Cushman HAULER PRO 2014 Service Manual
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Cushman HAULER PRO 2014 Service Manual

72v electric powered utility vehicle
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TECHNICIAN'S REPAIR AND SERVICE MANUAL
72V Electric Powered Utility Vehicle
634756
ISSUED MAY 2014

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Summary of Contents for Cushman HAULER PRO 2014

  • Page 1 TECHNICIAN’S REPAIR AND SERVICE MANUAL 72V Electric Powered Utility Vehicle 634756 ISSUED MAY 2014...
  • Page 2 SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills, vehicles may coast at faster speeds than those encountered on a flat surface. To prevent loss of vehicle control and pos- sible injury, speeds should be limited to no more than the maximum level ground speed indicated in GENERAL SPECIFICATIONS.
  • Page 3 REPAIR AND SERVICE MANUAL 72V ELECTRIC UTILITY VEHICLE HAULER PRO STARTING MODEL YEAR 2014 CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and brith defects or other reproductive harm. In addition, certain fluids con- tained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 4 GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless oth- erwise indicated. The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: General

    SAFETY INFORMATION SAFETY INFORMATION 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. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: GENERAL Many vehicles are used for a variety of tasks beyond their original intended use;...

  • Page 6: Maintenance

    SAFETY INFORMATION MAINTENANCE ALWAYS: • Replace damaged or missing warning, caution or information labels. • Maintain the vehicle in accordance with the manufacturer’s periodic service schedule. • Ensure that repairs are performed by trained and qualified persons. • Follow the manufacturer’s maintenance procedures. •...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION GENERAL ........................III GENERAL OPERATION....................III MAINTENANCE ....................... IV VENTILATION........................IV GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER LABEL LOCATION ................1 TRANSPORTING VEHICLE ..................... 1 Towing ........................1 Hauling ......................... 1 SERVICING THE ELECTRIC VEHICLE ................1 ROUTINE MAINTENANCE....................
  • Page 8 TABLE OF CONTENTS Center Compartment Replacement ..............13 Cowl Replacement ....................13 Brush Guard Replacement .................13 Rocker Panel Replacement ................14 Side Panel Replacement ..................14 Rear Fender Replacement ..................14 Rear Body Panel Replacement ................15 PAINTING ........................16 Minor Scratches ....................16 Larger Scratches ....................16 Complete Panel Repair ..................16 WHEELS AND TIRES WHEEL AND TIRE SERVICE..................
  • Page 9 TABLE OF CONTENTS Rack and Pinion Unit Disassembly and Inspection ..........32 Rack and Pinion Unit Replacement ..............33 Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance ..33 Steering Wheel Replacement ................34 Steering Shaft and Column Replacement ............35 ELECTRONIC SPEED CONTROL SPEED SENSOR......................
  • Page 10 TABLE OF CONTENTS Accessory Wiring ....................58 Faulty Wire Replacement ..................58 Headlight Replacement ..................58 Taillight Replacement ..................59 FAULT DIAGNOSIS......................60 General .......................60 Testing Battery Voltage ..................60 Continuity Check ....................60 Testing a Switch for Continuity ................61 Testing a Solenoid for Continuity ................61 BRAKES BRAKE SYSTEM OVERVIEW..................
  • Page 11 TABLE OF CONTENTS Brake Cable and Equalizer Assembly Removal and Installation ....... 82 Compensator Assembly, Removal and Installation ..........82 Brake Pedal Removal and Installation ............... 82 Park Brake Catch Bracket Removal and Installation ......... 83 Park Brake Pedal Removal and Installation ............83 Pedal Bumper Adjustment .................
  • Page 12 TABLE OF CONTENTS Rear Spring Removal ..................91 Rear Spring Installation ..................92 Rear Axle Assembly Removal ................92 Rear Axle Assembly Installation .................92 REAR AXLE REAR AXLE MAINTENANCE..................95 Checking the Lubricant Level ................95 REAR AXLE DISASSEMBLY ..................95 Axle Shaft Removal and Disassembly ..............95 Axle Shaft Seal Removal and Replacement ............96 Axle Shaft Replacement ..................97 WEATHER PROTECTION...
  • Page 13 TABLE OF CONTENTS VEHICLE DIMENSIONS ....................116 INCLINE AND TURNING CLEARANCE ............... 117 PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE ................119 APPENDIX A DELTA-Q USER’S GUIDE ....................A 634756 Repair and Service Manual...
  • Page 14 TABLE OF CONTENTS Notes: Repair and Service Manual 634756...

