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Repair & Service Manual 48V ELECTRIC POWERED UTILITY VEHICLE 632904 ISSUED MAY 2013 REVISED JANUARY 2014...
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SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
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REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLE SHUTTLE 8 STARTING MODEL YEAR 2012 E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.
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.
TABLE OF CONTENTS TITLE PAGE SAFETY ........................Inside Covers GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BATTERIES AND CHARGING......................C BODY ...............................D BRAKES............................E ELECTRICAL SYSTEM ........................F ELECTRONIC SPEED CONTROL ....................G FRONT SUSPENSION AND STEERING ..................H MOTOR ............................
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TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...
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.
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. •...
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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.
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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...
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GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LABEL LOCATION................ A - 1 TRANSPORTING VEHICLE ..................
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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...
GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERIAL NUMBER LABEL Maximum speed with sun top installed is 50 mph (80 kph). LOCATION If the vehicle is to be transported at highway speeds, the sun top must be removed and the seat bottom...
GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. It is in the best interest of both vehicle owner and servic- ing dealer to carefully follow the procedures recom- mended in this manual.
GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE CLEANING AND CARE that will not crack, peel or flake over a wide temperature range (P/N 606312).
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 •...
GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
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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...
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SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTICES, CAUTIONS WARNINGS AND DANGERS ..........B - 1 IMPORTANT SAFETY WARNING ................
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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...
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,...
SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. powertrain. necessitating proper ventilation. Five air exchanges per hour is considered the Use care not to contact hot objects. minimum requirement.
SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. immediately removed with a putty knife and wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion Overfilling batteries may result in electrolyte being...
SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE Center of Tool List Qty. Front Axle Floor jack ..............1 Jack stands..............4 Chocks................. 4 Some servicing operations may require the vehicle to be raised.
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. SAFETY .........................C - 1 BATTERY ........................C - 1 BATTERY MAINTENANCE...................C - 1 At Each Charging Cycle ......................
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BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page C-ii...
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY the charge cycle. Expelled electrolyte may cause damage to the vehicle and storage Always observe the following warnings when working facility.
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’...
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. maintain the correct electrolyte level within the battery cells. Watering gun similar to the type included in the Battery Maintenance Kit To prevent battery damage, be sure that all battery caps are tightly installed.
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Replacement nals and battery wire terminals with a commercially available protective coating. Front of Vehicle BL+ to Charger BL- to B-...
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. to prevent self discharge. The batteries should be • The charger connector/cord set is protected from tested or recharged at thirty day minimum intervals.
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. this point there is nothing that can be done to salvage which means that the electrolyte weighs 1.280 times the the battery;...
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY CHARGER points of each other. Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should Description be recharged and the test repeated.
BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. charging. Polarized Receptacle Fig. 10 Polarized Receptacle The charger will automatically start a few seconds after plug insertion.
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. BODY ..........................D - 1 General............................ D - 1 BODY COMPONENT REPLACEMENT ................D - 1 Instrument Panel Replacement ....................
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page D-ii...
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Drill Out Rivet Pop Rivet Head Only NOTICE In the following text, there are references to removing/install- ing bolts etc.
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BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 2 Body Components (Front) Repair and Service Manual Page D-2...
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BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Body Components (Seats and Rear Body) Repair and Service Manual Page D-3...
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BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Back Support or Seat Bed Frame Fig. 4 Body Components (Cargo Box, Seat, Foot Rest) Repair and Service Manual Page D-4...
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Instrument Panel Replacement Tool List Qty. Phillips Screwdriver ............. 1 Tool List Qty. Rivet Gun ..............1 Electric/air Drill ............1 Duct Tape ..............
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Seat Pod Replacement Tool List Qty. Wrench, 9/16" ..............1 Tool List Qty. Rivet Gun ..............1 Wrench, 7/16" .............. 2 Phillips Screwdriver............1 Wrench, 1/2"...
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. rear body. Repeat procedure on other seat back sup- from rear body. Repeat procedure on other seat back port.
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To remove the front seat back, remove bolt securing lifting device be used to remove the cargo bed seat back and rear hand hold bar to the back support from the vehicle Install replacement in the reverse order of disassembly.
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tool List Qty. Rivet Gun ..............1 Small Pry Bar .............. 1 All painting must be done in an area with ade- Phillips Screwdriver .............
