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Fairplay ZX Manual

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Mal
February 5, 2025

Where is the reverse buzzer located

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1 comments:
Thomas (tom) coulter
March 12, 2025

@Mal show backup alarm

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ashcraft
June 24, 2025

any way to get a replacement key

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Summary of Contents for Fairplay ZX

  • Page 2 Division of FAIRPLAY CO. LTD. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 3 SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact an FAIRPLAY representative for clarification. 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.
  • Page 4 A WARNING indicates a hazardous condition which could result in serious injury or death. Please observe these NOTES, CAUTIONS and WARNINGS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.
  • Page 5 ◆ To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, with vehicle serial number and manufacturer code. ◆ The use of non FAIRPLAY parts may void the warranty. ◆ Overfilling of batteries may void the warranty.
  • Page 6 The information contained in this manual is subject to change without notice. FAIRPLAY Company is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 7 Do not make any such modifications or changes. FAIRPLAY prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
  • Page 8 Always use specified replacement parts. Never use replacement parts of lesser quality. Always use recommended tools. Always determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle. Always support the vehicle using wheel chocks and safety stands.
  • Page 9 CONTENTS GENERAL INFORMATION & ROUTINE MAINTENANCE ------------------------------------A SAFETY ---------------------------------------------------------------------------------------------------------B FRONT SUSPENSION AND STEERING ---------------------------------------------------------------C REAR SUSPENSION -----------------------------------------------------------------------------------------D REAR AXLE --------------------------------------------------------------------------------------------------------E MECHANICAL BRAKES---------------------------------------------------------------------------------------F WHEELS AND TIRES--------------------------------------------------------------------------------------------G MOTOR --------------------------------------------------------------------------------------------------------------H ELECTRONIC SPEED CONTROL ------------------------------------------------------------------------I BATTERY CHARGER -----------------------------------------------------------------------------------------J BODY -----------------------------------------------------------------------------------------------------------------K ACCESSORY WIRINGS ---------------------------------------------------------------------------------------------L P A I N T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - M TROUBLESHOOTING ---------------------------------------------------------------------------------------N GENERAL SPECIFICATIONS ------------------------------------------------------------------------O...

  • Page 10: Table Of Contents

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS SERIAL NUMBER PLATE LOCATIO--------------------------------------------------------------------------A-2 TOWING-------------------------------------------------------------------------------------------------A-2 SERVICING THE VEHICLE-------------------------------------------------------------------------A-4 ROUTINE MAINTENANCE--------------------------------------------------------------------------A-6 REAR AXLE---------------------------------------------------------------------------------------------A-6 REPLACING THE LUBRICANT---------------------------------------------------------------------------- A-7 DAILY BRAKE TEST---------------------------------------------------------------------------------------- A-7 VEHICLE CONTROL SYSTEM------------------------------------------------------------------ A-8 TIRES---------------------------------------------------------------------------------------------------A-8 CARE AND CLEANING OF THE VEHICLE-------------------------------------------------- A-8...

  • Page 11: Serial Number Plate Locatio

    Fig.A1 Serial Number Plate Location TOWING Tow bars applicable to your vehicles may be ordered from FAIRPLAY Service Part Department. Prior to towing operation, the Run-Tow/Maintenance switch of vehicles should be set to its position “Tow/” in order to protect the motor and controller from damage.

  • Page 12: Fig.a2 Run-Tow/Maintenance

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section A and B completely prior to operation or repair of golf car should be used when towing vehicle. Do not tow a single vehicle in excess of 12 mph (19 kph), or multiple vehicles (not more than 3 towed vehicles) in excess of 5 mph (8 kph).

  • Page 13: Servicing The Vehicle

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section A and B completely prior to operation or repair of golf car SERVICING THE VEHICLE Read and understand the following text and warnings before attempting to service a vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

  • Page 14: Fig.a3 Initial Service Chart

    Read section B completely prior to operation or repair of golf car intervals, is the best guarantee for keeping the FAIRPLAY vehicle both dependable and economical. Before attempting to carry out any electric service of vehicles, the Run-Tow/Maintenance switch must be set to its Tow/Maintenance' position.

  • Page 15: Routine Maintenance

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section A and B completely prior to operation or repair of golf car ROUTINE MAINTENANCE This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic Service Schedule (Ref Fig.A8) for appropriate service intervals. Refer to Lubrication Points (Ref FigA4) for appropriate lubrication locations.

  • Page 16: Replacing The Lubricant

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section B completely prior to operation or repair of golf car REPLACING THE LUBRICANT To replace lubricant, it is required to jack up the vehicle, clean the surface around the oil filler plug, and then remove the oil filler plug. Remove the oil drain bolt to discharge the lubricant inside the rear axle casing, tighten the oil drain bolt, and fill up fresh lubricant of 1.5L from oil filler plughole.

  • Page 17: Vehicle Control System

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section A and B completely prior to operation or repair of golf car VEHICLE CONTROL SYSTEM According to the monthly interval, the vehicle control system may be tested by releasing the accelerator pedal and allowing the vehicle to run upward steep slope, and it indicates that the brake system may function if the vehicle is braked when the pedal is released.