  • Page 15: General Information And Routine Maintenance

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER LABEL LOCATION SERVICING THE ELECTRIC VEHICLE Two serial number and manufacture date code labels are on the vehicle.

  • Page 16: Routine Maintenance

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE The only maintenance required for the first five years is INITIAL SERVICE CHART the periodic inspection of the lubricant level.

  • Page 17: Vehicle Cleaning And Care

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Multi-Purpose Hand Cleaner (P/N 607636) • VEHICLE CLEANING AND CARE An industrial strength cleaner containing no harsh solvents, yet gently lifts grease off hands.

  • Page 18: Hardware

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Periodically, the vehicle should be inspected for loose fas- HARDWARE teners. Fasteners should be tightened with care and in Generally, three classes of standard hardware and three accordance with the Torque Specifications table or as classes of metric hardware are used in the vehicle.

  • Page 19: Safety

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

  • Page 20: Before Servicing The Vehicle

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BEFORE SERVICING THE VEHICLE smoking materials, open flame or sparks away from the batteries. Before attempting to inspect or service a vehicle, be sure to read and understand the following warnings: Hydrogen gas is generated in the charging cycle of batteries and is explosive in...

  • Page 21: Battery Removal And Installation

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. to the battery racks or surrounding area should not be Aerosol containers of battery terminal protec- present. If any corrosion is found, remove with a putty tant must be used with extreme care.

  • Page 22: Lifting The Vehicle

    SAFETY Read all of SAFETY 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 FloorJack ..............1 Jack Stands ..............4 Chocks................. 4 Some servicing operations may require the vehicle to be raised.
  • Page 23 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 634756 Repair and Service Manual...
  • Page 24 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 25: Body

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Drill out rivet Pop Rivet head only In the following text, there are references to removing/ installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in origi- nal positions unless otherwise specified.

  • Page 26: Instrument Panel Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 4 Front Body Components Instrument Panel Replacement Tool List Qty. Drill ................1 Drill Bit, #10 ..............1 To prevent personal injury, disconnect nega- Pry Bar.................

  • Page 27: Center Compartment Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Drill out seven rivets (6) across top of instrument panel (1) Center Compartment Replacement that secure the instrument panel to the cowl (11) (Ref. Tool List Qty.

  • Page 28: Rocker Panel Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove four bolts (25), washers (26), and nuts (27) Rocker Panel Replacement securing side panel (21) to rear fender (28) (Ref. Fig. 7) Tool List Qty.

  • Page 29: Rear Body Panel Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove two rivets (43) securing rear fender (41) to the Rear Body Panel Replacement rear body panel (47). Tool List Qty.

  • Page 30: Painting

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING Larger Scratches For larger scratches, the manufacturer suggests the fol- Follow the paint manufacturer’s recommendations for lowing steps be taken to repair the Durashield™ body: specific painting procedures and information.

  • Page 31: Wheels And Tires

    WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEELS AND TIRES WHEEL AND TIRE SERVICE Use caution when inflating tires. Due to the low volume of Tools List Qty.

  • Page 32: Wheel Installation

    WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation To prevent injury, be sure mount- ing/demounting machine is Do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.

  • Page 33: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION AND STEERING Part of Frame Intermediate Shaft with U-Joints Wave Washer Bearing Outer Snap Ring Rack and Pinion Inner Snap Ring Thrust Washer...

