E-Z-GO ST SHUTTLE 4/6 2009 Technician's Repair And Service Manual
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E-Z-GO ST SHUTTLE 4/6 2009 Technician's Repair And Service Manual

E-Z-GO ST SHUTTLE 4/6 2009 Technician's Repair And Service Manual

Electric powered personnel carriers and golf car
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612342
TECHNICIAN'S
REPAIR AND SERVICE MANUAL
ELECTRIC POWERED PERSONNEL
CARRIERS AND GOLF CAR
ISSUED APRIL 2009 REVISED JULY 2011

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Summary of Contents for E-Z-GO ST SHUTTLE 4/6 2009

  • Page 1 612342 TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR ISSUED APRIL 2009 REVISED JULY 2011...

  • Page 2: Safety

    SA FE TY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 E-Z-GO Division of TEXTRON Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

  • Page 4: General Information

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

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE SAFETY ........................Inside Covers MODELS ............................i GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C WHEELS AND TIRES ........................D FRONT SUSPENSION ........................E ELECTRONIC SPEED CONTROL ....................F MOTOR ............................
  • Page 6 TABLE OF CONTENTS Notes: Page iv Repair and Service Manualal...

  • Page 7: Safety Information

    E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation.
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page viii Repair and Service Manual...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION ................. A - 1 TRANSPORTING VEHICLE ..................A - 1 TOWING ......................A - 1 HAULING ......................A - 1 SERVICING THE ELECTRIC VEHICLE..............A - 1 ROUTINE MAINTENANCE ..................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page A-ii Repair and Service Manual...

  • Page 13: General Information & Routine Maintenance

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

  • Page 14: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REAR AXLE ITEM SERVICE OPERATION The only maintenance required for the first five years is Charge batteries Batteries the periodic inspection of the lubricant level.

  • Page 15: Vehicle Care Products

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

  • Page 16: Hardware

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

  • Page 17: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. PERIODIC SERVICE SCHEDULE Check Clean, Adjust, etc. Replace NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY BEFORE USE: Check service brake general operation...

  • Page 18: Fig. 4 Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Check for bent/binding linkage rod Check for damage or wear to latch arm or catch bracket PARK BRAKE Lubricate as required, use light oil.
  • Page 19 SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. GENERALANSI / NGCMA Z130.1-1993, Part II ............B - 1 GENERAL (ASME / ANSI B56.8 - 1988) ..............B - 4 NOTES, CAUTIONS AND WARNINGS ..............B - 9 IMPORTANT SAFETY WARNING ................
  • Page 20 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page B-ii Repair and Service Manual...
  • Page 21 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. GENERAL 5.2.1. Steep Grade The following text is provided as recommended by part II In areas where steep grades exist, golf car operations of ANSI / NGCMA Z130.1 - 1993.

  • Page 22: Safety

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. MAINTENANCE ceiling in pockets, a minimum of 5 air changes per hour is recommended. The controlling party shall consult applica- Introduction ble fire and safety codes for the specific ventilation levels required as well as the use of explosion proof electrical...
  • Page 23 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 6.2.5.7. Brakes, steering mechanisms, warning devices, The controlling party shall supervise the governors and all other safety devices shall be inspected storage and handling of liquid fuels in accor- and maintained in a safe and proper operating condition dance with applicable fire and safety require-...
  • Page 24 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. GENERAL Where authorized modifications have been made, the user shall ensure that capacity, operation, warning, and The following text is provided as recommended by part II maintenance instruction plates, tags, or decals are of ASME/ANSI B56.8-1988.
  • Page 25 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. shall be maintained within limits specified in the American (a) instructional material provided by the manufacturer; Conference of Governmental Industrial Hygienists publi- (b) emphasis on safety of passengers, material loads, cation, “Threshold Limit Values for Chemical Substances carrier operator, and other employees;...
  • Page 26 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 8.1.125.4.5Maintain a safe distance from the edge of caution on grades, ramps, or inclines; normally travel ramps and platforms. straight up and down.
  • Page 27 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Operator Care of Personnel and Burden Carriers Maintenance Procedures 8.1.345.7.1At the beginning of each shift during which 8.3.16.2.1Maintenance and inspection of all carriers shall the carrier will be used, the operator shall check the be performed in conformance with the manufacturer’s carrier condition and inspect the tires, warning...
  • Page 28 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. prevent the use of the carrier until the leak has been elim- inated. (o) The carrier manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals shall be maintained in legible condition.