  • Page 18: Vehicle Care Products

    Read section B completely prior to operation or repair of golf car VEHICLE CARE PRODUCTS To help maintain the vehicle, FAIRPLAY recommends several products, available through a local Distributor, an FAIRPLAY Branch, or the FAIRPLAY Service Parts Department. Touch-up paint specially formulated to match vehicle colors for use on both metal and plastic bodies.

  • Page 19: Hardware

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section A and B completely prior to operation or repair of golf car If the vehicle is to be transported on a trailer at highway speeds, the windshield and top must be removed and the seat bottom secured. Always check that the vehicle and contents are adequately secured before trailering vehicle.

  • Page 20: Periodic Service Schedule

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section B completely prior to operation or repair of golf car PERIODIC SERVICE SCHEDULE Check ◆Clean, Adjust, etc. ▲Replace Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions. DAILY BODY Clean body components as required...

  • Page 21: Fig.a8 Periodic Service Schedule

    GENERAL INFORMATION& ROUTINE MAINTEN NCE Read section A and B completely prior to operation or repair of golf car ABSORBERS FRONT SPRINGS Check for loose hardware, cracks at attachments Check for unusual tire wear, align if required. See FRONT FRONT WHEEL ALIGNMENT SUSPENSION AND STEERING section Check for bent/binding linkage rod Check for damage or wear to latch arm or catch bracket...

  • Page 22: Table Of Contents

    SAFETY Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS GENERAL (MAINTENANCE AND OPERATIONS)------------------------------------------B-2 NOTES, CAUTIONS AND WARNINGS---------------------------------------------------------------B-11 IMPORTANT SAFETY WARNING-------------------------------------------------------------------B-11 MODIFICATIONS TO VEHICLE----------------------------------------------------------------------B-12 GENERAL MAINTENANCE---------------------------------------------------------------------------B-12 BEFORE SERVICING THE VEHICLE--------------------------------------------------------------B-12 OTHER WARNINGS------------------------------------------------------------------------------------B-13 (CARS)BATTERY REMOVAL &...

  • Page 23: General (Maintenance And Operations

    SAFETY Read section A and B completely prior to operation or repair of golf car GENERAL MAINTENANCE AND OPERATIONS GENERAL SAFETY PRACTICES Introduction Like other machines, golf cars can cause injury if improperly used or maintained. This section contains broad safety practices recommended for safe golf car operations. Before operation, the controlling party should establish such additional specific safety practices as may reasonably be required for safe operations.
  • Page 24 SAFETY Read section A and B completely prior to operation or repair of golf car be repaired if possible, or chained or roped off to prevent golf car operation or identified by a suitable warning to operators not to operate golf cars in this area due to loose terrain or possible hazardous conditions.
  • Page 25 SAFETY Read section A and B completely prior to operation or repair of golf car gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air changes per hour is recommended. The controlling party shall consult applicable fire and safety codes for the specific ventilation levels required as well as the use of explosion proof electrical apparatus.
  • Page 26 SAFETY Read section A and B completely prior to operation or repair of golf car The controlling party shall maintain in a legible condition all nameplates, warnings and instructions which are supplied by the manufacturer. The controlling party shall not perform any modification or addition which affects capacity or safe operation, or make any change not in accordance with the owner's manual without the manufacturer's prior written authorization.
  • Page 27 SAFETY Read section A and B completely prior to operation or repair of golf car Like other machines, golf cars can cause injury if improperly used or maintained. This section contains broad safety practices applicable to golf car operations. Before operation, the user shall establish such additional specific safety practices as may reasonably be required for safe operation.
  • Page 28 SAFETY Read section A and B completely prior to operation or repair of golf car sound-producing and/or visual devices and be responsible for providing and maintaining such devices, in accordance with the manufacturer's recommendations. OPERATING SAFETY RULES AND PRACTICES Personnel and Burden Golf car Operator Qualifications Only persons who are trained in the proper operation of the golf car shall be authorized to operate the golf car.
  • Page 29 SAFETY Read section A and B completely prior to operation or repair of golf car When a golf car is to be left unattended, stop golf car, apply the parking brake, stop the engine or turn off power, turn off the control or ignition circuit, and remove the key if provided. Block the wheels if machine is on an incline.
  • Page 30 SAFETY Read section A and B completely prior to operation or repair of golf car Under all travel conditions the golf car shall be operated at a speed that will permit it to be brought to a stop in a safe manner. Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift the load, endanger passengers, or overturn the golf car.
  • Page 31 SAFETY Read section A and B completely prior to operation or repair of golf car Do not operate a golf car with a leak in the battery(s). Do not use open flames for checking electrolyte level in storage battery(s). MAINTENANCE PRACTICES Introduction Golf cars may become hazardous if maintenance is neglected.

  • Page 32: Notes, Cautions And Warnings

    SAFETY Read section A and B completely prior to operation or repair of golf car modifications have been made, the user shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are changed accordingly. ◆ Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment.

  • Page 33: Modifications To Vehicle

    SAFETY Read section A and B completely prior to operation or repair of golf car MODIFICATIONS TO VEHICLE Do not modify the vehicle in any manner that will change the weight distribution of the vehicle. Changes to the weight distribution or the center of gravity may make the vehicle unstable or prone to roll over which could result in injury or death to the operator or passenger (s).