  • Page 34: Maintenance

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE Do not use more than three (3) pumps of grease in InIn the following text, there are references to removing/ any grease fitting at any one time.

  • Page 35: Wheel Bearing Adjustment

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To pack a bearing manually, place a dab of grease in loosen the castellated nut to align with the closest avail- palm of hand and dip bearing in grease.
  • Page 36 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. front and rear of the tires (Ref. Fig. 5). The measurement taken at the front of the tires should be 0" - 1/8" (0 - 3 mm) less than the rear.

  • Page 37: Front Suspension

    FRONT SUSPENSION AND STEERING Read all of SAFETY 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. 7 Front Suspension Components 634756 Repair and Service Manual...

  • Page 38: Front Shock Absorber Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Shock Absorber Replacement pinion unit to the steering column from pulling apart due to the weight of the steering system. Tool List Qty.

  • Page 39: Front Spring Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Spring Replacement Tool List Qty. Jack Stands ..............4 Ratchet ................1 Socket, 3/4" ..............1 Socket, 5/8" ..............1 Wrench, 5/8"...

  • Page 40: Hub Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driver side spring installation is the reverse order of dis- Replace upper portion of floor mat in plastic trim retainers. assembly making sure to install the long bolt (20), spring Install front wheels per WHEELS AND TIRES section and plate (24), spacer (23), nut (21) and washer (22) in their...

  • Page 41: Wheel Bearing And Race Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A - Install this side of seal Front of Vehicle into housing B - Lubricate lip of seal Fig.

  • Page 42: Steering

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STEERING Front of Vehicle Flat Section Fig. 14 Steering Components section (Ref. Fig. 14). Rack Ball Joint Replacement Remove passenger side front wheel and turn steering Tool List Qty.

  • Page 43: Tie Rod Inspection/Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wrench, 11/16" ............1 Ball Joint Separator .............1 Plastic Faced Hammer ..........1 Socket, 11/16"..............1 Torque Wrench, ft. lbs..........1 Crowfoot Socket, 3/4"...

  • Page 44: Bellows Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To install ball joint, thread on new jam nut and then, using measurement made earlier, screw ball joint to pre- vious location in threaded tube.

  • Page 45: Spindle Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Spindle Replacement Tool List Qty. Needle Nose Pliers ............1 Wrench, 11/16" ............1 To avoid damage to the aluminum rack and pinion unit, secure unit in vice by the mounting ears only.

  • Page 46: Rack And Pinion Unit Disassembly And Inspection

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle The rack and pinion gears are not serviceable items. If they are found to be damaged or excessively worn, a new rack and pinion unit must be installed.

  • Page 47: Rack And Pinion Unit Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. grease specified in tool list. Remove the three lock nuts (18) securing rack and pinion unit to front axle and discard nuts. Remove rack and pin- Assemble rack and pinion unit by installing pinion in ion unit from vehicle.

  • Page 48: Steering Wheel Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle To maintain correct orientation when replacing steering wheel, turn wheels straight ahead. To prevent damage to the clipboard, perform the fol- lowing removal procedure.

  • Page 49: Steering Shaft And Column Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not strike steering nut or end of steering shaft directly with ball peen hammer. Internal damage to rack and pinion unit can result.
  • Page 50 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Install with arch Small up as shown Retaining Ring Steering Shaft Bearing Groove Fig. 27 Small Retaining Ring Orientation Repair and Service Manual 634756...
  • Page 51 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 634756 Repair and Service Manual...
  • Page 52 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 53: Electronic Speed Control

    ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRONIC SPEED CONTROL The main wire harness, throttle position sensor, and SPEED SENSOR speed sensor are connected to the controller through a The speed sensor uses a sealed sensor to sense teeth of 35-pin plug.

