Fault Codes....................J - 2 MAINTENANCE INSTRUCTIONS ................J - 2 LIST OF ILLUSTRATIONS...
  • Page 96 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page J-ii Repair and Service Manual...

  • Page 97: Portable Charger Installation

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. CHARGER DESCRIPTION cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way –...

  • Page 98: Understanding The Charger

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 99 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Repair and Service Manual Page J-3...
  • Page 100 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page J-4 Repair and Service Manual...
  • Page 101 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ’K’ SECTION TITLE PAGE NO. BRAKE SYSTEM OVERVIEW ........................... K - 1 General Description ............................K - 1 How the Service Brake Works ........................K - 2 Equalizer Link ..............................K - 2 Automatic Adjuster Mechanism ........................
  • Page 102 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ’K’ SECTION TITLE PAGE NO. Fig. 15 Adjuster Mechanism ............................ K - 12 Fig. 16 Brake Shoe Wear ............................K - 13 Fig. 17 Orientation of Brake Shoe Springs ......................K - 13 Fig.
  • Page 103 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Parking Brake Pedal Torsion Springs Push Nut Identification Hole Hinge Pin Pedal Latch Service Brake Pedal Kick Off Spacer Catch Bracket...
  • Page 104 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. 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 105 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 106 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace Condition of:...
  • Page 107 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Adjuster Tries Disassemble Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.
  • Page 108 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. 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...
  • Page 109 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Condition Possible Cause Correction Neither wheel locks when park brake Incorrect compensator spring adjust- Return to factory specification ment is latched.
  • Page 110 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. TROUBLESHOOTING AND INSPEC- TION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes.
  • Page 111 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 112 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point 0.0" Gap Push (0.0 mm) Catch...
  • Page 113 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 114 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. 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 115 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 7. Check the condition and operation of the moving The pattern of normal brake shoe wear is anchor assembly (Ref.
  • Page 116 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. MAINTENANCE AND REPAIRS travel will limit braking capability. Too little pedal free travel may cause the brakes to drag (not fully released). Tool List Qty.
  • Page 117 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Check to see that the clevis pins attaching the brake cables to the brake levers are loose (Ref. Fig. 19 on Page K-15).
  • Page 118 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. one additional inner brake drum washer (total of 2) to shoes or the friction surface of the brake drum. Use only obtain required spacing.
  • Page 119 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Backing Plate/Entire Wheel Brake Assembly accumulated brake dust from the backing plate and adjuster mechanism using a brush or air hose. Removal and Installation If the brake is being removed for an axle bearing and Remove the four bolts (1) and lock nuts (2) securing the...
  • Page 120 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. The brake shoe end is squared off and engages the the hole in the axle. Maximum torque 140 ft. lbs. (190 screw end of the adjuster.
  • Page 121 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TOP PULL ADJUSTER ASSEMBLY Fig. 27 Brake shoes and Springs Compensator Assembly, Removal and with brake lights. Unhook the torsion spring (4) by insert- ing a thin blade screwdriver between the small hook and Installation the bracket.
  • Page 122 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.. Remove the two bolts (1) and nuts (2) which secure the catch bracket. Replace the catch bracket with a new one, replace and tighten the hardware to 85 - 95 in.
  • Page 123 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. setscrew heads in the kick-off cam should be approxi- Parking Brake Kick-Off Cam Removal, mately 1/4" - 3/8” (6 - 9.5 mm). Replacement and Installation.
  • Page 124 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page K-22 Repair and Service Manual...

  • Page 125: Direction Selector

    DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ’L’ SECTION TITLE PAGE NO. DIRECTION SELECTOR ............................L - 1 Removing Direction Selector ..........................L - 1 Replacing the Reverse Warning Buzzer ......................L - 1 Replacing the Direction Selector Switch ......................L - 1 LIST OF ILLUSTRATIONS Fig .
  • Page 126 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page L-ii Repair and Service Manual...
  • Page 127 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. DIRECTION SELECTOR Prior to removing the direction selector switch from the body, the battery positive cable must be disconnected to prevent the possibility of electrical spark or ‘shorting out’...
  • Page 128 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Direction Selector State of Charge Direction Key Switch Meter Selector w/o Lights WHT/ Clip State of Charge Direction Key Switch Fig.
  • Page 129 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Repair and Service Manual Page L-3...
  • Page 130 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page L-4 Repair and Service Manual...