  • Page 29: Notes, Cautions And Warnings

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

  • Page 30: Additional Warnings

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. powertrain. ventilation. Five air exchanges per hour is considered the minimum requirement. Use care not to contact hot objects. Be sure that the key switch is off and all Any servicing requiring adjustments to be electrical accessories are turned off before...

  • Page 31: Battery Removal & Installation

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. could result in an explosion. be present. If any corrosion is found, it should be imme- diately removed with a putty knife and wire brush. The area should be washed with a solution of sodium bicar- bonate (baking soda) and water and thoroughly dried Overfilling batteries may result in electrolyte being...

  • Page 32: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. LIFTING THE VEHICLE Tool List Qty. Required Floor jack ..............1 Jack stands..............4 When lifting the vehicle, position jack stands only in the Chocks.................
  • Page 33 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Repair and Service Manual Page B-13...
  • Page 34 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page B-14 Repair and Service Manual...

  • Page 35: Body

    BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY ........................C - 1 General ......................C - 1 BODY COMPONENT REPLACEMENT ..............C - 1 Instrument Panel Replacement ................ C - 5 Cowl Replacement ................... C - 5 Front Shield Replacement................
  • Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page C-ii Repair and Service Manual...

  • Page 37: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Dangers and Warnings BODY that the rivet head be removed in order to push out the shank of the rivet. The rivet head is easily removed by drilling into the head with a sharp drill bit that is slightly NOTICE larger than the shank of the rivet (Ref.
  • Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Frame Fig. 2 Body Components (Front) Page C-2 Repair and Service Manual...
  • Page 39 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. SHUTTLE 4 MODEL ONLY 54 53 Fig. 3 Body Components (Seats and Rear) Page C-3 Repair and Service Manual...
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Seat Back Support or Seat Bed Frame Fig. 4 Body Components (Cargo Box, Seat, Foot Rest) Page C-4 Repair and Service Manual...

  • Page 41: Instrument Panel Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Instrument Panel Replacement Duct tape ..............1 Allen key, 3/16" ............1 Tool List Drill out the rivets (6) across the top of instrument panel Electric/air drill .............

  • Page 42: Rear Body Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Rear Body Replacement Remove the rocker panel sill plates (28) by removing the hardware (29) securing them to the frame (Ref. Fig. 3). As Tool List the sill plate is removed, be sure to locate the three spac- Electric/air drill ............1...

  • Page 43: Foot Rest Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Remove the rear rocker panel ends as described above. Remove the rear seat from the rear body (32) (Ref. Fig. NOTICE Remove the hardware (35) attaching rear option (cargo To avoid damage to the plastic body component, remove or...

  • Page 44: Front Seat Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. To replace the short bumper, place the rear bumper against the rear chassis and install new rivets on each end of bumper.

  • Page 45: Minor Scratches

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Adjust as necessary by moving tab to the front or back to quate coverage and finish. Always remember to shake allow full engagement of latch assembly on tab.
  • Page 46 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page C-10 Repair and Service Manual...

  • Page 47: Wheels And Tires

    WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ................... D - 1 Tire Repair ....................... D - 1 Wheel Installation..................... D - 1 LIST OF ILLUSTRATIONS Fig. 1 Wheels and Tires..................D - 2 Page D-i Repair and Service Manual...
  • Page 48 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page D-ii Repair and Service Manual...
  • Page 49 Wear OSHA approved safety equipment Do not use Low Inflation Pressure tires on any when mounting/demounting tires. E-Z-GO vehicle. Do not use any tire which has a recommended Inflation Pressure less than Follow all instructions and safety warnings provided by the Inflation Pressure recommended in Own- the mounting/demounting machine manufacturer.
  • Page 50 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. (Ref Fig. 1 on page 2). Then, tighten lug nuts to 50 - 85 NOTICE ft.
  • Page 51 FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE ......................E - 2 Lubrication ....................... E - 2 Wheel Bearing and King Pin Bushing Inspection ..........E - 2 Wheel Bearing Packing ..................E - 2 Wheel Bearing Adjustment................
  • Page 52 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page E-ii Repair and Service Manual...
  • Page 53 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Wave Washer Bearing Outer Snap Ring Inner Snap Ring Front of Vehicle Intermediate Rack & Pinion Shaft with Unit U-Joints...