  • Page 54: Solenoid Replacement

    ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove bolt (22), u-nut (23) and hex nut (21) and remove SOLENOID REPLACEMENT the controller cover (12) to access the controller (13) (Ref. Tool List Qty.
  • Page 55 ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 634756 Repair and Service Manual...
  • Page 56 ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 57: Motor

    MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MOTOR Use an insulated wrench to disconnect the negative (-) GENERAL battery cable from the battery (Ref. Fig. 1). Mark both the axle and motor housings to assist with realignment during reassembly of motor to rear axle (Ref.

  • Page 58: Motor Tests

    MOTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Motor Tests Item Torque Specification The armature and motor housing are not available as 5, 9 72 - 78 in. lbs. (8 - 9 Nm) individual parts.

  • Page 59: Batteries And Charging

    BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERIES AND CHARGING SAFETY Any electrolyte spills should be neutralized with a solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1-1/2 gallons (6 liters) of water, and flushed with water.

  • Page 60: Battery Maintenance

    BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY MAINTENANCE Tool List Qty. Insulated Wrench, 9/16" ..........1 Battery Carrier ............. 1 Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage.

  • Page 61: Cleaning Batteries

    BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use of a water hose without first neutralizing any acid, will move acid from the top of the batteries to another area of the vehicle or storage facility where it will attack the metal structure or the concrete/asphalt floor.

  • Page 62: Battery Replacement

    BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Replacement Before any electrical service is performed, the Run- Tow/Maintenance switch must be placed in the ‘Tow/ Maintenance’...

  • Page 63: Battery Charging

    BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The batteries must be cleaned and all deposits neutral- • The charging connector components must be in ized and removed from the battery case to prevent self good condition and free from dirt or debris.

  • Page 64: Hydrometer

    BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. can be done to salvage the battery; however, the individ- that the electrolyte weighs 1.280 times the weight of the ual battery should be replaced with a good battery of the same volume of water.
  • Page 65 BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. test. If results indicate a weak cell, the battery or batteries should be removed and replaced with a good battery of the same brand, type and approximate age.
  • Page 66 BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 67: Electrical System

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM CONTROLLER RUN/TOW Mate these connectors for off board charger vehicles or connect to on board charger harness RED/BLU RED/BLU if vehicle has an on board charger.

  • Page 68: Electrical System

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECEPTACLE OFF BOARD BATT 1 BATT 2 BATT 3 BATT 4 BATT 5 BATT 6 BATT 7 BATT 8 BATT 9 CHARGER RECEPTACLE...

  • Page 69: Electrical System

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY TEMP SENSOR BLU SWITCH ENABLE WHT 12V SWITCHED CHARGER 8-PIN PLUG RED 12V UNSWITCHED BLK GROUND RECEPTICAL LED RED/BLU DC/DC 2-PIN PLUG CHARGER 2-PIN PLUG...

  • Page 70: Awg To Metric Conversions

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery voltage can be checked using a voltmeter. Attach AWG TO METRIC CONVERSIONS the negative (-) lead of the DVOM to the ground terminal of the battery.
  • Page 71 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Negative Cable (-) Front of Vehicle Fig. 4 72V Battery Set Connections Use of incorrect fuse rating can damage electrical Due to the resistance of the wires involved within the components.

  • Page 72: Accessory Wiring

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accessory Wiring After determining that there is power to the fuse panel, and the fuse is good, continue checking the circuit using the procedures previously used to check the power sup- Following procedure is applicable for vehicles with LED ply, i.e.

  • Page 73: Taillight Replacement

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 6 Headlights Taillight Replacement To replace the taillight bulb or the brake light bulb, roll the rubber bezel from around the edge of the taillight and remove lens (Ref.

  • Page 74: Fault Diagnosis

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT DIAGNOSIS Testing Battery Voltage It is important to determine the condition of the battery set General before proceeding with any electrical fault diagnosing. An open voltage test is of little use since a battery that has In order to effectively fault diagnose the circuits that deteriorated to the point of needing replacement can still...