  • Page 34: Other Warnings

    SAFETY Read section A and B completely prior to operation or repair of golf car OTHER WARNINGS Before working on the electrical system, be sure to read and understand the following warnings that pertain to electrical system repair or maintenance: Keep all exothermic materials, open flame or sparks away from the batteries.

  • Page 35: (Cars)Battery Removal & Installation

    SAFETY Read section A and B completely prior to operation or repair of golf car Battery Removal & Installation Tool List Qty. Required Insulated open end wrench, 13# ......1 Socket, 10# and 13#, for drive device ....1 Battery golf car ............. 1 Torque wrench, in.

  • Page 36: Lifting The Vehicle

    SAFETY Read section A and B completely prior to operation or repair of golf car Inspect all wires and terminals and clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate (baking soda) and wire brush if required. Use care to connect the battery cables as shown in the following illustration (Ref Fig.
  • Page 37 SAFETY Read section A and B completely prior to operation or repair of golf car Lower the jack and test the stability of the vehicle on the two jack stands. Place the jack at the center of the front axle. Raise the vehicle and position jack stands under the frame crossmember as indicated.
  • Page 38 FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS FRONT SHOCK ABSORBER REPLACEMENT ---------------------------------------------------------------------C-2 FRONT AXLE REPLACEMENT------------------------------------------------------------------------------------------C-3 FRONT SPRING REPLACEMENT --------------------------------------------------------------------------------------C-5 TIE ROD, WHEEL BEARING, KING PIN INSPECTION ---------------------------------------------------- -------C-6 TIE ROD REPLACEMENT------------------------------------------------------------------------------------------ -------C-7 STEERING WHEEL REPLACEMENT--------------------------------------------------------------------------- -- -- -C -8 UNIVERSAL JOINT REPLACEMENT --------------------------------------------------------------------------- -- -- -C -9...

  • Page 39: Front Shock Absorber Replacement

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Additional hardware that is removed must always be installed in ins original position unless otherwise specified. Non-specified specifications are as shown in the table contained in Section A. To prevent possible injury or death, follow the lifting procedures in Section B of this manual.

  • Page 40: Front Axle Replacement

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Installation of shock absorber is reverse of disassembly. The only difference is that the mounting nuts should be tightened until rubber bushings (5) expand to diameter of shock absorber washers (6). Front Axle Replacement Tool List Qty.
  • Page 41 FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car spindle, and turn them to the side. Remove the hardware (12) that secures the front end of spring leaf to the front axle. Front axle installation is the reverse order of disassembly.

  • Page 42: Front Spring Replacement

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Front Spring Replacement Tool List Qty. Required Wheel chocks ............4 Floor jack.............. 1 Jack stands ............4 Torque wrench............1 Air impact wrench ..........1 Socket.16# ............

  • Page 43: Tie Rod, Wheel Bearing, King Pin Inspection

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car After the springs are replaced, the axle will need to be aligned to frame. Unless the axle has been replaced, wheel alignment will not be affected. However, it is always good practice to check wheel alignment any time the front-end components are replaced or adjusted.

  • Page 44: Steering Wheel Replacement

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Fig. C5: Tie Rod Replacement A worn tie rod is likely caused by incorrect wheel alignment. Before returning the repaired vehicle to the customer, the wheels shall be positioned and aligned correctly (Ref Fig. C14). Adjust the tie rod to 25.39 inches (64.5 centimetres) from both-end center of tie rod, and the installation sequence is just reverse of disassembly (Ref Fig.
  • Page 45 FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Fig. C6: Clipboard Removal To prevent damage to the clipboard, perform the following removal procedures. Do not use a screwdriver to push or pry the retaining tabs. From the front side of the steering wheel (4), remove the clipboard (5) by first pulling straight up on the bottom of the clipboard to release the two bottom retaining tabs and raising the locking tabs on top of the steering wheel (Ref Fig.

  • Page 46: Universal Joint Replacement

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Fig. C7: Steering Wheel Replacement Universal Joint Replacement Tool List Qty. Required Air impact wrench ..........1 Socket 13# ............1 White chalk............1 First align the front wheels to the straight ahead position, remove the set bolt (27) from both ends of the universal joint, allow the universal joint to draw back to its center and separate itself from the steering shaft (12) and steering gear case (14) (Ref Fig.

  • Page 47: Steering Gear Case Assembly Replacement

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Socket 13# ............1 Inner snap ring pliers ..........1 Outer snap ring pliers ........... 1 Bearing separator ..........1 Remove the steering wheel and universal joint (as stated before). Remove the combination switch (8) and ornament strip (25), and remove the four connecting bolts (19) that secure the steering column (9) (Ref Fig.

  • Page 48: Wheel Bearing Inspection/Lubrication

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Open end wrench 17# .......... 1 Socket 17# ............1 Torque spanner ............ 1 Socket 13# ............1 Floor jack.............. 1 Unless the steering gear case assembly is severely damaged, it is unnecessary to remove the steering gear case (14) from the vehicle.