  • Page 54: Maintenance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. MAINTENANCE NOTICE Front of Vehicle In the following text, there are references to removing/installing bolts etc.

  • Page 55: Wheel Bearing Adjustment

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Clean all bearings, grease seal, hub and dust cap in sol- vent and dry thoroughly. Inspect for signs of damage. Pitting or a blue coloration of the rollers will require replacement of the bearing.
  • Page 56 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. position, roll it forward approximately five feet in order to allow the tires to take their normal running position. Remove Bolt Measure the distance between the chalk lines at both the front and rear of the tires (Ref Fig.

  • Page 57: Front Suspension

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. FRONT SUSPENSION Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.

  • Page 58: Front Axle Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Front Axle Replacement ing axle to springs and discard lock nuts. At the 3 1/2" long bolt (20) securing front of left spring, remove nut Tool List Qty.

  • Page 59: Front Spring Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. spring plate (24) from axle and spring. Retain above items (20 - 24) for assembly at their original locations. Pull upper driver side of floor mat out of plastic trim retainer and away from floor.

  • Page 60: Hub Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. View from Underside of Vehicle Equal Distance Fig. 9 Hub Replacement Fig. 8 Front Axle Alignment Check front wheel alignment and adjust if necessary.
  • Page 61 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fig. 11 Wheel Bearing Replacement Inspect for signs of damage. Pitting or a blue coloration of the rollers requires replacement of the bearing.

  • Page 62: Steering

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. STEERING Front of Vehicle Part of Frame 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...

  • Page 63: Tie Rod Inspection/Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. To install new rack ball joint close to its correct position, Tie Rod Inspection/Replacement measure amount of threads exposed from jam nut (Ref Tool List Qty.

  • Page 64: Bellows Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Remove lock nut (10) until tie rod ball joint (6) threads are protected. Using a ball joint separator as a lever, apply pressure to ball joint and tap nut with plastic faced hammer to release tie rod from spindle arm.

  • Page 65: Spindle Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. To access the pinion seal, remove rack and pinion unit from vehicle. “Rack and Pinion Unit Replacement” on page E-15 Anchor in vice by clamping on the mounting The spindle bearings are designed to be used "dry".

  • Page 66: Rack And Pinion Unit Disassembly And Inspection

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Secure rack and pinion unit in vice by the mounting Front of Vehicle ears only. The rack and pinion unit is made of alumi- num and can be damaged if held otherwise.

  • Page 67: Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Assemble rack and pinion unit by first installing pinion in tap nut with plastic faced hammer to release ball joint reverse order of removal making sure to lubricate pinion from passenger side spindle arm.

  • Page 68: Steering Wheel Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Steering Wheel Replacement adjustment is made at the rack ball joint (6) (Ref Fig. 19).

  • Page 69: Steering Shaft And Column Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Loosen front wheels. Lift and support front of vehicle per SAFETY section and remove front wheels. Remove the bolt (1) and washer (2) that secures the intermediate shaft (3) to the steering shaft (4).
  • Page 70 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Install with arch Small up as shown Retaining Ring Steering Shaft Bearing Groove Fig. 25 Small Retaining Ring Orientation Tighten bolt (1) securing intermediate shaft to steering shaft to 156 - 216 in.

  • Page 71: Electronic Speed Control

    ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. OPERATION ......................F - 2 Pedal Box......................F - 3 Speed Sensor ....................F - 3 Controller ......................F - 3 GENERAL TROUBLESHOOTING................F - 3 Symptoms ......................F - 4 Testing ......................
  • Page 72 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Dangers and Warnings. Notes: Page F-ii Repair and Service Manual...
  • Page 73 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. PERFORMANCE b) the accelerator pedal is released for more than one second NOTICE the pedal-up feature will slow the vehicle (the warning beeper will not sound) until either the vehicle speed is The vehicle will operate only when the Run - Tow/Maintenance switch is in the ’RUN’...