  • Page 75: Testing A Switch For Continuity

    ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Testing a Switch for Continuity Testing a Solenoid for Continuity Place one probe on one contact of the switch. Place the Place one probe on one of the large terminals and the second probe on the second terminal of the switch (Ref.
  • Page 76 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...
  • Page 77 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 634756 Repair and Service Manual...
  • Page 78 ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 634756...

  • Page 79: Brake System Overview

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

  • Page 80: Equalizer Link

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cables. Each brake cable pulls a brake lever which pushes the rear brake shoe against the brake drum. When the rear shoe contacts the brake drum, it can no longer move rearward.

  • Page 81: Fault Diagnosis Flowchart

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT DIAGNOSIS FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Condition of: Replace Includes...
  • Page 82 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjuster Tries Disassemble Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure. Replace Free Movement of Torque Lug Nuts.

  • Page 83: Fault Diagnosis Table

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Test (PBPT), and Aggressive Stop Test is performed (Ref. FAULT DIAGNOSIS TABLE Fig. 6). Refer to the following fault diagnosis table only after the thorough visual inspection, Periodic Brake Performance Condition Possible Cause...

  • Page 84: Fault Diagnosis And Inspection

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Wheel not locking is not adjusting Check brake operation of wheel that is Unequal braking (one wheel locks not locking while other rotates) Sticky/dragging cable...

  • Page 85: Brake Pedal And Linkage Inspection

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Pedal and Linkage Inspection Check the brake pedal free travel. Brake pedal free travel refers to the distance the Inspect brake pedal return bumper.
  • Page 86 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjust brake pedal free travel as described “MAINTE- Not to NANCE AND REPAIRS” on page 76 if required. exceed Inspect the brake cables.

  • Page 87: Periodic Brake Performance Test (Pbpt)

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 10. Inspect catch bracket and latch arm. acceptable stopping distance (see below). Actual stop- Replace if showing signs of wear or damage (Ref. ping distances will be influenced by weather conditions, Fig.

  • Page 88: Aggressive Stop Test

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. force and travel to the service brake pedal while moving. Do not latch the park brake. Do this a total of 10 times with the first few at slow speed. If brake function is adequate or improves, increase speed A subtle loss of performance may take place over time;...
  • Page 89 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. star wheel, it has been damaged and both wheel brake assemblies must be replaced. • If the adjuster arm engages the star wheel but fails to rotate it, the adjuster assemblies must be replaced with new color-coded adjusters.

  • Page 90: Maintenance And Repairs

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 10. Inspect the brake shoe springs. Ensure springs are not broken or damaged and are NOTE: correctly installed. The springs must be inserted Top pull brake drum shown;...

  • Page 91: Adjusting Brake Pedal Free Travel

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjusting Brake Pedal Free Travel All brake tests must be done in a safe location with regard for the safety of all personnel. Brake pedal free travel must be checked and adjusted any time the brake system is serviced, or In a safe location, free from people and vehicles, drive the...

  • Page 92: Brake Drum Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use care when raising the adjuster arm. Excessive force will damage the adjuster and necessitate both wheel brake assemblies be replaced. If the drum does not slide from the brake assembly, the brake shoes must be retracted.

  • Page 93: Backing Plate/Entire Wheel Brake Assembly Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the brake drum as described in “Brake Drum and Installation” on page 78 Removal and Installation” on page 78. Repeat on other side of vehicle.

  • Page 94: Brake Shoe Removal

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove clevis pin securing brake cable to brake lever. Inspect brake shoes. If a brake shoe has less than 0.40 lining material thickness AT ANY POINT on either shoe Installation is reverse of removal.

  • Page 95: Brake Shoe Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Shoe Installation The leading brake shoe (marked “17L”) is angled to a nar- row end and engages the backside of the adjuster.(Ref. Fig.

  • Page 96: Brake Cable And Equalizer Assembly Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Cable and Equalizer Assembly Brake Pedal Removal and Installation Removal and Installation Disconnect the compensator assembly (1) from the brake pedal by removing the cotter pin (2) and the clevis pin (3) (Ref.