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. adequate coverage and finish. Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match.
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL........................E - 1 System Description ......................... E - 1 Wheel Brake..........................
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BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page E-ii...
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Pedal Part of Frame Retaining Ring Shaft Master Cylinder Bushing Torsion Bushing Spring Linkage Bellcrank Part of Frame Flexible Brake...
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE Daily Brake Performance Test Do not allow brake fluid to contact painted surfaces. Wipe off immediately. NOTICE After making any repairs to hydraulic lines, wheel cylin- To assure correct braking performance, all periodic mainte- ders or master cylinder, the brakes must be bled to...
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MASTER CYLINDER REPLACE- Disconnect clevis yoke from upper arm of bellcrank in front of master cylinder. Disconnect linkage rod clevis MENT yoke from lower arm of bellcrank to allow bellcrank to swing out of the way.
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Linkage Master cylinder piston should begin to move immediately upon any activation of the brake pedal. The brake pedal linkage is set at the factory. However, if the master cylinder should have to be replaced, the link- age may require adjustment.
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE DRUM REMOVAL AND Wheel Brake Service INSTALLATION (Continued) Tool List Qty. Dust mask ..............1 Remove cap to gain access to the castellated nut and Safety glasses .............
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BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Flexible Hose Clip Flexible Brake Line Banjo Bolt Copper Gaskets Brake Brake Banjo Union Line Line Bolt Brake Cable Wheel Bracket...
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove parking brake strut and lever. Check springs for loss of tension and damage. Replace weak springs and any damaged or badly worn parts. Remove shoe hold-down springs and remove shoes.
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ROUTINE MAINTENANCE (Con- Actuator Linkage Bushings tinued) Removing the front shield may improve access (See BODY) The brake fluid should be checked at regular intervals The actuator linkage is connected to the lower actuator (as specified in the Periodic Service Schedule) or imme- pivot with a flat washer and cotter pin.
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BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cause failure of the braking system. Dispose of in Switch on the park brake lever turns on the warning accordance with Federal, state and local codes.
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjustment To adjust the parking brake, loosen the screw in the end Adjustment Knob of the lever and turn the knob to tighten or loosen ten- Magnetic sion on the brake cable.
ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ..................F - 1 TROUBLESHOOTING....................
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ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page F-ii...
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ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DIGITAL VOLT OHM METER TROUBLESHOOTING A typical digital volt ohm meter (DVOM) is shown (Ref. In order to effectively troubleshoot the circuits that Fig.
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ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Inline Fuse RED/ Passenger Side Driver Side Marker Headlight Headlight Marker Turn Turn DC - DC Converter BLU/WHT Horn + 12V...
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ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. POWER SUPPLY NOTICE Tool List Qty. The green wire supplies power to the entire fuse block. DVOM ................. 1 1.
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ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. that secures the front part of the light to the rear housing automotive type fuse. Headlight and taillight bulbs and (Ref.
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ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle For Models before 2 Oct 2013 Mounting Black Plate DC converter Harness Harness DC converter Washer Washer Screw...
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ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page F-6...
ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. PERFORMANCE ......................G - 1 Speed Control ......................... G - 1 Pedal-Up Features ........................
ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘G’ (CONT.) SECTION TITLE PAGE NO. Fig. 16 ITS Adjustment (Sheet 2 of 2) ..................G - 16 Fig.
ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERFORMANCE The pedal-up feature will slow the vehicle (the warning beeper will not sound) until either the vehicle speed is reduced to 8 mph (13 kph), at which it freely coasts NOTICE between 8 and 3 mph (5 kph), or the accelerator pedal...
ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. b) the brake is engaged so as to prevent vehicle NOTICE motion The controller will sense a stalled motor condition and 48 volt vehicles operate only in the ‘RUN’...
ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the operator attempts to override the electronic brak- Controller ing feature by moving the direction selector or key The controller is a solid state unit that activates a sole- switch to another position, the warning beeper will noid and controls the function of the vehicle by...
ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL TROUBLESHOOTING To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage. Tool List Qty.
ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. removing the BL- connection to the battery. Always use insulated wrenches when working on batteries. To check for continuity, set the DVOM to the KW setting Battery and select ‘Continuity’.
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the continuity test indicates that contacts are not TROUBLESHOOTING DIAGRAMS “welded” and the wiring to the solenoid coil is good, the The following diagrams will assist in servicing the vehi- coil has failed and the solenoid must be replaced.