  • Page 49: Seal Installation

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Remove the front wheels, and remove from spindle the dust cap (14), cotter pin (15), castellated nut (16), exterior roller bearing (18), and hub splice plate (17) (Ref Fig. C9). Use relatively soft Nonferrous punch to tap the periphery of exterior hub bearing race, and remove the inner shaft oil seal (20), inner roller bearing (18), and bearing race (19).

  • Page 50: Bearing Adjustment

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car Fig.C10:Seal Installation BEARING ADJUSTMENT Assemble hub and install on spindle. Reinstall the wheel onto the hub. Rotate the wheel while tightening the castellated nut (1) (Ref Fig. C11). Tighten the castellated nut till slight resistance may be felt. Fig.

  • Page 51: King Pin Bush Replacement

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car KING PIN BUSH REPLACEMENT Tool List Qty. Required Floor jack.............. 1 Jack stands ............2 Wheel chocks ............4 Pliers ..............1 Torque wrench, ft lb, specification: 1/2 inch ..

  • Page 52: Wheel Alignment

    FRONT SUSPENSION AND STEERING Read section A and B completely prior to operation or repair of golf car WHEEL ALIGNMENT Tool List Qty. Required Floor jack.............. 1 Jack stands ............2 Wheel chocks ............4 Line tape............... 1 Chalk ..............1 16# Open end wrench ..........
  • Page 53 REAR SUSPENSION Read section A and B completely prior to operation or repair of golf car. TABLE OF CONTENTS SHOCK ABSORBER REMOVAL----------------------------------------------------------------------------------D-2 SHOCK ABSORBER INSTALLATION---------------------------------------------------------------------------D-3 REAR LEAF SPRING REMOVAL----------------------------------------------------------------------------------D-3 REAR LEAF SPRING INSTALLATION--------------------------------------------------------------------------D-3 REAR AXLE ASSEMBLY REMOVAL----------------------------------------------------------------------------D-3 REAR AXLE INSTALLATION--------------------------------------------------------------------------------------D-5 LIST OF ILLUSTRATIONS D1: Disconnect Battery Cable----------------------------------------------------------------------------D-4 Fig.

  • Page 54: Shock Absorber Removal

    REAR SUSPENSION Read section A and B completely prior to operation or repair of golf car In the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in their original positions unless otherwise specified.

  • Page 55: Shock Absorber Installation

    REAR SUSPENSION Read section A and B completely prior to operation or repair of golf car. Shock Absorber Installation Shock absorber installation is in the reverse order of disassembly except that the shock absorber nuts (1,3) must be tightened until the shock absorber bushings (4) expand to the diameter of the shock absorber washer (5).
  • Page 56 REAR SUSPENSION Read section A and B completely prior to operation or repair of golf car remove wires from the motor。 (See safety procedures in SAFETY section of this manual). The shorting of motor wires could cause an explosion. Before any electrical service is performed on PDS model vehicles, the “Run-Tow/Maintenance”...

  • Page 57: Rear Axle Installation

    REAR SUSPENSION Read section A and B completely prior to operation or repair of golf car. Rear Axle Installation Assembly is in the reverse order of disassembly. Tighten the motor terminal fastening pieces to 66 inch pound (7 N.m) (Ref Fig. D2), (Ref Fig. D3). Install a new cotter pin.
  • Page 58 REAR AXLE Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS REAR AXLE DISASSEMBLY-----------------------------------------------------------------------------------------------E-2 AXLE SHAFT REMOVAL AND DISASSEMBLY----------------------------------------------------------------------E-2 REAL AXLE SHAFT SEAL REMOVEMENT AND REPLACEMENT--------------------------------------------E-2 REAR AXLE SHAFT REPLACEMENT----------------------------------------------------------------------------------E-3 LIST OF ILLUSTRATIONS Fig.
  • Page 59 Use a puller to remove the seal (Ref Fig. E2). Use care to prevent damage to the inner surface of the axle tube at the sealing area. To install the seal, use the special FAIRPLAY seal installer to drive the seal into its correct position.
  • Page 60 REAR AXLE Read section A and B completely prior to operation or repair of golf car To prevent seal damage, lightly coat the axle shaft with bearing grease and support the shaft during installation. Fig. E1: Removing/installing Rear Axle Shaft Fig.
  • Page 61 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS BRAKE SYSTEM OVERVIEW-------------------------------------------------------------------------------------------- F-3 GENERAL DESCRIPTION---------------------------------------------------------------------------------------------F-3 HOW THE SERVICE BRAKE WORKS-----------------------------------------------------------------------------------F-4 EQUALIZER LINK-----------------------------------------------------------------------------------------------------------F-4 AUTOMATIC ADJUSTER MECHANISM-------------------------------------------------------------------------------F-4 HOW THE PARKING BRAKE WORKS---------------------------------------------------------------------------------F-5 COMPENSATOR ASSEMBLY----------------------------------------------------------------------------------------------F-6 KICK-OFF ACTUATING LINKAGE---------------------------------------------------------------------------------------F-7 TROUBLESHOOTING FLOWCHART----------------------------------------------------------------------------------F-10...
  • Page 62 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F7 Troubleshooting Table(Continued)------------------------------------------------------------------------ ----F-11 Fig. F8: Brake Pedal Bumper Inspection------------------------------------------------------------------------------ F-12 Fig. F9: Brake Pedal Inspection------------------------------------------------------------------------------------------F-13 Fig. F10: Check Free Travel ----------------------------------------------------------------------------------------------F-13 Fig. F11: Equalizer and Compensator----------------------------------------------------------------------------------F-15 Fig.