  • Page 74: Operation

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

  • Page 75: Pedal Box

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Controller If the operator attempts to override the electronic brak- 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 respond-...

  • Page 76: Testing

    A typical DVOM is shown in illustrations. A recom- tors may be indicated by readings that could be up to mended DVOM is available through the E-Z-GO Service one volt less than the reference voltage. No reading indi- Parts Department as P/N 27481-G01. Any DVOM may cates an “open”...

  • Page 77: Testing A Switch For Continuity

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Battery Reference Voltage Positive Negative Probe Press to Probe to B+ activate to B- switch Front of Vehicle Fig.

  • Page 78: Troubleshooting Diagrams

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TROUBLESHOOTING DIAGRAMS The following diagrams will assist in servicing the vehi- cle. By utilizing the Fault Codes, considerable time will be saved in determining the probable vehicle operating malfunction.
  • Page 79 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fault Fault Vehicle Operation Corrective Action Code Change - - - Direction Selector Fault Vehicle Operates in •...
  • Page 80 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 4 - 3 M- fault Vehicle will not run • Check M- wiring and repair; Replace controller 4 - 4 Auxiliary contact did not Vehicle will not run...
  • Page 81 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 48 Volt Battery Pack Pedal Box Charging Connector Reed To Hand Solenoid Switch Motor Held Motor Diagnostic Speed...
  • Page 82 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Pedal Box Charging Connector Reed Solenoid Switch WHT/YEL Switch ORN/RED SPARE WHT/BLK RED/YEL SPARE Performance RED/WHT Plug SPARE...
  • Page 83 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 84 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Motor Speed Sensor SPARE SPARE SPARE All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 85 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 48 Volt Battery Pack Charging Connector 1264 Controller Motor Solenoid This test will verify secondary circuit voltage. Please reference the chart for probe connections. If not/ Then Probe Connection Voltage...
  • Page 86 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. INDUCTIVE THROTTLE SENSOR (ITS) Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the TESTING AND REPLACEMENT plastic pedal box studs.
  • Page 87 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 7/32"...
  • Page 88 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ± ± 0.5 volts 0.3 volts Fig. 17 ITS Adjustment (Sheet 2 of 2) Page F-16 Repair and Service Manual...
  • Page 89 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. CONTROLLER REPLACEMENT Replace controller mount assembly in vehicle. Replace and tighten nuts to 6 - 8 ft. lbs. (8 - 11 Nm) torque. Tool List Qty.
  • Page 90 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. and the 5/16" terminal nuts to 50 - 60 in. lbs (6 - 7 Nm) Reconnect the BL- battery cable and replace the seat.

  • Page 91: Motor

    MOTOR TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. GENERAL.........................G - 1 Motor Removal....................G - 1 Motor Disassembly ..................G - 1 Bearing Replacement..................G - 3 Field Coil Replacement ..................G - 3 Brush Replacement..................G - 3 Motor Assembly ....................
  • Page 92 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page G-ii Repair and Service Manual...
  • Page 93 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. GENERAL Do not hold vehicle on hill by using accelerator and motor. Leaving the motor in a stalled condition for more than 3-4 seconds will raise the commutator bars result- ing in unacceptable noise and accelerated brush wear and cause permanent damage to motor.
  • Page 94 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fig. 3 Motor Components Page G-2 Repair and Service Manual...
  • Page 95 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Bearing Replacement Press the armature into the new bearing using moderate heat to aid installation. Tool List Qty.
  • Page 96 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Motor Installation Pull back each brush until each of the springs (15) rest against the side of its brush (Ref Fig. 5 on page G-4). Tool List Qty.

  • Page 97: Batteries & Charging

    BATTERIES & CHARGING TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. SAFETY ........................H - 1 BATTERY ......................... H - 1 BATTERY MAINTENANCE ..................H - 1 At Each Charging Cycle ................... H - 1 Monthly ......................H - 2 Electrolyte Level and Water ................
  • Page 98 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page H-ii Repair and Service Manual...

  • Page 99: Safety

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

  • Page 100: Monthly

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. At Each Charging Cycle and the increase in volume of the electrolyte that results from the charging cycle. To reduce the possibility of fire, never attach a Do not overfill batteries.

