Ezgo Express L4 Service Manual
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Ezgo Express L4 Service Manual

Electric powered personnel vehicle
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See also: Owner's Manual , Technician's Repair and Service Manual
625610
TECHNICIAN'S REPAIR AND SERVICE MANUAL
ELECTRIC POWERED PERSONNEL VEHICLE
625620
ISSUED JUNE 2012
REVISED AUGUST 2012

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Summary of Contents for Ezgo Express L4

  • Page 1 625610 TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED PERSONNEL VEHICLE 625620 ISSUED JUNE 2012 REVISED AUGUST 2012...
  • 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 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 SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual. TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124 SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 INTERNATIONAL: PHONE: 001-706-798-4311, FAX: 001-706-771-4609 Repair and Service Manual Page i...

  • 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 GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C WHEELS AND TIRES ........................D FRONT SUSPENSION AND STEERING ..................E ELECTRONIC SPEED CONTROL ....................F MOTOR ............................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL OPERATION ALWAYS: use the vehicle in a responsible manner and maintain the vehicle in safe operating condition. read and observe all warnings and operation instruction labels affixed to the vehicle.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ALWAYS: test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic.
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page viii Repair and Service Manual...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTANENCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION ................. A - 1 TRANSPORTING VEHICLE ..................A - 1 Towing ......................A - 1 Hauling......................A - 1 SERVICING THE ELECTRIC VEHICLE..............A - 1 ROUTINE MAINTENANCE ..................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page A-ii Repair and Service Manual...

  • Page 13: Transporting Vehicle

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERIAL NUMBER LABEL kg). Lock the park brake and secure the vehicle using ratchet tie downs. LOCATION SERVICING THE ELECTRIC Two serial number and manufacture date code label are...

  • Page 14: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE ITEM SERVICE OPERATION The only maintenance required for the first five years is Batteries Charge batteries the periodic inspection of the lubricant level.

  • Page 15: Vehicle Care Products

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUN TOP AND WINDSHIELD cause damage to seals, plastics, the electrical system, body finish or seat material. Do not use pressure in excess of 700 psi (4826 kPa) to wash vehicle.

  • Page 16: Hardware

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HARDWARE Generally, two grades of hardware are used in the vehicle. Periodically the vehicle should be inspected for loose •...

  • Page 17: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
  • Page 18 GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page A-6 Repair and Service Manual...

  • Page 19: Safety

    SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTICES, CAUTIONS WARNINGS AND DANGERS..........B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE ................B - 1 GENERAL MAINTENANCE ..................B - 1 BEFORE SERVICING THE VEHICLE ...............B - 1 Additional Warnings..................B - 2 BATTERY REMOVAL &...
  • Page 20 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page B-ii Repair and Service Manual...

  • Page 21: Notices, Cautions Warnings And Dangers

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

  • Page 22: Additional Warnings

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. become caught in the moving parts of the necessitating proper ventilation. Five air powertrain. exchanges per hour is considered the minimum requirement.

  • Page 23: Battery Removal & Installation

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint.

  • Page 24: Lifting The Vehicle

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE Center of Tool List Qty. Front Axle Floor jack ..............1 Jack stands..............4 Chocks................. 4 Some servicing operations may require the vehicle to be raised.
  • Page 25 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page B-5...
  • Page 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page B-6 Repair and Service Manual...

  • Page 27: Body

    BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY ..........................C - 1 General..........................C - 1 Body Component Replacement.................... C - 1 PAINTING Minor Scratches........................C - 6 Larger Scratches ........................C - 6 Complete Panel Repair ......................C - 6 LIST OF ILLUSTRATIONS Fig.
  • Page 28 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page C-ii...