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fault Fault Vehicle Operation Corrective Action Code Change - - - Direction selector fault Vehicle operates in •...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4 - 3 M- fault Vehicle will not run • Check M- wiring and repair; Replace controller 4 - 4 Auxiliary contact did not Vehicle will not run...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Ground To Hand Speed Input Held MAIN Sensor +15V Diagnostic RUN/ STORE SWITCH (20 A) Charger Interlock Throttle Switch (Optional) Pot High...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Charger Interlock Switch (Optional) Pot High Logic Enable Pot Low Fuse Sense Pot Wiper Logic Power Ground Main Contactor Brake Light Relay...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Ground SPARE Speed Input SPARE Sensor +15V SPARE All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAIN This test will verify secondary circuit voltage. Please reference the chart for probe connections. If not/ Then Probe Connection Voltage Positive probe on BL+ and...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INDUCTIVE THROTTLE SENSOR (ITS) Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the TESTING AND REPLACEMENT plastic pedal box studs.
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 7/32" drill bit to measure gap between plunger Micro switch...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2.7 ± 0.5 volts 1.0 ± 0.3 volts Fig. 16 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page G-16...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTROLLER REPLACEMENT SOLENOID REPLACEMENT Tool ListQty. Tool ListQty. Socket, 10mm ............. 1 Socket, 3/8" ..............1 Socket, 7/16"...
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ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Nm) and the 5/16" terminal nuts to 50 - 60 in. lbs (6 - 7 Nm) torque. Reconnect the BL- battery cable and replace the control- ler cover and seat.
FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. MAINTENANCE......................H - 2 Lubrication..........................H - 2 Wheel Bearing and King Pin Bushing Inspection ..............
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘H’ (CONT.) SECTION TITLE PAGE NO. Fig. 15 Bellows Replacement......................H - 12 Fig.
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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...
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE NOTICE Do not use more than three pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that In the following text, there are references to removing/installing bolts etc.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Bearing Packing Rotate the wheel 2 - 3 more turns to displace excess grease. If required, tighten castellated nut (3) again Tool List Qty.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lift the front of the vehicle and support on jack stands as per SAFETY section. Confirm the alignment of the front Remove Bolt springs.
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.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installation of shock absorber is reverse of disassembly. prevent pulling apart intermediate shaft. Mounting nuts should be tightened until rubber bushings Remove the three 1 3/4"...
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (19) securing driver side spring to axle and discard lock nuts (19). Hold nut (21) with wrench and loosen long bolt (20). Note location of washer (22) and thread long bolt out as far as possible to remove the washer, nut and spacer (23).
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. apply a light coating to the outer bearing race. Install outer wheel bearing (4) and secure hub loosely View from Underside of Vehicle with castellated nut.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. hub and dust cap (7) in solvent and dry thoroughly. Inspect for signs of damage. Pitting or a blue coloration of the rollers requires replacement of the bearing.
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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.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tie Rod Inspection/Replacement To install new rack ball joint close to its correct position, measure amount of threads exposed from jam nut (Ref. Tool List Qty.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. faced hammer to release tie rod from spindle arm. large end loose until rack extension-to-rack and pinion Remove nut to drop tie rod from spindle arm.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To access the pinion seal, remove rack and pinion unit from vehicle. “Rack and Pinion Unit Replacement” on page H-15 Anchor in vice by clamping on the mounting ears of the rack and pinion unit.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE The rack and pinion gears are not serviceable items. If they Front of Vehicle are found to be damaged or excessively worn, a new rack and pinion unit must be installed.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. seal lip prior to installing seal. “Pinion Seal Replace- from ball joint and ball joint from spindle arm. ment”...
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. wrench to thread shaft of rack extension (7) further into Steering Wheel Replacement rack ball joint. This will provide more travel for the steer- Tool List Qty.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Shaft and Column Replacement Loosen the steering wheel retaining nut (6) two to three turns (Ref.
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FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Slide wave washer (10) out bottom end of steering col- umn and keep for reuse. Remove small retaining ring (11) and press bearing from steering shaft.
MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL........................J - 1 Motor Removal ......................... J - 1 Motor Disassembly ........................
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MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page J-ii...
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MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Mark both the axle and motor housings to permit realignment during reassembly of motor to rear axle (Ref.