  • Page 101: Cleaning Batteries

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Automatic watering devices such as the one included in area of the vehicle or storage facility where it will attack the Battery Maintenance Kit (P/N 25587-G01) can be the metal structure or the concrete/asphalt floor.

  • Page 102: Battery Replacement

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. BATTERY REPLACEMENT Front of Vehicle BL+ to Charger BL- to B- Solenoid on ESC Before any electrical service is performed on PDS model vehicles, the Run-Tow/Maintenance switch must be placed in the ‘Tow/Maintenance’...

  • Page 103: Battery Charging

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. that may result from personnel running over or trip- ping over the cord set. • The charger is automatically turned off during the connect/disconnect cycle and therefore no electri- cal arc is generated at the DC plug/receptacle con-...

  • Page 104: Hydrometer

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. placed with a good battery of the same brand, type and tery will test at 1.275 - 1.280 while a discharged battery approximate age.
  • Page 105 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Since the hydrometer test is in response to a vehicle ex- hibiting a performance problem, the vehicle should be recharged and the test repeated.
  • Page 106 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page H-8 Repair and Service Manual...

  • Page 107: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................J - 1 PORTABLE CHARGER INSTALLATION ..............J - 1 Charger Maintenance..................J - 1 LIST OF ILLUSTRATIONS Fig. 1 Charger Installation ............J - 1 Fig. 2 Polarized Receptacle ..........J - 1 Fig.
  • Page 108 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page J-ii Repair and Service Manual...
  • Page 109 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. CHARGER DESCRIPTION The battery charger accompanying this vehicle is 120 volt AC, 60 Hz input with 48 volt DC output. Contact charger manufacturer for maintenance or service parts.
  • Page 110 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page J-2 Repair and Service Manual...

  • Page 111: Brakes

    BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. SYSTEM DESCRIPTION ..................K - 1 MASTER CYLINDER REPLACEMENT ..............K - 1 BRAKE MASTER CYLINDER FLUID ................ K - 1 ROUTINE MAINTENANCE ..................K - 2 REPLACEMENT OF WEAR ITEMS ................K - 2 Brake Pad Replacement ..................
  • Page 112 BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO. Fig. 3 Mechanical Brake System ..............K - 4 Fig. 4 Wheel Brake Adjustment ..............K - 5 Fig. 5 Parking Brake and Kick-Off Mechanism ..........K - 6 Fig.

  • Page 113: System Description

    BRAKES FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. SYSTEM DESCRIPTION ator assembly housing. Install new master cylinder, and tighten nuts to 12 - 14 ft. lbs torque. Install brake line to new master cylinder and tighten to 15 in.
  • Page 114 BRAKES FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ROUTINE MAINTENANCE fluid is lost or a brake line is disconnected, there is no need to bleed the system. Tool List Qty.

  • Page 115: Bleeding Brakes

    BRAKES FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. actuator pivot and the linkage rod (See Actuator linkage Attach a short length of clear hose to the caliper bleed bushings).

  • Page 116: Brake System Overview

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

  • Page 117: Automatic Adjuster Mechanism

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. adjusters will function. Free pedal travel, pedal force, shoe to drum clearance and braking capability are Brake Lever closely related.

  • Page 118: Compensator Assembly

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. The brake compensator assembly applies a spring load to the parking brake system and insures that the parking Older brake remains under tension whenever it is engaged.
  • Page 119 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Condition of: Replace...
  • Page 120 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Disassemble Adjuster Tries Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.
  • Page 121 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TROUBLESHOOTING TABLE Test (PBPT), and Aggressive Stop Test is performed (Ref Fig. 8). Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Condition Possible Cause...
  • Page 122 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Condition Possible Cause Correction Neither wheel locks when park brake Incorrect compensator spring adjust- Return to factory specification ment is latched.

  • Page 123: Troubleshooting And Inspection

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TROUBLESHOOTING AND INSPEC- TION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes.
  • Page 124 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. properly. lem is likely in the wheel brake. 6. Inspect the brake cable equalizer linkage. Inspect for signs of corrosion, damage, wear or exces- Measured Amount of Free Travel sive misalignment (Ref Fig.
  • Page 125 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 12. Inspect kick-off cam linkage and bushings. Check for wear and damage. The kick-off cam pivot Hinge Torsion and bushings should move freely and be free of corro-...
  • Page 126 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. sure the vehicle stopping distance from the point at which the brakes were latched. The vehicle should stop within the “normal”...

