Ezgo EXPRESS L6 2012 Technician's Repair And Service Manual

Electric powered utility vehicles

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Table of Contents

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625610

TECHNICIAN'S REPAIR AND SERVICE MANUAL

ELECTRIC POWERED UTILITY VEHICLE

625621

ISSUED JUNE 2012

REVISED AUGUST 2012

Table of Contents

Chapters

Table of Contents

Summary of Contents for Ezgo EXPRESS L6 2012

Page 1 625610 TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLE 625621 ISSUED JUNE 2012 REVISED AUGUST 2012...
Page 2: Safety
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 collect in the ceiling of buildings powertrain. necessitating proper ventilation. Five air exchanges per hour is considered the Use care not to contact hot objects.
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. should be present. If any corrosion is found, it should be immediately removed with a putty knife and wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly Overfilling batteries may result in electrolyte being...
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 Instrument Panel Replacement .................... C - 5 Cowl Replacement ....................... C - 5 Front Fascia Replacement ....................C - 5 Rocker Panel Replacement....................
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 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Drill Out Rivet Pop Rivet Head Only NOTICE In the following text, there are references to removing/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. FRONT BASKET BRUSH GUARD Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...
Page 31 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Body Components (Seats and Rear) Repair and Service Manual Page C-3...
Page 32 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Back Support or Seat Bed Frame Fig. 4 Body Components (Cargo Box and Seat Foot Rest) Repair and Service Manual Page C-4...
Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Instrument Panel Replacement Rivet Gun..............1 Duct Tape..............1 Tool List Qty. Allen Key, 3/16”............1 Drill ................1 Drill out the rivets (6) across the top of instrument panel Drill Bit, 7/32”...............
Page 34 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. rocker panel is removed, be sure to locate the three spac- Socket, 9/16”, deepwell, 3/8” drive ......1 ers (30) under each rocker panel for reuse when rocker Ratchet, 3/8”...
Page 35 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. At the front of the rear body, remove the rivets (44) secur- Remove the nut (43) securing the horizontal foot rest ing the rear body to the frame and floorboard area.
Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To replace the front facing rear seat, install in the reverse NOTICE order of removal. Rear Facing Rear Seat The following text is sequenced to remove the rear body.
Page 37 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. utes between coats, increasing to 45 - 60 minutes in ence in painting ‘TPE’ panels. TPE is a common material higher humidity) using brush on touch-up paint, until in modern automobile bodies and all body shops should coating layer is visible, slightly above the surface of...
Page 38 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-10...
Page 39: 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 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. NOTES: Repair and Service Manual Page D-ii...
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. WHEEL AND TIRE SERVICE Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section Tools List Qty.
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. 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 43 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 44 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 45: Front Suspension And Steering
FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE ......................E - 3 Lubrication ..........................E - 3 Wheel Bearing and King Pin Bushing Inspection ..............E - 3 Wheel Bearing Packing ......................E - 4 Wheel Bearing Adjustment ....................E - 4 Wheel Alignment ........................E - 5 FRONT SUSPENSION ....................
Page 46 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 47 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. EXPRESS L6 Wave Washer Bearing Outer Snap Ring Inner Snap Ring Front of Vehicle Intermediate Shaft with U-Joints Rack &...
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. EXPRESS S6 Front of Vehicle Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate Shaft with U-Joints Rack Ball Joint...
Page 49 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 Front of Vehicle In the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washers etc.) that is removed must always be installed in its original position unless otherwise specified.
Page 50 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. vehicle on stands before starting any repair procedure. Always place chocks in front and NOTICE behind wheels not being raised.
Page 51 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. If completing a wheel bearing adjustment as part of another procedure, tighten front wheels per WHEELS NOTICE AND TIRES section.
Page 52 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 EXPRESS L6 Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.
Page 53 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of EXPRESS S6 Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.
Page 54 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 Axle Replacement long bolt (20) securing front of left spring, note location of washer (22) and remove it from end of bolt. Remove Tool List Qty.
Page 55 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 front wheels. Lift and support front of vehicle per SAFETY section. In addition, support front axle with jack NOTICE stands.
Page 56 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 front wheel(s). Lift and support front of vehicle Lower vehicle per SAFETY section and tighten front wheel(s) per WHEELS AND TIRES section.
Page 57 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. 13 Axle Linkage Rod Replacement Fig. 12 Wheel Bearing Replacement Install inner wheel bearing (4) and new grease seal in hub and mount hub to spindle.
Page 58 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 EXPRESS L6 Part of Frame Flat Section Fig. 14 Express L6 Steering Components Repair and Service Manual Page E-12...
Page 59 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 EXPRESS S6 Flat Section Fig. 15 Express S6 Steering Components Rack Ball Joint Replacement Plastic Faced Hammer ..........1 Tape Measure ..............1 Tool List...
