Cushman SHUTTLE 4X Technician's Repair And Service Manual
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Cushman SHUTTLE 4X Technician's Repair And Service Manual

Electric powered utility vehicles
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TECHNICIAN'S REPAIR AND SERVICE MANUAL
ELECTRIC POWERED UTILITY VEHICLES
625615
ISSUED MARCH 2012
REVISED AUGUST 2012

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  • Page 1 TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLES 625615 ISSUED MARCH 2012 REVISED AUGUST 2012...

  • Page 2: Transporting Vehicle

    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 prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 SERVICE AND REPAIR MANUAL ELECTRIC POWERED UTILITY VECHICLE SHUTTLE 4X STARTING MODEL YEAR 2012 DISCLAIMER: The E-Z-GO Division of Textron Inc. (E-Z-GO) reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously.

  • 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 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 SPEED CONTROL........................... F MOTOR ............................
  • Page 6 TABLE OF CONTENTS 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 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: General Operation

    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: Table Of Contents

    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: Hauling

    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 Charge batteries 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 ...
  • 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: Repair and Service Manual Page A-6...

  • Page 19: Table Of Contents

    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 TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY ........................C - 1 General ......................C - 1 BODY COMPONENT REPLACEMENT ..............C - 1 PAINTING ........................ C - 7 Minor Scratches ....................C - 7 Larger Scratches....................C - 7 Complete Panel Repair .....................
  • 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: Page C-ii Repair and Service Manual...
  • 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 order to push out the shank of the rivet. The rivet head is easily removed by drilling into the head with a sharp drill bit that is slightly larger than the shank of the rivet (Ref Fig.
  • Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Glove Box Door Splash Panel Cowl Instrumental Panel Fender Flare Front Basket Floorpan Brush Guard Fig. 2. Front Body Components 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. ASHTRAY Gun Holder FLOOR MOUNT GUN HOLDER Floor Mat Seat Frame Rocker Panel Fig. 3. Floor Mount Gun Holder and Ashtray. 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. Access Panel Cover Rear Bumper Battery Tray Splash panel Rear Fender Fig. 4. Rear Body Components 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. PAINTING 2. Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- Follow the paint manufacturer’s recommendations for up paint.
  • Page 34 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page C-6 Repair and Service Manual...
  • Page 35 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 36 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 37 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 38: Wheel Installation

    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 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. NOTES: Repair and Service Manual Page D-3...
  • 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-4...

  • Page 41: Fig. 2 Lubrication Points

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE......................E - 2 Lubrication ..........................E - 2 Wheel Bearing and King Pin Bushing Inspection..............E - 2 Wheel Bearing Packing......................E - 2 Wheel Bearing Adjustment ....................E - 3 Wheel Alignment........................
  • Page 42 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 43 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...
  • 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. 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 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. Remove hub from spindle and disassemble. See Illus- Check for smooth and free rotation of the wheel and an tration “Seal Installation”...
  • 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. Measure the distance between the chalk lines at both the front and rear of the tires (Ref Fig. 4). The measure- ment taken at the front of the tires should be 0"...