  • Page 29: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Drill Out Rivet NOTICE Pop Rivet Head Only In the following text, there are references to removing/installing bolts etc.
  • Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cowl Splash Panel Glove Box Door Fender Flare Instrumental Panel Front Fascia Front Basket Splash Panel Floorpan Brush Guard Fig.
  • Page 31 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Floor Mat Frame Rocker Panel Rear Fender Ashtray Floor Mount Gun Holder Fig. 3 Front Body Components (Continued) Repair and Service Manual Page C-3...
  • Page 32 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Support Splash Panel Battery Tray Box Cooler Box Cooler and Bracket Access Panel Seat Hinge Plate Rear Cowl Notched Rear Bumber Fig.
  • Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Flip Flop Seat Bottom Assembly Top of Vehicle Seat Back Support Handrail Seat Frame Weldment Footrest Handle Front of Vehicle Footrest Weldment Seat Back Assembly Seat Back Support...

  • Page 34: Painting

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING 2. Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- up paint.
  • Page 35 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page C-7...
  • Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page C-8...

  • Page 37: 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 - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheel and Tire Installation ................. D - 2 Repair and Service Manual Page D-i...
  • Page 38 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-ii...
  • Page 39 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEEL AND TIRE SERVICE Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section Tools List Qty.
  • Page 40 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger tighten lug nuts as shown. Then, tighten lug nuts to 50 - 85 ft.
  • Page 41 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-3...
  • Page 42 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-4...

  • Page 43: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE ......................E - 3 Lubrication ..........................E - 2 Wheel Bearing and King Pin Bushing Inspection ..............E - 2 Wheel Bearing Packing ......................E - 3 Wheel Bearing Adjustment ....................E - 3 Wheel Alignment ........................E - 3 FRONT SUSPENSION ....................
  • Page 44 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-ii...
  • Page 45 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Decal Steering Wheel Cover Steering Wheel Steering Wheel Column Wave Washer Bearing Outer Snap Ring Inner Snap Ring Front of Vehicle Intermediate...

  • Page 46: Maintenance

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

  • Page 47: Wheel Bearing Packing

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Bearing Packing new cotter pin (2). If the hole does not align, the castel- lated nut must be loosened to align with the closest Tool List Qty.
  • Page 48 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Measure the distance between the chalk lines at both the front and rear of the tires (Ref Fig. 4). The measure- Remove Bolt ment taken at the front of the tires should be 0"...

  • Page 49: Front Suspension

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

  • Page 50: Front Shock Absorber Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. components, secure rack and pinion unit (16) Front Shock Absorber Replacement to front springs with wire. This will prevent the Tool List Qty.

  • Page 51: Front Spring Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Spring Replacement Driver side spring installation is the reverse order of dis- assembly making sure to install the long bolt (20), spring Tool List Qty.

  • Page 52: Hub Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Replace upper portion of floor mat in plastic trim retain- Adjust bearing. See “Wheel Bearing Adjustment” on ers.

  • Page 53: Axle Linkage Rod Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Ball Joint Nut Fig. 10 Wheel Bearing Replacement Install inner wheel bearing (4) and new grease seal in hub and mount hub to spindle.

  • Page 54: Steering

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STEERING Front of Vehicle Part of Frame Flat Section Fig. 12 Steering Components Repair and Service Manual Page E-10...

  • Page 55: Rack Ball Joint Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rack Ball Joint Replacement Tool List Qty. Needle Nose Pliers............1 After replacing or servicing steering components, always Wrench, 11/16"...

  • Page 56: Bellows Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Loosen jam nut (7) at threaded tube (8). To replace bellows (1) (Ref Fig. 15), first loosen passen- ger side front wheel and lift and support front of vehicle NOTICE per SAFETY section.

  • Page 57: Pinion Seal Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pinion Seal Replacement NOTICE Tool List Qty. The bore has a positive stop to correctly locate the seal during Vice ................

  • Page 58: 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 Notices, Cautions, Warnings and Dangers. joint separator as a lever, apply pressure to ball joint and Rack and Pinion Unit Disassembly and tap nut with plastic faced hammer to release tie rod from Inspection spindle arm (4).

  • Page 59: Rack And Pinion Unit Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Set proper rack extension-to-rack and pinion unit clear- ance. See “Spindle Contact with Front Axle” on page E - Rack and Pinion Unit Replacement Tool List Qty.