  • Page 131: Electrical System

    ELECTRICAL SYSTEM TABLE OF CONTENTS FOR SECTION ’M’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ............................M - 1 TROUBLESHOOTING ...............................M - 1 POWER SUPPLY ...............................M - 3 MAIN & ACCESSORY WIRING ..........................M - 3 LIST OF ILLUSTRATIONS Fig. 1 DVOM ................................M - 1 Fig.
  • Page 132 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page M- ii Repair and Service Manual...
  • Page 133 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 134: Electrical System

    ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Turn Marker Headlight Headlight Marker Turn Inline Fuse DC - DC converter RED/WHT BLU/WHT Horn + 12V ORN /WHT 15 AMP 15 AMP...
  • Page 135 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTE: Connectors are viewed from rear of the connector GRAY GREEN WHITE ORANGE/RED BLACK BLUE BLACK WHITE WHITE/YELLOW GREEN-WHITE...

  • Page 136: Power Supply

    ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. POWER SUPPLY 3. Check Converter Supply Firmly attach the black probe (-) to the most negative Tool List Qty.
  • Page 137 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REVERSE BUZZER GRN/ Control Harness DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER, LABEL AND PLATE Fig.
  • Page 138 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. KEY SWITCH AND KEY SET HOUR METER DETAIL TURN SIGNALS HORN BUTTON Floorboard Fig. 4 Electrical Accessories Repair and Service Manual Page M-6...
  • Page 139 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Rear Fender TAILLIGHTS WHT to BLK from Harness - Both Sides BLK to BLU/WHT from Harness - Both Sides RED to WHT from Harness - Driver Side RED to YEL from Harness - Passenger Side RED TO BRN from Harness - (W/O Turn Signals)
  • Page 140 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page M-8 Repair and Service Manual...

  • Page 141: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ’N’ SECTION TITLE PAGE NO. REAR SUSPENSION ..............................N - 1 GENERAL .................................. N - 1 Shock Absorber Removal ..........................N - 1 Shock Absorber Installation ........................... N - 1 Rear Spring Removal ............................ N - 1 Rear Spring Installation ..........................
  • Page 142 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page N-ii Repair and Service Manual...
  • Page 143 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of NOTICE disassembly except that the shock absorber nuts (1, 3) must be tightened until the shock absorber bushings (4) In the following text, there are references to removing/install- expand to the diameter of the shock absorber washer...
  • Page 144 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. persons should remove the rear axle and NOTICE motor assembly. Disconnect the negative (BL-) battery cable To remove the rear axle assembly will require the use of an with an insulated wrench before attempting to overhead hoist that can support the motor.
  • Page 145 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fig. 3 Rear Suspension Repair and Service Manual Page N-3...
  • Page 146 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page N-4 Repair and Service Manual...
  • Page 147 REAR AXLE TABLE OF CONTENTS FOR SECTION ’P’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE ............................ P - 1 Checking the Lubricant Level ........................P - 1 REAR AXLE DISASSEMBLY ............................. P - 1 Axle Shaft Removal and Disassembly ......................P - 1 Axle Shaft Seal Removal and Replacement ....................
  • Page 148 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page P-ii Repair and Service Manual...
  • Page 149 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. For further axle information, see Electric Rear Axle Man- NOTICE ual P/N 28148-G01. Refer to REAR SUSPENSION section for axle removal. It is recommended that whenever a bearing, seal or ‘O’...
  • Page 150 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 151 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Axle Shaft Replacement NOTICE Carefully insert the axle shaft and bearing through the Tighten the castellated axle nut to 70 ft. lbs. (95 Nm) torque oil seal.
  • Page 152 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page P-4 Repair and Service Manual...