  • Page 63: Brake System Overview

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F1: Mechanical Brake System BRAKE SYSTEM OVERVIEW General Description This vehicle is equipped with a mechanically activated rear drum brake system. The brake system consists of a service brake and parking brake pedal, parking brake release linkage, Compensator assembly, equalizer link, brake cable, and self adjusting wheel brake assembly (Ref Fig.

  • Page 64: How The Service Brake Works

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car How the Service Brake Works Depressing the service brake pedal pulls the compensator assembly and equalizer link, which are connected to the brake cables (Ref Fig. F1). The first part of the pedal travel removes slack from the system.

  • Page 65: How The Parking Brake Works

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Brakes adjust only while the vehicle is moving. When the brake pedal is depressed, the brake lever moves toward the front of the vehicle (A). The other end of the brake lever moves to the rear of the vehicle (B) where it contacts the brake adjuster arm, causing it to move.

  • Page 66: Compensator Assembly

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig.F3: Parking Brake Kick-Off Mechanism As the parking brake is depressed, the service brake is applied until the notch in the latch arm engages with the catch bracket.

  • Page 67: Kick-Off Actuating Linkage

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Kick-Off Actuating Linkage The kick-off actuating linkage may require periodic adjustment to compensate for the normal wear. Replacement of any linkage components will also require an adjustment. As the parking brake is depressed, the service brake is applied until the notch in the latch arm engages with the catch bracket.
  • Page 68 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Visually Check Condition of: Remove the two brake BRAKE CABLES: Visual External drums, and do not fiddle Inspection Adjustment and with the brakes Worn condition Includes correction Damage condition...
  • Page 69 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Can not Does the adjuster require to Disassemble Install wheel and tire, move the star wheel? Can brake, clean, check tire pressure. the star wheel rotate? lube.

  • Page 70: Troubleshooting Table

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car 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 Fig F6 on page F-9). Trouble Probable Cause Solution...

  • Page 71: New Vehicle Troubleshooting And Inspection

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Brake pivot hardware is rusted Replace or sticky Brake system requires complete Adjust entire system adjustment Wheel do not lock Check brake pedal linkage Brake pedal not returning Check the brake pedal free travel Drive the vehicle at maximum level...

  • Page 72: Brake Pedal And Linkage Inspection

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Instructions for removal or replacement of parts and adjustments referred to in this section of the manual are described in detail under 'MAINTENANCE AND REPAIRS'. Satisfactory brake performance does not eliminate the need for routine brake testing and inspection as shown on the Periodic Service Schedule in Section A.
  • Page 73 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F9: Brake Pedal Inspection Brake pedal free travel is the distance the pedal moves from rest to the point at which the brake shoes first contact the brake drums.
  • Page 74 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car The brake pedal latching force may be checked as verification after setting brake pedal free travel; to check parking brake latching force, place a 'bathroom' scale on the service and parking brake pedals. Using both feet press the scale down against the parking brake pedal until it latches.
  • Page 75 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F11: Equalizer and Compensator 9. Check the condition and operation of the parking brake latching mechanism. The parking brake should latch firmly and release as soon as the accelerator pedal is depressed. Fig.

  • Page 76: Periodic Brake Performance Test (Pbpt

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car The parking brake latch arm, kick-off cam and catch bracket are hardened parts. Do not grind or file them. New parts must be used. 10.
  • Page 77 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car The Periodic Brake Performance Test (PBPT) should be performed regularly (see Periodic Service Schedule in the GENERAL INFORMATION AND ROUTINE MAINTENANCE section of this manual) as an evaluation of braking system performance.
  • Page 78 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F14: Periodic Brake Performance Test Repeat test two more times. If the vehicle fails to pass two of three Periodic Brake Performance Tests, perform the Aggressive Stop Test 10 times as described below, then repeat the Periodic Brake Performance Test three more times (second set of three).

  • Page 79: Aggressive Stop Test

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Aggressive Stop Test All brake tests must be done in a safe location with regard for the safety of all personnel. Always conduct a visual inspection and evaluate pedal travel before operating a vehicle to verify some braking function is present.
  • Page 80 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car pressurized air to blow dust from brake assemblies. Replace both brake shoes on both wheels if one or more shoes are worn below . 06" (1.5mm) thickness at any point. Do NOT touch any of the wheel brake mechanism except as instructed.
  • Page 81 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Operate the brake lever. Observe the brake adjuster arm and note if the arm engages the star wheel and attempts to rotate it (Ref Fig.
  • Page 82 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car 9.Measure the brake shoe thickness. Measure at the most worn area. Brake shoe thickness must never be less than .06" (1.5 mm) at any point on the shoe.