  • Page 60: 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 Notices, Cautions, Warnings and Dangers. turned fully to the right forcing passenger spindle arm With spindle arm resting against front axle, cut wire tie against front axle.

  • Page 61: 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 Notices, Cautions, Warnings and Dangers. bottom retaining tabs. Then, using thumb for leverage as Inspect the four retaining tabs on the steering wheel shown, reach from behind steering wheel with fingertips cover (2) for white stress lines (Ref Fig.
  • Page 62 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove large retaining ring (8) on bottom end of column and pull shaft and bearing (9) out as an assembly. Slide wave washer (10) out bottom end of steering column and keep for reuse.
  • Page 63 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-19...
  • Page 64 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-20...

  • Page 65: Electronic Speed Control

    ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. GENERAL .............................. F - 1 PERFORMANCE OPTIONS & DIAGNOSTICS .................. F - 1 Changing Performance Options ....................F - 1 OPERATION ............................F - 2 Pedal Box ........................... F - 3 Speed Sensor ..........................
  • Page 66 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page F-ii Repair and Service Manual...

  • Page 67: General

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL • Walk-Away to limit vehicle movement without driver input, slowing the vehicle to 2 mph (3 kph) and sounding an audible alarm (reverse beeper) TruCourse Technology (TCT) system vehicles are oper- •...

  • Page 68: Controller

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. service brake to control speed and proceed with diag- the accelerator pedal is depressed, the electronic nostic check.
  • Page 69 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Run-Tow/Maintenance switch located under the passen- ger seat. The Electronic Speed Control system consists of three separate units;...

  • Page 70: General Troubleshooting

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL TROUBLESHOOTING Tool List Qty. Floor jack ..............1 Battery Reference Jack stands..............2 Voltage Wheel chocks .............. 4 Jumper wire (with alligator clips) .........

  • Page 71: Testing A Switch For Continuity

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Before any electrical service is performed on TCT model vehicles, the Run-Tow/Maintenance switch must be placed in the ‘Tow/Maintenance’ position. If a power wire (battery, motor or controller) is discon- nected for any reason on the TCT model vehicle, the Run-Tow/Maintenance switch must be left in the ‘Tow/...

  • Page 72: Troubleshooting Diagrams

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING DIAGRAMS The following diagrams will assist in servicing the vehicle. By utilizing the diagnostic mode Fault Codes, considerable time will be saved in determining the probable vehicle operating malfunction.
  • Page 73 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Controller Recover 1311 Display Explanation Tested When Possible Cause Response When High Pedal Disable Controller powers up 1.
  • Page 74 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 16 PIN Plug from Main Wire Harness to Controller CB- To Battery BL- 10AWG Black Motor Wire 10AWG White Motor Wire A1 - From Motor 4AWG C - From Motor 4AWG...
  • Page 75 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 9 Controller Wiring Diagram Repair and Service Manual Page F-9...

  • Page 76: Inductive Throttle Sensor (Its) Testing And Replacement

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INDUCTIVE THROTTLE SENSOR (ITS) Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the TESTING AND REPLACEMENT plastic pedal box studs.
  • Page 77 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 7/32" drill to measure gap between plunger Micro switch...
  • Page 78 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2.7 ± 0.5 volts 1.0 ± 0.3 volts Fig. 12 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page F-12...

  • Page 79: Controller Replacement

    ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTROLLER REPLACEMENT Reconnect the BL- battery cable and replace the seat. SOLENOID REPLACEMENT Tool List Qty. Socket, 3/8"...
  • Page 80 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Replace the environmental cover and tighten the mount- ing bolts to 35 - 44 in. lbs. (4 - 5 Nm) torque. Reconnect the BL- battery cable and replace the seat.
  • Page 81 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page F-15...
  • Page 82 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Page F-16 Repair and Service Manual...
  • Page 83 MOTOR TABLE OF CONTENTS FOR SECTION ’G’ SECTION TITLE PAGE NO. GENERAL .................................. G - 1 Motor Removal ..............................G - 1 Motor Disassembly ............................G - 1 Bearing Replacement ............................ G - 3 Brush Replacement ............................G - 3 Motor Assembly ............................. G - 4 Motor Tests ..............................
  • Page 84 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page G-ii Repair and Service Manual...