Page 60 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To remove rack ball joint (1), loosen passenger side extension and rack and pinion unit when steering is turned fully to the right forcing passenger spindle arm front wheel and lift and support front of vehicle per against front axle (Ref Fig.
Page 61 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To replace bellows (1) (Ref Fig. 18), first loosen passen- NOTICE ger side front wheel and lift and support front of vehicle per SAFETY section.
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. Pinion Seal Replacement NOTICE Tool List Qty. The bore has a positive stop to correctly locate the seal during Vice................
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. joint separator as a lever, apply pressure to ball joint and tap nut with plastic faced hammer to release tie rod from spindle arm (4).
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. Install rack and pinion unit on vehicle. See “Rack and Pinion Unit Replacement” on page E - 18. Anchor in vice Pinion Unit Replacement”...
Page 65 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. Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque and continue to tighten as needed to insert new cotter pin.
Page 66 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. Plastic Faced Hammer ..........1 nut and strike plastic faced hammer sharply with a ball peen hammer.
Page 67 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. Bearing Driver Set ............1 of column and press steering shaft and bearing assem- bly into column base. Secure with large retaining ring Torque Wrench, ft.
Page 68 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-22...
Page 69: Electronic Speed Control
ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. PERFORMANCE ...................... F - 1 Speed Control ....................F - 1 Pedal-Up Features ................... F - 1 Walk Away Feature ..................F - 1 Anti Roll Back Feature ..................F - 1 Anti Stall Feature .....................
Page 70 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-ii...
Page 71 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERFORMANCE Pedal-Up Feature The pedal-up feature slows the vehicle when the accel- erator pedal is released while the vehicle is moving NOTICE between 8 mph (13 kph) and the vehicle’s top speed.
Page 72 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. backwards slightly before again stopping in the stalled • the controller is activated condition. This process will repeat itself periodically until •...
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 If the operator attempts to override the electronic brak- ing feature by moving the direction selector or key switch to another position, the warning beeper will The controller is a solid state unit that activates a sole- sound and the vehicle will brake rapidly until it reaches...
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. GENERAL TROUBLESHOOTING To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage. Tool List Qty.
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. removing the BL- connection to the battery. Always use insulated wrenches when working on batteries. To check for continuity, set the DVOM to the KW setting Battery and select ‘Continuity’.
Page 76 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the continuity test indicates that contacts are not TROUBLESHOOTING DIAGRAMS “welded” and the wiring to the solenoid coil is good, the The following diagrams will assist in servicing the vehi- coil has failed and the solenoid must be replaced.
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. Fault Fault Vehicle Operation Corrective Action Code Change - - - Direction Selector Fault Vehicle Operates in •...
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. 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 79 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 48 Volt Battery Pack Pedal Box Charging Connector Reed To Hand Solenoid Switch Motor Held Motor Diagnostic Speed Unit...
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. Pedal Box Charging Connector Reed Solenoid Switch WHT/YEL Switch ORN/RED SPARE WHT/BLK RED/YEL SPARE Performance RED/WHT Plug SPARE GRN/BLK...
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. All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
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. 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 83 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 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 84 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 85 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 86 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. 17 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page F-16...
Page 87 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. Tool List Qty. SOLENOID REPLACEMENT Socket, 10mm .............
Page 88 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Mount new solenoid and reconnect wiring. Tighten the solenoid mounting nuts to 67 - 82 in. lbs. (8 - 9 Nm) torque, the #10 terminal nuts to 13 - 17 in.
Page 89 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-19...
Page 90 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-20...
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 - 2 Field Coil Replacement ..................G - 3 Brush Replacement..................G - 3 Motor Assembly ....................G - 3 Motor Tests ......................G - 4 Motor Installation....................G - 4 LIST OF ILLUSTRATIONS...
Page 92 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-ii...
Page 93 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Mark both the axle and motor housings to permit realign- ment during reassembly of motor to rear axle (Ref. Fig. Do not hold vehicle on hill by using accelerator and motor.
Page 94 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Motor Components Bearing Replacement cover as possible, and press the armature out of the bearing. Tool List Qty.
Page 95 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brushes should be measured as shown and replaced when the minimum dimension of .62" (16 mm) is NOTICE reached (Ref.
Page 96 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Align the commutator end cover with the holes in the quantity of molybdenum grease to the male portion of motor housing and assemble (Ref.
Page 97 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 98 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-6...
Page 99: 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 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-ii...
Page 101 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 cause damage to the vehicle and storage facility. Always observe the following warnings when working on Aerosol containers of battery terminal pro- or near batteries: tectant must be used with extreme care.