  • Page 83: Maintenance And Repairs

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car 11. Repeat procedure at the opposite wheel brake. 12. Check/adjust brake pedal free travel. Whenever the brake system is serviced or requires a parts replacement, the brake pedal free travel must be checked and adjusted.

  • Page 84: Adjusting Brake Pedal Free Travel

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Adjusting Brake Pedal Free Travel Brake pedal free travel MUST be checked and adjusted any time that the brake system is serviced or when parts are replaced. Brake pedal free travel is the distance the pedal travels from rest to the point at which the brake cables start to move the brake levers.

  • Page 85: Brake Drum Removal And Installation

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car At the spherical nut, adjust the free travel as noted above. Drive again and brake aggressively 10 times. Repeat the previous step(s) until the pedal free travel does not change during the aggressive braking. Check to see that the clevis pins attaching the brake cables to the brake levers are loose (Ref Fig.
  • Page 86 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F21: Checking Parking Brake Latching Pressure Fig. F22: Brake Assembly Use care when raising the adjuster arm. Too much force will damage the adjuster and require that both wheel brake assemblies be replaced.

  • Page 87: Wheel Brake Service

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car To install the brake drum, clean the axle shaft and the splines on the brake drum to remove dirt, grease and foreign matter, and tighten the tire nuts to 70-80ft lb (95-108 N·m). Wheel Brake Service Wheel brake service consists of disassembly, cleaning, inspection, lubrication and re-assembly of the wheel brake.
  • Page 88 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F23: Wheel Brake Lubrication Points Install the actuator components, adjuster components and brake shoes. See “Brake Shoe and Adjuster Replacement”. If the brake shoes and drum are not to be replaced, sand the friction surfaces lightly with emery cloth to remove any foreign material.

  • Page 89: Backing Plate/Entire Wheel Brake Assembly Removal And Installation

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Backing Plate/Entire Wheel Brake Assembly Removal and Installation Remove the four bolts (4) and lock nuts (5) securing the wheel brake backing plate to the flange on the axle tube (Ref Fig.
  • Page 90 MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Be sure that the adjusting screw is screwed into the star wheel nut until only 1 - 2 threads are exposed. Install the adjuster mechanism. Be sure the two Teflon-coated washers are installed as shown (Ref Fig. F22).

  • Page 91: Brake Cable And Equalizer Assembly Removal And Installation

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Brake Cable and Equalizer Assembly Removal and Installation The brake cables and equalizer are only serviceable as a complete assembly. Remove the cotter pins and clevis pins connecting the brake cables to the brake levers. Remove the retaining rings connecting the brake cables to their brackets at the axle (rear of cable) and at the frame (front of cable/.

  • Page 92: Brake Pedal Removal And Installation

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Adjust the brake pedal free travel. See “Adjusting Brake Pedal Free Travel”. Brake Pedal Removal and Installation Disconnect the compensator assembly (1) from the brake pedal by removing the cotter pin (2) and the clevis pin (3).

  • Page 93: Parking Brake Pedal,Removal And Installation

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F27: Brake Pedal Removal and Installation Fig. F28: Catch Bracket and Latch Arm Parking Brake Pedal, Removal and Installation Note the location and orientation of the two torsion springs (8). Remove the push nut (9) and pin (10) (Ref Fig.

  • Page 94: Parking Brake Release Linkage Removal And Replacement

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Pedal Bumper Adjustment Loosen the bumper lock nut and adjust the bumper by rotating it (Ref Fig. F29). The brake pedal must contact the pedal bumper when pedal is released and the dimension from the top of the pedal arm to the setscrew heads in the kick-off cam should be approximately 1/4"...

  • Page 95: Parking Brake Release Linkage And Kick-Off Cam, Removal And Installation

    MECHANICAL BRAKES Read section A and B completely prior to operation or repair of golf car Fig. F30：Parking Brake Release Linkage and Kick-Off Cam Removal and Installation Parking Brake Release Linkage and Kick-Off Cam, Removal and Installation Disconnect the parking brake release linkage as described above. Loosen the two set screws (5) from the cam (6) and remove the cam pivot (7), cam and spacer (8) (Ref Fig.
  • Page 96 WHEELS AND TIRES Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS W H E E L A N D T I R E S E RV I C E - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 2 TIRE REPAIR------------------------------------------------------------------------------------------------------------------G-2 WHEEL INSTALLATION----------------------------------------------------------------------------------------------------G-3 LIST OF ILLUSTRATIONS...
  • Page 97 WHEELS AND TIRES Read section A and B completely prior to operation or repair of golf car WHEEL AND TIRE SERVICE Tool List Qty. Required Air impact wrench 19# Socket Torque wrench (torque wrench over 100) Tire condition should be inspected on a daily basis. Inflation pressure should be checked when the tires are cool.
  • Page 98 WHEELS AND TIRES Read section A and B completely prior to operation or repair of golf car Pressurize tire with small amount of air applied intermittently to seat beads. Never exceed the pressure value recommended by the tire manufacturer. Prevent the ejected air from damaging the face and eyes when removing valve core. The mounting/demounting machine must be anchored to floor.
  • Page 99 WHEELS AND TIRES Read section A and B completely prior to operation or repair of golf car Fig. G1: Wheels and Tires...
  • Page 100 MOTOR Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS REMOVING MOTOR--------------------------------------------------------------------------------------------H-2 DISASSEMBLING MOTOR--------------------------------------------------------------------------------------------H-4 REPLACING BEARING--------------------------------------------------------------------------------------------H-5 REPLACING EXCITING COIL--------------------------------------------------------------------------------------------H-6 REPLACING BRUSH--------------------------------------------------------------------------------------------H-6 BRUSH WEAR----------------------------------------------------------------------------------------------------------------H-7 ASSEMBLING MOTOR--------------------------------------------------------------------------------------------H-8 MOTOR TEST--------------------------------------------------------------------------------------------H-8 INSTALLING MOTOR--------------------------------------------------------------------------------------------H-8 LIST OF ILLUSTRATIONS Fig.