  • Page 85: Motor

    MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Front of Vehicle 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 Remove BL- resulting in unacceptable noise and accelerated brush...
  • Page 86 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Speed Sensor Fig. 3 Motor Components Repair and Service Manual Page G-2...
  • Page 87 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. On TCT motors, remove the magnet on the end of the NOTICE armature by carefully removing the snap rings and attaching screw.
  • Page 88 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Motor Tests Remove brushes and replace with new brush replace- ment kit. Locate springs against the side of each brush. The armature and motor housing are not available as Brush Brush...
  • Page 89 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page G-5...
  • Page 90 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page G-6 Repair and Service Manual...

  • Page 91: Batteries And Charging

    BATTERIES AND CHARGING TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. SAFETY ........................H - 1 BATTERY ......................... H - 1 BATTERY MAINTENANCE ..................H - 1 At Each Charging Cycle ................... H - 2 Monthly ......................H - 2 Electrolyte Level and Water ................
  • Page 92 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page H-ii...

  • Page 93: Safety

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY Overfilling batteries may result in electro- lyte being expelled from the battery during the charge cycle. Expelled electrolyte may cause damage to the vehicle and storage NOTICE facility.

  • Page 94: At Each Charging Cycle

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. At Each Charging Cycle tube. The electrolyte level is important since any por- tion of the plates exposed to air will be ruined beyond repair.

  • Page 95: Cleaning Batteries

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Even if the water is colorless, odorless, tasteless and fit a solution of sodium bicarbonate (baking soda) and for drinking, the water should be analyzed to see that it water to neutralize any acid deposits.

  • Page 96: Battery Replacement

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Replacement and battery wire terminals with a commercially available protective coating. Front of Vehicle Before any electrical service is performed on PDS model vehicles, the Run-Tow/Maintenance switch must be placed in the ‘Tow/Maintenance’...

  • Page 97: Battery Charging

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the charging plug from the vehicle receptacle. For on- • The charging connector components are in good board chargers, disconnect the charging harness from condition and free from dirt or debris.

  • Page 98: Hydrometer

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A cost effective way to identify a poorly performing bat- Specific gravity is the measurement of a liquid that is tery is to use a hydrometer to identify a battery in a set compared to a baseline.
  • Page 99 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. As a battery ages the specific gravity of the electrolyte will decrease at full charge. This is not a reason to replace the battery, providing all cells are within fifty points of each other.
  • Page 100 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page H-8...

  • Page 101: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................J - 1 PORTABLE CHARGER INSTALLATION ..............J - 1 UNDERSTANDING THE CHARGER .................J - 2 LED DISPLAY INFORMATION ..................J - 2 LED Operation Codes ..................J - 2 LED Fault Codes....................J - 2 MAINTENANCE INSTRUCTIONS................J - 2 LIST OF ILLUSTRATIONS...
  • Page 102 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-ii...
  • Page 103 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CHARGER DESCRIPTION supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way –...
  • Page 104 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LED Fault Code: NOTICE RED FLASH: Light turns on briefly, but does not Looping the DC cord through the steering wheel when charg- flash after that - check for valid AC voltage.
  • Page 105 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-3...
  • Page 106 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-4...
  • Page 107 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. BRAKE SYSTEM OVERVIEW .................. K - 1 General Description ..................K - 1 How the Service Brake Works................K - 1 Equalizer Link ....................K - 2 Automatic Adjuster Mechanism ................ K - 2 How the Parking Brake Works .................
  • Page 108 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO Fig. 15 Brake Shoe Wear ..................K - 13 Fig. 16 Orientation of Brake Shoe Springs ............K - 14 Fig. 17 Free Travel Adjustment ................K - 15 Fig.
  • Page 109 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Pedal Torsion Springs Push Nut Hinge Pin Service Brake Pedal Pedal Latch Spacer Kick Off Catch Bracket Cap Screw Brake Pedal Pivot Bolt...
  • Page 110 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. system. Continued motion of the brake pedal pulls both the left and right brake cables. Each brake cable pulls a Brake brake lever which pushes the rear brake shoe against Shoe...
  • Page 111 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Compensator Assembly Older Models The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref.