  • Page 47: 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 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. Installation of shock absorber is reverse of disassembly. Remove the three 1 3/4" long bolts (18), two 1 1/2" long Mounting nuts should be tightened until rubber bushings bolts (28), spring plate (24) and five lock nuts (19) secur- (4) expand to diameter of shock absorber washers (5).
  • 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. (23). Then pull long bolt and spring plate (24) from axle and spring. Retain above items (20 - 24) for assembly at their original locations.
  • 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. Install outer wheel bearing (4) and secure hub loosely with castellated nut. Place wheel onto hub and hand View from Underside tighten lug nuts.
  • 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. of the rollers requires replacement of the bearing. If the roller portion of the bearing is to be replaced, the race must also be replaced.
  • 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. STEERING Front of Vehicle Flat Section Fig. 12 Steering Components Rack Ball Joint Replacement To remove rack ball joint (1), loosen passenger side front wheel and lift and support front of vehicle per Tool List Qty.
  • 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. To install new rack ball joint close to its correct position, Tie Rod Inspection/Replacement measure amount of threads exposed from jam nut (Ref Tool List Qty.
  • Page 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. hammer to release tie rod from spindle arm. Remove nut large end loose until rack extension-to-rack and pinion to drop tie rod from spindle arm.
  • 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. To access the pinion seal, remove rack and pinion unit from vehicle. “Rack and Pinion Unit Replacement” on page E - 15 Anchor in vice by clamping on the mounting ears of the rack and pinion unit.
  • 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. Wire Tie, 10" Long ............1 Torque Wrench, in. lbs..........1 Front of Vehicle NOTICE The rack and pinion gears are not serviceable items. If they are found to be damaged or excessively worn, a new rack and pinion unit must be installed.
  • Page 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. If rack and pinion pass inspection, clean them, tensioner Remove cotter pin (2) and loosen castellated nut (3) and housing thoroughly and lubricate for assembly.
  • 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. Check for proper rack extension-to-rack and pinion unit torque. Secure bellows to rack and pinion unit with new clearance by first turning steering wheel fully to the right.
  • 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. Bearing Separator............1 Gear Puller..............1 Arbor Press..............1 Bearing Driver Set ............1 Torque Wrench, ft. lbs..........1 Torque Wrench, in. lbs..........1 Wheel Bearing Grease ..........AR To remove steering shaft (4) (Ref Fig.
  • 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. as far as possible using snap ring pliers (Ref Fig. 25). Use fingers to push retaining ring fully into groove. Slide wave washer into base of steering column.
  • 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. NOTES: Repair and Service Manual Page E-19...
  • 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. NOTES: Repair and Service Manual Page E-20...
  • Page 63 ELECTRONIC SPEED CONTROL - TCT 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 ...........................
  • Page 64 ELECTRONIC SPEED CONTROL - TCT 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 65 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCOURSE TECHNOLOGY Performance options of the TCT System include: SYSTEM™ • Anti-Roll back to limit backward motion of the vehicle down an incline to less than 2 mph (3 kph).
  • Page 66 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. At monthly intervals, test the TCT system by allowing the vehicle to roll down an incline with the accelerator pedal released.
  • Page 67 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. allowing the vehicle to roll freely before damage can be of the motor. Magnetic pulses are converted into electri- done.
  • Page 68 ELECTRONIC SPEED CONTROL - TCT 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. Battery Reference Floor jack ..............1 Voltage Jack stands..............2 Wheel chocks ..............
  • Page 69 ELECTRONIC SPEED CONTROL - TCT 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’...
  • Page 70 ELECTRONIC SPEED CONTROL - TCT 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 71 ELECTRONIC SPEED CONTROL - TCT 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 72 ELECTRONIC SPEED CONTROL - TCT 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 73 ELECTRONIC SPEED CONTROL - TCT 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 74 ELECTRONIC SPEED CONTROL - TCT 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 75 ELECTRONIC SPEED CONTROL - TCT 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"...
  • Page 76 ELECTRONIC SPEED CONTROL - TCT 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 77 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTROLLER REPLACEMENT SOLENOID REPLACEMENT Tool List Qty. Tool List Qty. Socket, 3/8" ..............1 Socket, 3/8"...
  • Page 78 ELECTRONIC SPEED CONTROL - TCT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Reconnect the BL- battery cable and replace the seat. Red Wire Ring Terminal From Main Wire Harness SOL- From Controller SOL+ Blue Wire Ring Terminal...
  • Page 79 ELECTRONIC SPEED CONTROL - TCT 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 80 ELECTRONIC SPEED CONTROL - TCT 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 81 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 82 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 83 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 84 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 85 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 86 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 87 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 88 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 89: 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 90 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: Page H-ii Repair and Service Manual...

  • Page 91: Battery Maintenance

    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 Always observe the following warnings when working on or facility.
  • 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. At Each Charging Cycle and the increase in volume of the electrolyte that results from the charging cycle. To reduce the possibility of fire, never attach a Do not overfill batteries.
  • Page 93 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. batteries which should also be sprayed with the sodium Watering gun similar to the type included in the bicarbonate (baking soda) solution.
  • Page 94 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (baking soda) and water and thoroughly dried before the battery terminals and battery wire terminals with a priming and painting with a corrosion resistant paint.
  • Page 95 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Prolonged Storage Battery charger, controller and other electronic devices need to be disconnected since they will contribute to the premature discharge of batteries.
  • Page 96 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. that may result from personnel running over or trip- Hydrometer ping over the cord set. A hydrometer (P/N 50900-G1) is used to test the state of •...

  • Page 97: Using A 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. weak cell, the battery or batteries should be removed and replaced with a good battery of the same brand, type and approximate age.
  • Page 98 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: Page H-8 Repair and Service Manual...