  • Page 101: Removing Motor

    MOTOR Read section A and B completely prior to operation or repair of golf car It is not recommended to remove the motor except for replacing bearings that are worn or give out excessively high noises. When motor is removed, clear up the accumulated dust, and check brush length.
  • Page 102 MOTOR Read section A and B completely prior to operation or repair of golf car Fig. H1: Disconnect Battery Wires Fig. H2: Wheel Shaft and Motor When installing the motor onto the rear bushing, be careful not to damage the splines. Screw off the 6 bolts securing the motor onto the bushing, and pull the motor with care out of the wheel shaft splines.

  • Page 103: Disassembling Motor

    MOTOR Read section A and B completely prior to operation or repair of golf car DISASSEMBLING MOTOR Tool List Qty. Required Flat blade ......screwdriver Ratchet ............ 1 Socket 10#..........1 Plastic faced hammer ....... Insulated wrench 13# ......1 Insulated wrench 14# ......

  • Page 104: Replacing Bearing

    MOTOR Read section A and B completely prior to operation or repair of golf car Remove the bolt (2) securing the commutator end cap (3) onto the motor casing (4). Pull the commutator end cap hard so that the armature (5) and its cover hood may be removed (as a single piece) from the motor casing.

  • Page 105: Replacing Exciting Coil

    MOTOR Read section A and B completely prior to operation or repair of golf car To install armature on the bearing / end cap component, support the inner race of bearing so as to avoid damage. Heat relevant components moderately so as to press the armature into the new bearing. Remove the brush from commutator.

  • Page 106: Brush Wear

    MOTOR Read section A and B completely prior to operation or repair of golf car Fig. H4: Brush Wear BRUSH WEAR Remove the brush terminal component (12) in positions A1 and A2 (Ref Fig. H3). Remove the screw (13) securing the brush board (14). Remove the brush, brush holder, and brush board.

  • Page 107: Assembling Motor

    MOTOR Read section A and B completely prior to operation or repair of golf car ASSEMBLING MOTOR Tool List Qty. Required Socket, specification: 10#..... 1 Torque wrench, specification: 13#..1 Align the rectifier end cap to the motor casing receptacle, and fulfill assembling (Ref Fig. H3). Use bolt (2) to secure the rectifier end cap onto the motor casing, and tighten it to torque of 90 inch-pound (10 N.m).
  • Page 108 Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS GENERAL----------------------------------------------------------------------------------------------------------------------I-2 PEDAL BOX--------------------------------------------------------------------------------------------------------------------I-2 CONTROLLER----------------------------------------------------------------------------------------------------------------I-2 GENERAL TROUBLESHOOTING---------------------------------------------------------------------------------------I-3 SYMPTOMS-------------------------------------------------------------------------------------------------------------------I-3 TESTING-----------------------------------------------------------------------------------------------------------------------I-4 TESTING BATTERY VOLTAGE------------------------------------------------------------------------------------------I-4 CONTINUITY CHECK-------------------------------------------------------------------------------------------------------I-5 TESTING A SWITCH FOR CONTINUITY------------------------------------------------------------------------------I-6 TESTING A SOLENOID FOR CONTINUITY--------------------------------------------------------------------------I-6 CONTROLLER PARAMETERS’...

  • Page 109: General

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car GENERAL The Electronic Speed Control system consists of two separate units, pedal box and controller. To work on the pedal box, remove the rocker panel first, raise the floor mat, and then open the access cover on the floor mat (Ref Fig.

  • Page 110: General Troubleshooting

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Fig. I 2: ADC300 Controller and Solenoid GENERAL TROUBLESHOOTING Tool List Qty. Required Floor jack -------------------------------------------------1 Jack stands ----------------------------------------------2 Wheel chocks -------------------------------------------4 DVOM -----------------------------------------------------1 Socket 13# -----------------------------------------------1 Phillips screwdriver ------------------------------------1...

  • Page 111: Testing

    General mechanical adjustment of pedal box may cause no change, therefore use DVOM to determine the malfunctioning components first. Ordinary DVOM is as shown in the figure. Contact the FAIRPLAY service part department to find out about the DVOM it recommends. Any DVOM may be used; however, the accuracy, controls, displays and features may vary depending on the make and model.

  • Page 112: Continuity Check

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Fig. I 3: Battery Reference Voltage CONTINUITY CHECK Prior to continuity check, turn the key switch to its position “OFF”, and set the direction selector to its FWD/REV.