  • Page 97: Park Brake Catch Bracket Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Connect brake light wiring harness, if equipped. Park Brake Pedal Removal and Installation Adjust the brake pedal free travel. See “Adjusting Brake Note the location and orientation of the two torsion Pedal Free Travel”...

  • Page 98: Park Brake Release Linkage Removal And Replacement

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Park Brake Release Linkage Removal and Park Brake Kick-Off Cam Removal, Replace- Replacement ment and Installation Remove the cotter pin (2), washers (3) and bushings (4) Disconnect the park brake release linkage as described from linkage rod (1).

  • Page 99: Optional Front Hydraulic Brakes

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. OPTIONAL FRONT HYDRAULIC BRAKES Front hydraulic brakes are optional, therefore may not be Remove Master Cylinder present on all vehicles. Remove bolts (1) securing the brake actuator assembly housing cover (2) and remove cover (Ref.

  • Page 100: Brake Master Cylinder Fluid

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE MASTER CYLINDER FLUID Never work on a vehicle supported by a jack Hydraulic brake systems must be totally flushed if the alone.

  • Page 101: Rotor Replacement

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The upper actuator pivot also is fitted with a nylon bush- Rotor Replacement ing between it and the brake cylinder clevis. To replace any of these bushings, the actuator linkage must be removed from the lower actuator pivot and the linkage rod.

  • Page 102: Brake Bleeding Procedure

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. pose of used fluid in accordance with Federal, state and local codes. Brake Bleeding Procedure The bleeder valve at the caliper must be closed at the Attach a short length of clear hose to the caliper bleed end of each stroke and before the brake pedal is valve and insert the other end into a suitable clean con-...

  • Page 103: Battery Charger

    BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY CHARGER rials and place in an area that permits maximum air flow CHARGER DESCRIPTION around and underneath the charger. For optimum perfor- The Delta Q charger supplied with this vehicle is an auto- mance and shortest charge times, place the charger in matic charger that is designed specifically for charging...
  • Page 104 BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 105: Rear Suspension

    REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Remove the bottom shock absorber nut (1) (Ref. Fig. 3). REAR SUSPENSION Compress the shock absorber (2) and remove the top shock absorber nut (3).

  • Page 106: Rear Spring Installation

    REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Spring Installation Front of Vehicle Reverse removal process to install new spring. Negative (-) Tighten shock absorber nuts (1, 3) until the shock absorber bushings (4) expand to the diameter of the shock absorber washer (5).
  • Page 107 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten the battery post hardware to 90 - 110 in. lbs. (10 - Place the Run-Tow/Maintenance switch in the ‘Tow/Main- 12 Nm).
  • Page 108 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 109: Rear Axle

    REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE For further axle information, see Electric Rear Axle Man- and understand all of the following text and illustra- ual P/N 28148-G01.

  • Page 110: Axle Shaft Seal Removal And Replacement

    REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bearing Separator Fig. 4 Pressing Bearing from Axle Shaft Fig. 2 Removing/Installing Outer Snap Ring Axle Shaft Seal Removal and Replacement Attach a slide hammer to the axle shaft thread and Tools List Qty.

  • Page 111: Axle Shaft Replacement

    REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Replacement Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with the dif- ferential side gears.
  • Page 112 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten the castellated axle nut to 70 ft. lbs. (95 Nm) torque minimum, 140 ft. lbs. (190 Nm) torque maximum. Continue to tighten until the slot in the nut aligns with the cotter pin hole.
  • Page 113 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 634756 Repair and Service Manual...
  • Page 114 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 115: Weather Protection

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WEATHER PROTECTION Straight Blade Screwdriver...........1 SUN TOP AND WINDSHIELD Rear Support Installation At driver side of vehicle, align the holes in the rear strut (5) with the holes in the seat back support bracket, being sure that the open end of the strut faces the front of the The sun top does not provide protection from...
  • Page 116 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Seat Back Support Bumper Front of Vehicle Front of Seat Vehicle Fig. 1 Sun Top Repair and Service Manual 634756...