Page 102 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. At Each Charging Cycle Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage. To reduce the possibility of fire, never attach a A battery being charged will ‘gas’...
Page 103 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. These watering devices are fast and accurate to use batteries which is conductive and will contribute to the and maintain the correct electrolyte level within the bat- discharge of the batteries.
Page 104 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 BL+ to Charger BL- to B- Solenoid...
Page 105 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. deposits neutralized and removed from the battery case • The charger connector is fully inserted into the to prevent self discharge.
Page 106 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 107 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 108 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 109: Battery Charger
BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. BATTERY CHARGER....................J - 1 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 110 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 111 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY CHARGER wait a few seconds and observe ammeter on charger to make sure it moves indicating that charger is charging. Description The battery charger accompanying this vehicle is 120 volt AC, 60 Hz input with 48 volt DC output.
Page 112 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-2...
Page 113: Brakes
BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. MECHANICAL 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 114: Brakes
BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO Spindle Replacement ..................K - 23 Actuator Linkage Bushings ................K - 23 Actuator Pivot Bushings ..................K - 23 BLEEDING BRAKES ..................... K - 24 LIST OF ILLUSTRATIONS Fig.
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. 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 116 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 117 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 118 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 119 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 120 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 121 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 122 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 123 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Either condition can prevent the brakes from adjusting loose, but brake pedal free travel is correctly adjusted properly.
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. soon as the accelerator pedal is depressed. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point 0.0"...
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. cles, several vehicles should be tested when new and the range of stopping locations or distances recorded. NOTICE Over time, a subtle loss of performance may take place;...
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. 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 127 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 128 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 Heavy Shoe Spring Plastic Tipped Hammer..........1 Puller (P/N 15947-G1) ..........1 Light Pry Bar .................1 Shoe Spring Dust Mask ..............1...
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. latches. The parking brake should latch between 65 and 7/8" - 1 1/8" (2.2 - 2.9 cm) 75 lbs.
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. 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 131 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 132 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 133 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. replace if needed. Remove the brake cable and equalizer the bracket. Move the hook back and to the side to assembly and discard.
Page 134 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 hardened part. Do not grind or file it as doing so will cause the part to lose its hardness char- Installation acteristics.
Page 135 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 136 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SYSTEM DESCRIPTION washers securing the master cylinder to the brake actu- ator assembly housing. Install new master cylinder, and NOTICE tighten nuts to 12 - 14 ft.
Page 137 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ROUTINE MAINTENANCE torque. NOTE: Unless fluid is lost or a brake line is dis- connected, there is no need to bleed the system. Tool List Qty.
Page 138 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. actuator pivot and the linkage rod (See Actuator linkage during this operation to prevent air from entering the bushings).
Page 139 BRAKES - FRONT DISC 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-25...
Page 140 BRAKES - FRONT DISC 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-26...
Page 141: 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 - 3 Check For Loose Or Bare Wires ...............L - 3 Check battery Condition ..................L - 3 Check Green Power Wire..................L - 3 Check Fuse .......................L - 3 ACCESSORY WIRING....................
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-ii...
Page 143 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 144 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driver Side Passenger Side Marker Headlight Headlight Marker Turn Turn BLU/WHT Horn + 12V ORN /WHT 15 AMP Fuse 15 AMP Brake...
Page 145 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 Place the red probe (+) to each wire terminal on the fuse block. A reading of battery voltage indicates that Tool List Qty.
Page 146 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. unlock and pull out bulb. Insert new bulb and rotate socket a quarter turn clockwise to secure. Turn Signal Light Headlights...
Page 147 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 STATE OF CHARGE METER AND KEY SWITCH FUSE BLOCK BLU/WHT (Light Switch) ORN/WHT (Horn Switch) (Brake Light Switch) Battery BL+...
Page 148 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Floormat Floorboard Fig. 6 Horn TURN SIGNAL HOUR METER Solenoid Fig. 7 Turn Signal & Hour Meter Repair and Service Manual Page L-6...
Page 149 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-7...
Page 150 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-8...
Page 151: Rear Suspension
REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................M - 1 General ......................M - 1 Shock Absorber Removal (Express S6) ............M - 1 Shock Absorber Installation (Express S6) ............M - 1 Rear Spring Removal (Express S6) ..............M - 1 Rear Spring Installation (Express S6) ..............M - 1 Shock Absorber (Express L6) .................M - 3 Shock Absorber Removal (Express L6)............M - 3...
Page 152 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 153: Rear Axle
REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers REAR SUSPENSION Shock Absorber Installation (Express S6) Shock absorber installation is in the reverse order of dis- assembly except that the shock absorber nuts (1,3) NOTICE must be tightened until the shock absorber bushings (4)
Page 154 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Front of the Vehicle Fig. 1 Rear Suspension (Express S6) Repair and Service Manual Page M-2...
Page 155 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Shock Absorber (Express L6) Install a rubber shock absorber bushing (29) and shock absorber washer (28); cupped surface facing down on Tool List Qty.
Page 156 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers flanged urethane bushings (11) and spacers (10) as Rear Spring Installation (Express L6) well. Spring installation is in the reverse order of disassembly. Remove the hex head bolt (3) and nut (5) from the for- Install the large flanged bushing (2) in the end forward ward leaf spring mounting bracket.
Page 157 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Removal and installation of the leaf spring is the same for both sides of the vehicle. Replace any worn or damaged hardware with new as required.
Page 158 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-6...
Page 159 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 160 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 161: Rear Axle
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 28148-G01. Refer to REAR SUSPENSION section for axle removal. It is recommended that whenever a bearing, seal or ‘O’...
Page 162 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 163 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 164 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 165: 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 - 1 Rear Support Installation.................. P - 1 Front Support Installation ................. P - 1 Sun Top Installation ..................
Page 166 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 P-ii...
Page 167 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP AND WINDSHIELD Rear Support Installation Tap end caps (item 7) into top of the rear support (items 1 and 2) with plastic faced mallet (Ref Fig.
Page 168 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 (Driver Side Shown) Front Of Vehicle (Driver Side Rear Shown) Front Of Vehicle Fig. 1 Sun Top Repair and Service Manual Page P-2...
Page 169 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPILT WINDSHIELD Insert bolt (4) through washer (5), rubber grommet (6) (Ref. Fig. 2) and existing hole in front strut. Secure with washer (5) Tool List Qty.
Page 170 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 P-4...
Page 171: Section Title
HANDHELD DIAGNOSTICS TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. HOW TO USE THE HANDHELD PROGRAMMER ............Q - 1 Primary Connection:..................Q - 1 Alternate Connection..................Q - 1 Navigation ......................Q - 1 Changing Data Value ..................Q - 2 Book Mark ......................Q - 2 Repair and Service Manual Page Q-i...
Page 172 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 Q-ii...
Page 173 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 174 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 175 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 176 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 177 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 178 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 Q-6 Repair and Service Manual...
Page 179: Troubleshooting
TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ’R’ SECTION TITLE PAGE NO. 1206HB-5201 Controller Faults and Troubleshooting ....................R - 1 Repair and Service Manual Page R-i...
Page 180 TROUBLESHOOTING 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 181 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 182 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 183 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 R-3...
Page 184 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page R-4 Repair and Service Manual...
Page 185 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 186 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 S-ii...
Page 187 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 188 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 189 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 190 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 S-4...
Page 191: General Specifications
GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. EXPRESS L6 ......................T - 1 EXPRESS S6 ......................T - 4 LIST OF ILLUSTRATIONS Fig. 1 EXPRESS L6 Vehicle Dimensions, Incline Specifications ........ T - 2 Fig. 2 EXPRESS L6 Incline Specifications, Turning Clearance Diameter ....T - 3 Fig.
Page 192 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 193 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 EXPRESS L6 Vehicle Dimensions, Incline Specifications MODEL: EXPRESS L6 TYPE: ELECTRIC POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No: 618867 Fig.
Page 194 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EXPRESS L6 76.0 in. (193.0 cm) 52.5 in. (133.5 cm) RECOMMENDED MAX SIDE TILT 25% or 14° MAX Front 37.5 in.
Page 195 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EXPRESS L6 6.5 ft. (1. 98 m) TURNING CLEARANCE INTERSECTING DIAMETER AISLE CLEARANCE 25ft 6inches (7.8 m) 6.5 ft.
Page 196 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 S6 TYPE: ELECTRIC POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No: 618865 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Precision Drive System™...
Page 197 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EXPRESS S6 72.0 in. 99.5 in. (253.0 cm) (183.0 cm) 48.8 in. 135.8 in. (345.0 cm) (124.0 cm) Front 37.8 in.
Page 198 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EXPRESS S6 RECOMMENDED MAX RAMP GRADE 25% or 14° MAX TURNING CLEARANCE DIAMETER 35 ft 6inches (10.8 m) RECOMMENDED MAX SIDE TILT 25% or 14°...
Page 199 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4.9" 9.7" (12.45cm) (24.6cm) 10.2" (25.90cm) 4.3" (10.9cm) Fig. 5 Delta - Q 48V Charger Repair and Service Manual Page T-7...
Page 200 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-8...
Page 202 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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