  • Page 153: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ’Q’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD ............................Q - 1 Tailering ................................. Q - 1 GOLF CAR SUN TOP ..............................Q - 1 Rear Support Installation ..........................Q - 1 Front Strut ..............................Q - 1 Sun Top .................................
  • Page 154 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page Q- ii Repair and Service Manual...
  • Page 155 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TOP AND WINDSHIELD bolt (4) with washer (3) through lower hole and secure with washer (3) and lock nut (6). Finger tighten hard- ware to allow for adjustment.
  • Page 156 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. FRONT OF VEHICLE DETAIL A DETAIL D (REAR) FRONT OF VEHICLE 1 18 DETAIL C (FRONT) DETAIL B Fig.
  • Page 157 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. SPLIT WINDSHIELD NOTICE Remove protective covering from the windshield (2) (Ref. Fig. 2 on Page Q-3). It may be necessary on early production sun tops to drill a 9/ Install sash (3) on each side of the lower section of wind- "...
  • Page 158 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ONE-PIECE FRONT WINDSHIELD Insert screw (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Remove protective covering from the windshield (2) and lock nut (7) (See Detail B).
  • Page 159 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REAR WINDSHIELD Place bottom section of rear windshield on rubber grom- mets and press the sash, starting at the bottom, onto the Remove protective covering from rear windshield (2) rear strut so that it snaps into place (See Details B and (Ref.
  • Page 160 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page Q-6 Repair and Service Manual...
  • Page 161 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. HOW TO USE THE HANDHELD PRO- • Engage and twist sleeve to secure GRAMMER The Curtis handheld Programmer is used for program- ming, testing, troubleshooting, tuning, diagnosing and parameter adjsutments for speed controller and auxiliary devices.
  • Page 162 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Press down the left arrow once or more on the naviga- MAIN MENU DEFINITIONS tion key to display the main menu. •...
  • Page 163 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value Profile Selection 1 - 5 Freedom Enable ON/OFF Speed...
  • Page 164 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 165 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value LCD Contrast -150 - 150 Program Language English...
  • Page 166 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page R-6 Repair and Service Manual...
  • Page 167 TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ’S’ SECTION TITLE PAGE NO. 1206HB-5201 Controller Faults and Troubleshooting ....................S - 1 Repair and Service Manual Page S-i...
  • Page 168 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page S-ii Repair and Service Manual...
  • Page 169 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 1206HB-5201 Controller Faults and Troubleshooting Controller Recover 1311 Display Explanation Tested When Possible Cause Response When Throttle applied to Hardware Failsafe 1.
  • Page 170 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Controller Recover 1311 Display Explanation Tested When Possible Cause Response When High Pedal Disable Controller powers up 1.
  • Page 171 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Repair and Service Manual Page S-3...
  • Page 172 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page S-4 Repair and Service Manual...
  • Page 173 LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. GROUNDING REQUIREMENTS................T - 1 GROUND SYSTEMS ....................T - 1 LIGHTINIG PROTECTION REQUIREMENTS............T - 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM ........T - 1 GROUND NETWORK REQUIREMENTS..............
  • Page 174 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page T-ii Repair and Service Manual...
  • Page 175 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 1.
  • Page 176 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REVISION: GS-726-006 TITLE: EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding Rev -, ECN 027194 10/19/92 6.
  • Page 177 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 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 178 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page T-4 Repair and Service Manual...
  • Page 179 PAINT TABLE OF CONTENTS FOR SECTION ’U’ SECTION TITLE PAGE NO. PAINTING ................................... U - 1 Minor Scratches ............................. U - 1 Larger Scratches ............................U - 1 Complete Panel Repair ..........................U - 1 Repair and Service Manual Page U-i...
  • Page 180 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page U-ii Repair and Service Manual...
  • Page 181 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. PAINTING adequate coverage and finish. Always remember to shake the can for a minimum of one minute to mix the Follow the paint manufacturer’s recommendations for paint and achieve the best color match.
  • Page 182 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page U-2 Repair and Service Manual...

  • Page 183: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ’V’ SECTION TITLE PAGE NO. TXT ELECTRIC - FLEET ............................V - 1 TXT ELECTRIC - FREEDOM ............................. V - 2 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions ............................V - 3 Fig. 2 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter ........... V - 4 Fig.
  • Page 184 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Page V-ii Repair and Service Manual...
  • Page 185 GENERAL SPECIFICATIONS MODEL: TXT 48V FLEET GOLF CAR TYPE: ELECTRIC 48V FLEET GOLF CAR MODEL YEAR 2010 Part No. : 612623 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS TrueCouse Technology: Programmable to any golf course terrain, wi h expanded regenerative braking function, and vehicle charger lockout...
  • Page 186 GENERAL SPECIFICATIONS MODEL: TXT 48V FREEDOM GOLF CAR TYPE: ELECTRIC 48V FREEDOM GOLF CAR MODEL YEAR 2010 Part No. : 614265 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS TrueCouse Technology: Programmable to any golf course terrain, with expanded regenerative braking function, and vehicle charger lockout...
  • Page 187 GENERAL SPECIFICATIONS 68 in. (173 cm) 46.5 in. (118 cm) Front 4.5 in. 34.0 in. (86 cm) (11.0 cm) Ground Rear Clearance 38.5 in. (97 cm) 66.0 in. (168 cm) 91.0 in. (231 cm) 47.0 in. (119 cm) Fig. 1 Vehicle Dimensions Repair and Service Manual Page V-3...
  • Page 188 GENERAL SPECIFICATIONS RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP 25% GRADE or 14 o MAX 25% GRADE or 14 o MAX TURNING CLEARANCE DIAMETER 19 ft. (5.8 m) Fig. 2 Vehicle dimensions, Incline Specifications and Turning Clearance Diameter Repair and Service Manual Page V-4...
  • Page 189 GENERAL SPECIFICATIONS 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" (26.7 cm) 4.8" (12.2 cm) 5.4" 4.1" (13.7 cm) (10.4 cm) Fig. 3 Battery Charger Dimensions Repair and Service Manual Page V-5...
  • Page 190 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. NOTES: Repair and Service Manual Page V-6...
  • Page 191 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, ob- nent failures or the manner in which each component...
  • Page 192 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department...

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