  • Page 117: Split Windshield

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Insert bolt (4) through washer (5), rubber grommet (6) SPLIT WINDSHIELD and existing hole in front strut. Secure with washer (5) Tool List Qty.

  • Page 118: Full Windshield

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Insert screw (4) through washer (5), rubber grommet (6) FULL WINDSHIELD and existing hole in front strut. Secure with washer (5) Tool List Qty.

  • Page 119: Handheld Diagnostics

    HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HANDHELD DIAGNOSTICS HOW TO USE THE HANDHELD PRO- GRAMMER The Curtis handheld programmer is used for program- The handheld programmer will not function when the ming, testing, troubleshooting, tuning, diagnosing and Run-Tow switch is in the Tow position.

  • Page 120: Navigation

    HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Navigation Main Menu Definitions A blinking square on the left indicates the position of the cursor. Indicates vehicle profile setting and PROGRAM The blinking square will move adjustability.
  • Page 121 HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value Profile Selection 1 - 5 Freedom Enable ON/OFF Speed 4 - 8...
  • Page 122 HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value Main Welded 0 - 255 Speed Sensor Fault 0 - 255 Main Driver On 0 - 255...
  • Page 123 HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value LCD Contrast -150 - 150 Program Language English English...
  • Page 124 HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 125: Troubleshooting

    TROUBLESHOOTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING ELECTRICAL SYSTEM Condition Possible Cause Correction VEHICLE WILL NOT MOVE See ELECTRONIC SPEED CONTROL section. VEHICLE SPEED ERRATIC Faulty ESC system Test and replace components as indicated by test procedure...

  • Page 126: Suspension And Steering

    TROUBLESHOOTING Read all of SAFETY 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 Water has entered steering box and may...
  • Page 127 TROUBLESHOOTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 634756 Repair and Service Manual...
  • Page 128 TROUBLESHOOTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 129: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS MODEL: HAULER PRO TYPE: ELECTRIC 72V POWERED TRUCK MODEL YEAR: 2014 Part No:. 634182 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Solid State continuously variable AC speed controller Full torque, reduced speed reverse...

  • Page 130: Vehicle Dimensions

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE DIMENSIONS 10.5 in (27.0 cm) 44.5 in (113.0 cm) (Front) 75.3 in (191.3 cm) 37.0 in (94.0 cm) 111.0 in (281.0 cm) (Rear) 38.8 in (98.6 cm)

  • Page 131: Incline And Turning Clearance

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INCLINE AND TURNING CLEARANCE RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIA.

  • Page 132: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 133: Periodic Service Schedule

    PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE C - CHECK C/A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires and rims...
  • Page 134 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 634756...

  • Page 135: Delta-Q User's Guide

    APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. APPENDIX A DELTA-Q USER’S GUIDE Repair and Service Manual...
  • Page 136 APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 8VHU·V *XLGH SAVE THESE IMPORTANT INFORMATIONS IMPORTANTES DE SÉCURITÉ SAFETY INSTRUCTIONS Ce manuel contient des instructions importantes This manual contains important safety and operating concernant la sécurité...
  • Page 137 APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4. Optional Charger Single-LED Display (internal or external) LED Colour Indication (following “Power-On Self Test”) Green Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short: <80% Charge.
  • Page 138 APPENDIX A Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual...

  • Page 139: General Specifications

    Read the following warnings before operating vehicle: Read the following information and warnings before operating vehicle: In any product, components will eventually fail to perform prop- erly as the result of normal use, age, wear or abuse. It is virtually impossible to anticipate all possible component failures or the manner in which they may fail.
  • Page 140 E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Road, Augusta, Georgia 30906-3852 USA CONTACT US: North America: Phone: 1-800-774-3946, FAX: 1-800-448-8124 Technical Assistance & Warranty Phone: 1-888-GETEZGO (1-888-438-3946), FAX: 1-800-752-6175 Service Parts International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts &...

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