  • Page 127: Wheel Brake Inspection

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. found, the drum must be replaced. NOTICE 3. Remove any accumulated brake dust from the wheel The brake adjuster mechanism must expand and release fully brake assembly with a brush.
  • Page 128 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 7. Check the condition and operation of the moving anchor assembly (Ref Fig. 24). The pattern of normal brake shoe wear is Operate the brake lever to check for free motion.

  • Page 129: Maintenance And Repairs

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Parts Replacement vs. Repair Some maintenance or repair tasks can take consider- able labor to do correctly. Assessment of the condition of Heavy Shoe worn components is critical to the operation of the brake Spring...

  • Page 130: Brake Drum Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 65 and 75 lbs. (29 - 34 kg) indicated on the scale (Ref Fig. 22). 7/8" - 1 1/8" (2.2 - 2.9 cm) Use a 'bathroom' scale to confirm the latching force required to engage and latch...

  • Page 131: Wheel Brake Service

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Wheel Brake Service NOTICE Wheel brake service consists of disassembly, cleaning, Do not apply the brake when removing the nut as the shoes inspection, lubrication and re-assembly of the wheel may not fully retract preventing removal of the brake drum.

  • Page 132: Backing Plate/Entire Wheel Brake Assembly Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Backing Plate/Entire Wheel Brake Assembly Removal and Installation Backing Plate Remove the four bolts (1) and lock nuts (2) securing the wheel brake backing plate to the flange on the axle tube (Ref Fig.

  • Page 133: Brake Cable And Equalizer Assembly Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Heavy Shoe Spring New Brake Shoes Screw Adjusting Screw In Shoe Clamp Until 1 - 2 Threads Are Exposed Existing Brake Shoes Adjust 'in' 10 - 15 'clicks' (Minimum of 1 - 2 Threads Must Be Exposed)

  • Page 134: Compensator Assembly, Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Cotter Clevis Compensator Assembly Equalizer Bracket Spherical Lock Brake Compensator Cables Fig. 28 Brake Cable, Equalizer and Compensator cables to the brake levers using new clevis pins and new cotter pins.

  • Page 135: Parking Brake Pedal, Removal And Installation

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. If required, adjust the kick-off cam (3). “Parking Brake nents, do not attempt to re-new worn compo- Kick-Off Cam Removal, Replacement and Installation”...
  • Page 136 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Accelerator Pedal 8 10 Fig. 32 Parking Brake Release Linkage and Kick-Off Cam Removal and Installation With the parking brake engaged and fully latched, there must be no gap between the top of the cam and the latch arm.
  • Page 137 ELECTRICAL COMPONENTS & WIRING TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ................... L - 1 TROUBLESHOOTING ....................L - 1 POWER SUPPLY...................... L - 3 ACCESSORY WIRING....................L - 3 LIGHT BULB REPLACEMENT ................. L - 3 FUSE REPLACEMENT.....................
  • Page 138 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page L-ii Repair and Service Manual...
  • Page 139 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. DIGITAL VOLT OHM METER TROUBLESHOOTING A typical digital volt ohm meter (DVOM) is shown (Ref In order to effectively troubleshoot the circuits that Fig.
  • Page 140 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Driver Side Passenger Side Marker Headlight Headlight Marker Turn Turn BLU/WHT Horn + 12V ORN /WHT 15 AMP Fuse 15 AMP...

  • Page 141: Light Bulb Replacement

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. POWER SUPPLY the fuse is in good condition. No reading indicates a faulty fuse; replace with a good 15 amp fuse. Tool List Qty.
  • Page 142 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Turn Signal Marker Light Light Headlights Marker Turn Light Signal Light Fig. 3 Headlight, Turn Signal & Marker Light Bulb Replacement Roll Rubber Bezel Away...
  • Page 143 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. STATE OF CHARGE METER AND KEY SWITCH FUSE BLOCK BLU/WHT (Light Switch) ORN/WHT (Horn Switch) (Brake Light Switch) Battery BL+...
  • Page 144 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Front of Vehicle Floormat Floorboard Fig. 6 Horn TURN SIGNAL HOUR METER Solenoid Fig. 7 Turn Signal, Headlight, Tail Light Page L-6 Repair and Service Manual...