  • Page 99: Electrical System

    ELECTRICAL SYSTEM TABLE OF CONTENTS FOR SECTION ’J’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ............................. J - 1 TROUBLESHOOTING ..............................J - 1 POWER SUPPLY ................................ J - 4 MAIN & ACCESSORY WIRING ..........................J - 4 LIST OF ILLUSTRATIONS Fig.
  • Page 100 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page J- ii Repair and Service Manual...
  • Page 101 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 In order to effectively troubleshoot the circuits that A typical DVOM (digital volt ohm meter) is shown (Ref. include the horn, lighting, brake/turn signals and Fig.
  • Page 102 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 Driver Side Passenger Side converter Turn Marker Headlight Headlight...
  • Page 103 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 GRAY GREEN WHITE GREEN WHITE ORANGE/RED ORANGE/RED BLACK BLACK BLUE...
  • Page 104 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 3. Check Converter Supply Firmly attach the black probe (-) to the most negative Tool List Qty.
  • Page 105 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 Fig. 5 Electrical Accessories Repair and Service Manual Page J-5...
  • Page 106 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 Key Switch and Key set Turn Signal Flasher unit Turn Singal Switch Assembly Fuse Block Floorboard Horn Button Horn...
  • Page 107 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURN SIGNAL HEAD LIGHT & TAIL LIGHTS 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 108 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page J-8 Repair and Service Manual...
  • Page 109 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 110 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 111 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 Identification Hole* Service Brake Pedal Pedal Latch Spacer Kick Off Catch Bracket Cap Screw...
  • Page 112 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 113 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 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 FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Condition of: Replace Includes...
  • 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. Disassemble Adjuster Tries Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.
  • 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 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 117 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 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 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 119 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 120 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 121 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. Over time, a subtle loss of performance may take place;...
  • 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. To perform an Aggressive Stop Test, equally load both friction surface. Turning will make the drum too sides of the vehicle (Ref.
  • 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. 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 124 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 125 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 126 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 127 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lubricate the backing plate friction points of the shoes Backing Plate/Entire Wheel Brake Assembly and moving anchor with Multi Purpose Grease (MPG) Removal and Installation lubricant (Ref.
  • 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. Always replace both brake shoes on both wheels as a Heavy Shoe Spring set. Install the shoes as indicated and install the shoe clamp (5) over the shoe clamp pin (4) and rotate 90°...
  • 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. replace if needed. Remove the brake cable and equalizer the bracket. Move the hook back and to the side to assembly and discard.
  • 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. 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 131 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 132 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 133: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................L - 1 PORTABLE CHARGER INSTALLATION ..............L - 1 UNDERSTANDING THE CHARGER ................ L - 2 LED DISPLAY INFORMATION................. L - 2 LED Operation Codes ..................L - 2 LED Fault Codes....................L - 2 MAINTENANCE INSTRUCTIONS ................
  • Page 134 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page L-ii Repair and Service Manual...
  • Page 135 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 136: Understanding The Charger

    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 137 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 L-3...
  • Page 138 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page L-4 Repair and Service Manual...

  • Page 139: 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 ......................
  • Page 140 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page M-ii Repair and Service Manual...
  • Page 141 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of NOTICE removal except that the shock absorber nuts (2,5) must be tightened until the shock absorber bushings (6) In the following text, there are references to removing/installing expand to the diameter of the shock absorber washer...
  • Page 142 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Rear Suspension Repair and Service Manual Page M-2...
  • Page 143 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 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: Page M-4 Repair and Service Manual...

  • Page 145: 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 ....................
  • Page 146 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 147 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 148 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 149 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 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-4 Repair and Service Manual...
  • Page 151 WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD................... P - 1 Trailering ......................P - 1 SUN TOP ........................P - 1 Rear Support Installation.................. P - 1 Front Strut ......................P - 1 Sun Top ......................
  • Page 152 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 P-ii Repair and Service Manual...
  • Page 153 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 Front Strut 1. Remove and discard the four bolts from the front cowl. 2. At the upper hole (both sides of vehicle), install the front strut (7) with bolt ( 8) and lock washer (9) on the The top does not provide protection from roll outside of strut, and a spacer (10) between the front...
  • Page 154 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 Front of Vehicle Fig. 1 Sun Top Repair and Service Manual Page P-2...
  • Page 155 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 NOTICE Remove protective covering from the windshield (3 or 4) (Ref. Fig. 2 on Page P-3). It may be necessary on early production sun tops to drill a "...
  • Page 156 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 157 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-5...
  • Page 158 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 P-6 Repair and Service Manual...
  • Page 159 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 160 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 161 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 162 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 163 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 164 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 165 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 166 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 167 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 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 R-ii Repair and Service Manual...
  • Page 169 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 170 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 171 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 172 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 173 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 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: Page S-ii Repair and Service Manual...
  • Page 175 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 : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 1.
  • Page 176 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: EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding Rev -, ECN 027194 10/19/92 6.
  • Page 177 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 : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 trating or structurally damaging the building.
  • Page 178 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 S-4 Repair and Service Manual...

  • Page 179: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ’T’ SECTION TITLE PAGE NO. SHUTTLE 4X ..............................T - 1 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions ............................T - 2 Fig. 2 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter ........... T - 3 Fig.
  • Page 180 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page T-ii Repair and Service Manual...
  • Page 181 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE 4X TYPE: ELECTRIC POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 619212 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS...
  • Page 182 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 52.4 in (133.0 cm) 5.5 in (14.0 cm) 74.5 in. 65.5 in (166.0 cm) (189.0 cm) 106.0 in (268.0 cm) Front 38.0 in.
  • Page 183 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER SHUTTLE 4X 20.5 ft (6.3 m) Fig. 2 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter Repair and Service Manual Page T-3...
  • 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. 11.4" (28.9 cm) 7.8" (19.8 cm) 1.8" (4.5 cm) 6.3" (16 cm) 1.4" 3.5cm 2.5" (6.3 cm) 10.5"...
  • 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. Notes: Repair and Service Manual Page T-5...
  • 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. Notes: Repair and Service Manual Page T-6...
  • Page 187 NOTICE NOTICE Read the following warnings before attempting to operate the Read and understand the following text and warnings before vehicle: attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. It is virtually impossible to anticipate all possible compo- To prevent personal injury or death, nent failures or the manner in which each component...
  • Page 188 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department...

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