  • Page 112: Rear Axle

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace Condition of: Includes...
  • Page 113 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disassemble Adjuster Tries Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.
  • Page 114 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING TABLE Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Test (PBPT), and Aggressive Stop Test is performed (Ref.
  • Page 115 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Unequal braking (one wheel locks Wheel not locking is not adjusting. Check brake operation of wheel that is not locking.
  • Page 116 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING AND INSPECTION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes. In this 1/4"...
  • Page 117 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 6. Inspect the brake cable equalizer linkage. Inspect for signs of corrosion, damage, wear or exces- sive misalignment. Replace if corrosion, damage, or Measured Amount of Free Travel wear is found.
  • Page 118 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point Push 0.0" Gap (0.0 mm) Catch Screw...
  • Page 119 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. stopping location or stopping distance. For fleets of vehi- cles, several vehicles should be tested when new and NOTICE the range of stopping locations or distances recorded.
  • Page 120 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To perform an Aggressive Stop Test, equally load both sides of the vehicle (Ref. Fig. 13) and apply maximum force and travel to the service brake pedal while moving.
  • Page 121 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. brake adjusters be replaced when installing new brake shoes. Wheel Brake Lever 10. Inspect the brake shoe springs. Be sure that they are not broken or damaged and are correctly installed.

  • Page 122: Brakes

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pliers ................1 Vernier/Dial Calipers ............1 Plastic Tipped Hammer..........1 Heavy Shoe Puller (P/N 15947-G1) ..........1 Spring Pry Bar .................1 Dust Mask ..............1 Light Emery Cloth ..............1...
  • Page 123 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The parking brake should latch between 65 and 75 lbs. 7/8" - 1 1/8" (2.2 - 2.9 cm) (29 - 34 kg) indicated on the scale.
  • Page 124 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. until a new cotter pin can be installed through the castel- lated nut and the hole in the axle. Maximum torque is 140 ft.
  • Page 125 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Backing Plate/Entire Wheel Brake Assembly Lubricate the backing plate friction points of the shoes and moving anchor with Multi Purpose Grease (MPG) Removal and Installation lubricant (Ref.
  • Page 126 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always replace both brake shoes on both wheels as a Heavy Shoe Spring set. Install the shoes as indicated and install the shoe Shoe Clamp clamp (5) over the shoe clamp pin (4) and rotate 90°...
  • Page 127 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the bracket. Move the hook back and to the side to release the torsion spring(Ref. Fig. 26). Cotter Clevis Compensator...
  • Page 128 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Catch Bracket Removal and n ent s. The parking b rake arm latc h is a hardened part.
  • Page 129 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Inspect the bushings (9,10) and spacer. If they are worn, replace them with new ones. Accelerator Pedal Fig.
  • Page 130 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page K-22...