  • Page 145: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................M - 1 GENERAL .........................M - 1 Shock Absorber Removal.................M - 1 Shock Absorber Installation ................M - 1 Rear Spring Removal ..................M - 1 Rear Spring Installation..................M - 2 LIST OF ILLUSTRATIONS Fig.
  • Page 146 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page M-ii Repair and Service Manual...
  • Page 147 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REAR SUSPENSION NOTICE In the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in their original positions Part of Frame...
  • Page 148 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Rear Spring Installation Tool List Qty. Torque wrench, ft. lbs., 1/2" drive.........1 Be sure the vehicle is on a firm and level sur- Socket, 9/16", deepwell, 1/2"...
  • Page 149 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Front of the Vehicle Fig. 2 Spring Replacement Page M-3 Repair and Service Manual...
  • Page 150 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page M-4 Repair and Service Manual...

  • Page 151: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. REAR AXLE REMOVAL ................... N - 1 REAR AXLE INSTALLATION................... N - 2 AXLE SHAFT DISASSEMBLY ................. N - 2 Axle Shaft Removal..................N - 2 Bearing Removal....................N - 3 AXLE COMPONENTS INSPECTION ................
  • Page 152 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page N-ii Repair and Service Manual...
  • Page 153 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. For further axle information, see Electric Rear Axle Man- Loosen both rear wheels by loosening each lug nut ual P/N 28148-G01.
  • Page 154 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Remove the four wires connected to the motor. Remove to 21 - 25 ft. lbs. (28 - 34 Nm) torque. Tighten axle the vinyl cap (1), hex nut (2), washer (3), bushing shock mounting hardware (4) to 16 - 20 ft.
  • Page 155 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Fig. 6 Removing Oil Seal with Puller NOTICE Fig. 4 Removing Brake Drum Line up the hole in the axle shaft flange with the backing It is recommended that whenever a bearing, seal or ‘O’...
  • Page 156 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. AXLE SHAFT ASSEMBLY After drilling, position a chisel across the hole and strike sharply to break the ring. Replace with a new ring at time of assembly.

  • Page 157: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD................... P - 1 Transporting..................... P - 1 SUN TOP ........................P - 2 Rear Support Installation.................. P - 2 Front Support Installation ................. P - 2 Sun Top Installation ..................
  • Page 158 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page P-ii Repair and Service Manual...

  • Page 159: Top And Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TOP AND WINDSHIELD Transporting To reduce the possibility of severe injury or The top does not provide protection from roll death while transporting vehicle: over or falling objects.
  • Page 160 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. SUN TOP washers (item 16) and lock nuts (item 17) underneath (See Detail D). Finger tighten hardware. Tool List Qty.
  • Page 161 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Front Of Vehicle (Driver Side Rear Shown) (Driver Side Shown) Front Of Vehicle Front Of Vehicle Fig.

  • Page 162: Fold Down Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. FOLD DOWN WINDSHIELD Position top grips (item 8) as shown (See Detail D) at top hole on each side of front strut. Secure with top grip fas- Tool List Qty.

  • Page 163: Full Front Windshield

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

  • Page 164: Rear Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REAR WINDSHIELD Insert screw (item 4) through washer (item 5), rubber grommet (item 6) and existing hole in rear strut. Secure Tool List Qty.
  • Page 165 TROUBLESHOOTING AND DIAGNOSTICS TROUBLESHOOTING AND DIAGNOSTICS TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. HOW TO USE THE HAND HELD DIAGNOSTIC UNIT ..........R - 1 MENUS ........................R - 1 Diagnostics Report................... R - 1 Battery and Warranty ..................R - 3 Error Messages....................
  • Page 166 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page R-ii Repair and Service Manual...