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MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Motor Components Bearing Replacement Push back each brush until its spring (15) is resting against the side of the brush (Ref. Fig. 3). This keeps Tool List Qty.
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MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove brush terminal hardware (12) at A1 and A2 (Ref. Fig. 3). When installing armature into the bearing/end cover Remove screws (13) securing brush plate (14).
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MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Motor Tests The motor housing is not available as an individual part. No testing is recommended to determine the specific area of failure.
REAR AXLE REAR AXLERead all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE ..................K - 1 Checking the Lubricant Level ....................K - 1 REAR AXLE DISASSEMBLY ..................K - 1 Axle Shaft Removal and Disassembly ...................
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REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page K-ii Repair and Service Manual...
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REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For further axle information, see Electric Rear Axle NOTICE Manual P/N 28148G01. Refer to REAR SUSPENSION section for axle removal. It is recommended that whenever a bearing, seal or ‘O’...
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REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Removal and Disassembly (Continued) Use care to prevent damage to the inner surface of the Attach a slide hammer to the axle shaft thread and axle tube at the sealing area.
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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.
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REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page K-4 Repair and Service Manual...
REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................L - 1 General............................. L - 1 Shock Absorber Removal......................
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REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page L-ii...
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REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of disassembly except that the shock absorber nuts (1,3) NOTICE must be tightened until the shock absorber bushings (4) expand to the diameter of the shock absorber washer...
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REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of the Vehicle Fig. 1 Rear Suspension Repair and Service Manual Page L-2...
WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD ....................M - 1 Trailering ..........................
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WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page M-ii...
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WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP AND WINDSHIELD Rear Support Installation Using a plastic faced hammer, tap end caps (5) into the top of the rear struts (3, 4) (Ref.
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WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Of Vehicle Rear of Vehicle (Driver Side Shown) Front Strut Front of Vehicle Fig. 1 Shuttle 8 Sun Top Repair and Service Manual Page M-2...
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WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPILT WINDSHIELD Insert bolt (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.
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WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FULL WINDSHIELD Insert screw (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.
WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ..................N - 1 Tire Repair..........................
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WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page N-ii...
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WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEEL AND TIRE SERVICE Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section Tools List Qty.
WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation With the valve stem to the outside, mount the wheel onto the hub with lug nuts (1). Finger tighten lug nuts (1) as shown.
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. ELECTRICAL SYSTEM....................P - 1 Basic Electrical Power System Troubleshooting ..............P - 2 Basic Electrical Troubleshooting for Accessories..............
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TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page P-ii...
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TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM For non-PDS vehicles, see Electronic Speed Control Section. For PDS vehicles, see Electronic Speed Control (PDS) Section. For PDS vehicles, also use Diagnostic Mode, PDS Fault Codes and Troubleshooting Diagrams.
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TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction BATTERIES WILL NOT CHARGE Vehicle/charger connector damaged Replace connector (Continued) Battery case damage Replace battery Low electrolyte level Maintain correct electrolyte level Battery capacity deficient...
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TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUSPENSION AND STEERING Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment (Incorrect toe in) Align front tires STIFF STEERING Bent rack...
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TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page P-4...
LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. Grounding Requirements ....................... Q - 1 Ground Systems ..........................
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LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page Q-ii...
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LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 1.
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LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 6.
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LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 from penetrating or structurally damaging the building.
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LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page Q-4...
GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. SHUTTLE 8........................R - 1 LIST OF ILLUSTRATIONS Fig.
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GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page R-ii...
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GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE™ 8 TYPE: ELECTRIC POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 626500 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Precision Drive System™...
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GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lowest Clearance at Differential 3.00 in. (7.6 cm) 123.5 in. (313.7 cm) 149.0 in. (3178.5 cm) 167.5 in. (425.5 cm) 46.0 in.
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GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING CLEARANCE DIAMETER 33 ft (10.1 m) RECOMMENDED MAX SIDE TILT 25% or 14° MAX RECOMMENDED MAX RAMP GRADE 25% or 14°...
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GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page R-4...
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NOTICE NOTICE Read the following warnings before attempting to operate the Read and understand the following text and warnings before vehicle: attempting to service vehicle: In any product, components will eventually fail to per- form properly as the result of normal use, age, wear or abuse.
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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...