  • Page 131: Electrical System

    ELECTRICAL SYSTEM TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ................... L - 1 TROUBLESHOOTING ....................L - 1 POWER SUPPLY...................... L - 4 Check For Loose Or Bare Wires ...............L - 4 Check battery Condition ..................L - 4 Check Green Power Wire..................L - 4 Check Fuse .......................L - 4 MAIN AND ACCESSORY WIRING ................
  • Page 132 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page L-ii...
  • Page 133 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 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 134 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Turn Marker Headlight Headlight Marker Turn Inline Fuse DC - DC converter RED/WHT BLU/WHT Horn + 12V ORN /WHT 15 AMP 15 AMP...
  • Page 135 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTE: Connectors are viewed from rear of the connector GRAY GREEN WHITE ORANGE/RED BLACK BLUE BLACK WHITE WHITE/YELLOW GREEN-WHITE PURPLE...
  • Page 136 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. POWER SUPPLY negative battery post. A reading of battery voltage indicates that the fuse is in good condition. No reading Tool List Qty.
  • Page 137 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Reverse Buzzer GRN/ Control Harness Dash Mounted Direction Selector, State Of Charge Meter, Label And Plate Key Switch and Key set Fig.
  • Page 138 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering column cover Turn Signal Flasher unit Turn Singal Switch Assembly Fuse Block Floorboard Horn Button Horn Fig.
  • Page 139 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Head Light and Turn Signal Turn Signal Head Light Tail Light Rear Fender WHT to BLK from Harness - Both Sides BLK to BLU/WHT from Harness - Both Sides RED to WHT from Harness - Driver Side RED to YEL from Harness - Passenger Side...
  • Page 140 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hour Meter Front of Vehicle Electrical Components Passenger Side Seat Support Cover Note: Hold lower nut when tightening top nut.
  • Page 141 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page L-9...
  • Page 142 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page L-10...

  • Page 143: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................M - 1 General ......................M - 1 Shock Absorber Removal.................M - 1 Shock Absorber Installation................M - 1 Rear Spring Removal ..................M - 1 Rear Spring Installation ..................M - 1 REAR AXLE REMOVAL ...................M - 3 Rear Axle Installation ..................M - 3 LIST OF ILLUSTRATIONS...
  • Page 144 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page M-ii...
  • Page 145 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers REAR SUSPENSION Remove the bottom shock absorber nut (1) (Ref Fig. 1). Compress the shock absorber (2) and remove the top shock absorber nut (3).
  • Page 146 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Front of vehicle Fig. 1 Rear Suspension Repair and Service Manual Page M-2...
  • Page 147 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page M-3...
  • Page 148 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page M-4...

  • Page 149: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ’N’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE .......................N - 1 Checking the Lubricant Level .....................N - 1 REAR AXLE DISASSEMBLY .......................N - 1 Axle Shaft Removal and Disassembly ..................N - 1 Axle Shaft Seal Removal and Replacement ................N - 2 Axle Shaft Replacement ......................N - 3 LIST OF ILLUSTRATIONS Fig.
  • Page 150 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page N-ii Repair and Service Manual...
  • Page 151 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For further axle information, see Electric Rear Axle NOTICE Manual P/N 28148G01. Refer to REAR SUSPENSION section for axle removal. It is recommended that whenever a bearing, seal or ‘O’...
  • Page 152 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Removing/Installing Axle Shaft Remove the bearing by supporting the inner race of the bearing on an arbor press bed and apply pressure to the threaded end of the axle shaft (Ref.
  • Page 153 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Replacement NOTICE Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with Tighten the castellated axle nut to 70 ft.
  • Page 154 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page N-4 Repair and Service Manual...

  • Page 155: Handheld Diagnostics

    HANDHELD DIAGNOSTICS TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. HOW TO USE THE HANDHELD PROGRAMMER ........... P - 1 Primary Connection: 4 PIN TYCO..............P - 1 Alternate Connection: 4 PIN MOLEX ............... P - 1 Navigation......................P - 1 Changing Data Value ..................
  • Page 156 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page P-ii...
  • Page 157 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HOW TO USE THE HANDHELD PRO- GRAMMER The Curtis handheld Programmer is used for program- ming, testing, troubleshooting, tuning, diagnosing and parameter adjsutments for speed controller and auxiliary devices.
  • Page 158 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Press down the left arrow once or more on the naviga- Main Menu Definitions tion key to display the main menu. •...
  • Page 159 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value Profile Selection 1 - 5 Freedom Enable ON/OFF Speed...
  • Page 160 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value Main Welded 0 - 255 Speed Sensor Fault 0 - 255 Main Driver On...
  • Page 161 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Default Menu Submenu 1 Submenu 2 Submenu 3 Data Range Units Value LCD Contrast -150 - 150 Program Language English...
  • Page 162 HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page P-6 Repair and Service Manual...