  • Page 167: How To Use The Hand Held Diagnostic Unit

    Button 3 is used as ’enter’ or ’return’; hold the button for 3 seconds. The E-Z-GO logo will display when the unit is first pow- ered up, then the menu title is displayed on the first line MENUS of the display screen with the menu selections indented under it.
  • Page 168 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. motor by the pedal position. DIAG REPORT 9. MOTOR ACTUAL SPEED: displayed as VOLTAGE ’ACTSPEED’, the next line displays the actual motor 49.28 V speed in RPMs.
  • Page 169 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 16. SOLENOID: displayed as ’SOLENOID’, the next line displays the solenoid state as ’ON’ or ’OFF STATUS SOC BATT 85 %...

  • Page 170: Error Messages

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ERROR MESSAGES SETTING TOP SPEED AND PERFORMANCE PROFILES (read and write) To change the speed, scroll down the list and highlight SERVICE MENU one of the vehicles;...
  • Page 171 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Turn key to ’OFF’ and then back ’ON’. If car does not run proceed to step 2.
  • Page 172 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that all battery wires are securely fastened and have less than 0.1 ohms resis- tance between wire terminal and battery post.
  • Page 173 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Check both +5V and 5V GND to chassis, 1.
  • Page 174 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Turn key switch to ’OFF’ and unplug 23 pin connector from controller.
  • Page 175 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that all battery wires are securely fastened and have less than 0.1 ohms resis- tance between wire terminal and battery post.
  • Page 176 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Measured heat sink temper- 1.
  • Page 177 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. If this occurs with the key switch turned on: Throttle switch is closed at key start, the throttle switch must be...

  • Page 178: Troubleshooting

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. DIGITAL VOLT OHM METER over time, the obvious place to start is at the headlight that is not functioning.
  • Page 179 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. POWER SUPPLY Tool List Qty. DVOM................1 Check For Loose or Bare Wires Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame.
  • Page 180 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page R-14 Repair and Service Manual...
  • Page 181 LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. GROUNDING REQUIREMENTS................S - 1 GROUND SYSTEMS ....................S - 1 LIGHTINIG PROTECTION REQUIREMENTS............S - 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM ........S - 1 GROUND NETWORK REQUIREMENTS..............
  • Page 182 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page S-ii Repair and Service Manual...
  • Page 183 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 1.
  • Page 184 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REVISION: GS-726-006 TITLE: EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding Rev -, ECN 027194 10/19/92 6.
  • Page 185 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 trating or structurally damaging the building.
  • Page 186 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page S-4 Repair and Service Manual...
  • Page 187 SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. ST SHUTTLE 4/6 ...................... T - 1 LIST OF ILLUSTRATIONS Fig. 1 ST Shuttle 4/6 Vehicle Dimensions ............. T - 2 Fig. 2 ST Shuttle 4/6 Vehicle Dimensions ............T - 3 Vehicle Incline Specifications and Turning Diameter Fig.
  • Page 188 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page T-ii Repair and Service Manual...
  • Page 189 The weighted RMS acceleration; less than 2.5 m/s ** DO NOT use low inflation pressure tires on any E-Z-GO vehicle. DO NOT use any tire which has a recommended inflation pressure less than the inflation pressure recommended in the Owner’s Guide.
  • Page 190 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 95 in. (241.3 cm) 138 in. (350.52 cm) 46.5 in. (119 cm) Fig. 1 ST SHUTTLE 4/6 Vehicle Dimensions Page T-2 Repair and Service Manual...
  • Page 191 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 76 in. (193 cm) 52.5 in. (133.35 cm) RECOMMENDED MAX SIDE TILT 25% or 14° MAX Front 36.5 in.
  • Page 192 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. TURNING CLEARANCE DIAMETER 25ft 6inches (7.8 m) 78 in. (198 cm) INTERSECTING AISLE CLEARANCE 78 in. (198 cm) Fig.
  • Page 193 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. 4.9" 9.7" (12.45cm) (24.6cm) 10.2" (25.90cm) 4.3" (10.9cm) Fig. 4 Delta-Q 48V Charger Page T-5 Repair and Service Manual...
  • Page 194 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings. Notes: Page T-6 Repair and Service Manual...
  • Page 195 NOTICE NOTICE Read the following warnings before attempting to operate the Read and understand the following text and warnings before vehicle: attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. It is virtually impossible to anticipate all possible compo- To prevent personal injury or death, ob- nent failures or the manner in which each component...
  • Page 196 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department...

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