  • Page 163: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ’Q’ SECTION TITLE PAGE NO. 1206HB-5201 Controller Faults and Troubleshooting ....................Q - 1 Repair and Service Manual Page Q-i...
  • Page 164 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page Q-ii Repair and Service Manual...
  • Page 165 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 1206HB-5201 Controller Faults and Troubleshooting Controller Recover 1311 Display Explanation Tested When Possible Cause Response When Throttle applied to Hardware Failsafe 1.
  • Page 166 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Controller Recover 1311 Display Explanation Tested When Possible Cause Response When High Pedal Disable Controller powers up 1. Incorrect sequence of Vehicle input with Key, Direction and HPD (HIGH PEDAL KSI ON, Forward or...
  • Page 167 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page Q-3...
  • Page 168 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page Q-4 Repair and Service Manual...
  • Page 169 LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. GROUNDING REQUIREMENTS................R - 1 GROUND SYSTEMS ....................R - 1 LIGHTINIG PROTECTION REQUIREMENTS............R - 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM ........R - 1 GROUND NETWORK REQUIREMENTS..............
  • Page 170 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page R-ii Repair and Service Manual...

  • Page 171: Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 1.

  • Page 172: External Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 6.

  • Page 173: 10. Equipment Fault And Personal Safety System

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 from penetrating or structurally damaging the building.
  • Page 174 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page R-4...

  • Page 175: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. SUN TOP AND WINDSHIELD .................. S - 1 Trailering ......................S - 1 SUN TOP ........................S - 1 Rear Support Installation.................. S - 1 Front Strut ......................S - 1 Sun Top ......................
  • Page 176 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page S-ii Repair and Service Manual...
  • Page 177 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUN TOP AND WINDSHIELD Front Strut 1. Remove and discard the four bolts from the front cowl. 2.
  • Page 178 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle DETAIL D (REAR) (Passenger DETAIL B Side Shown) DETAIL A (Driver Side Shown) (Outside Tubing On Sun Top) Front of Vehicle DETAIL C...
  • Page 179 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPLIT WINDSHIELD Position top grips (8) as shown (See Detail D) at top hole on each side of front strut. Secure with top grip fas- teners (9).
  • Page 180 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FULL WINDSHIELD Insert screw (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with lock nut (7). Remove protective covering from the windshield (2) Do not over-tighten or squeeze grommet.
  • Page 181 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page S-5...
  • Page 182 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page S-6 Repair and Service Manual...

  • Page 183: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. EXPRESS L4 ......................T - 1 EXPRESS S4 ......................T - 2 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions and Vehicle Incline Specifications ........T - 3 Fig. 2 Turning Clearance Diameter ................T - 4...
  • Page 184 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page T-ii...
  • Page 185 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: EXPRESS L4 TYPE: ELECTRIC POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 618863 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS...
  • Page 186 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: EXPRESS S4 TYPE: ELECTRIC POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 618861 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS TruCourse Technology: Programmable to multiple vehcle terrains, with expanded regenerative braking function, and vehicle charger lockout Solid State continuously variable seperately excited speed controller...
  • Page 187 105.3 in (267.0 cm) Front 38.0 (97.0 cm) 48.5 in Rear (123.0 cm) 38.5 in (98.0 cm) Express L4 Express S4 RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 Fig. 1 Vehicle Dimensions and Vehicle Incline Specifications...
  • Page 188 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING CLEARANCE DIAMETER EXPRESS S4 19.0 ft (5.8 m) EXPRESS L4 19.0 ft (5.8 m) Fig. 2 Turning Clearance Repair and Service Manual...
  • Page 189 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and NOTES: Repair and Service Manual Page T-5...
  • Page 190 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and NOTES: Repair and Service Manual Page T-6...
  • Page 192 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...

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