  • Page 113: Testing A Switch For Continuity

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car TESTING A SWITCH FOR CONTINUITY Place a probe on the switch contact, and another probe on the other terminal (Ref Fig. I4). “BEEP”...

  • Page 114: Controller Parameters' Setup Specification

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Fig. I 5: Continuity Check of Solenoid Controller parameters’ setup specification Warning: This operation can be done only by trained professional technician or OEM electric engineers.
  • Page 115 Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car 4. If the install program detects duplicate files, please keep any files newer than what is on the install disk. 5. Attach the 9-pin D-shell connector to the 9-pin serial port connector on the back of the computer. KC_Host currently uses the PC’s serial port COMM 1 to communicate with controllers.
  • Page 116 Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Screenshot 1 Screenshot 3 Screenshot 2 Activate KC_Host First and User has selected to review KC_Host has established communication begins. Now, and SXDC GC setup values. communication.
  • Page 117 Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Screenshot 4 Screenshot 5 Screenshot 6 All values are allowed to be The User has changed the All values have their ranges modified after you input third setup value from 5 to 4 displayed if the user selects a...

  • Page 118: Test To Controller Fault

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car acceleration rate. Setting of the reverse acceleration Rev Accel Rate rate. A higher number allows a faster 1 – 3 acceleration rate. This setting is to control the deceleration regen rate once the Pedal Off Regen...

  • Page 119: Sxdc Gc Controller Fault Code Retrieval And Solutions

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car SXDC GC CONTROLLER FAULT CODE RETRIEVAL AND SOLUTIONS: Code Sound Implication Solution Remarks Every time 1 long 3 short Controller self-check error Replace controller a fault EEPROM current upper...

  • Page 120: Accelerator Testing And Replacement

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Check for looseness of wire connection of 3 long 8 short Velocity sensor error the velocity sensor, verify that it’s OK, and then restore the towing switch Check for correctness of velocity sensor Excessively high velocity...
  • Page 121 Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Fig. I 7: Accelerator Pedal Box Microswitch Potentiometer Set bolt Adjusting cam Fig. I 8: Potentiometer and Adjusting Cam Accelerator potentiometer is fixed inside a aluminum box by two bolts, be careful not to damage the potentiometer for fear of malfunction.

  • Page 122: Controller Replacement

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Loosen the locating bolt of adjusting cam, and adjust the potentiometer gear Fig. I 9: Potentiometer Adjustment CONTROLLER REPLACEMENT Tool List Qty. Required Socket 10# ----------------------------------------------- 1 Socket 13# ----------------------------------------------- 1 Socket 14# ----------------------------------------------- 1...

  • Page 123: Solenoid Replacement

    Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Open end wrench 13#--------------------------------- 1 Torque wrench ------------------------------------------ 1 Phillips screwdriver ------------------------------------ 1 Hexagon ring spanner 5# ---------------------------- 1 Remove the seat first. BL- must be removed before controller discharging, use a large screwdriver to short-circuit the terminals B+ and B- of controller and have the controller discharged.
  • Page 124 Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Replace the environmental cover and tighten the mounting bolts to torque of 12-15 N·m. Reconnect the BL- battery cable and replace the seat. Fig.
  • Page 125 Electronic Speed Control (Non-PDS) Read section A and B completely prior to operation or repair of golf car Fig. I 11: Wiring Diagram I-18...
  • Page 126 BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS BATTERY CARE AND MAINTENANCE---------------------------------------------------------------------------------J-2 EACH CHARGE CYCLE----------------------------------------------------------------------------------------------------J-3 ONCE EVERY MONTH------------------------------------------------------------------------------------------------------J-3 ELECTROLYTE LEVEL AND WATER LEVEL-------------------------------------------------------------------------J-3 CLEANING THE BATTERY-----------------------------------------------------------------------------------------------J-5 BATTERY REPLACEMENT------------------------------------------------------------------------------------------------J-6 PROLONGED STORAGE--------------------------------------------------------------------------------------------------J-7 CHARGING BATTERY------------------------------------------------------------------------------------------------------J-8 AC VOLTAGE------------------------------------------------------------------------------------------------------------------J-9...

  • Page 127: Battery Care And Maintenance

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car BATTERY CARE AND MAINTENANCE Keep any heating material, open fire or spark away from the battery Hydrogen gas is formed when charging batteries. In case of poor ventilation, do not charge the battery for fear of explosion when hydrogen concentration reaches 4%.

  • Page 128: Each Charge Cycle

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Tool List Qty. Required Insulated wrench 13#-------------------------------------- 1 Battery rack -------------------------------------------------- 1 Hydrometer -------------------------------------------------- 1 Battery maintenance box --------------------------------- 13 Each Charge Cycle Do not have the battery charger plugged in the unwatched vehicle after normal charge cycle is over.
  • Page 129 BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Battery must not be overfilled with water since the charge cycle may cause the electrolyte to overflow out of the battery, which may result in damage of relevant components. Do not fill in water before charging unless electrolyte level is even with or lower than the plate.

  • Page 130: Cleaning The Battery

    Use low air pressure fresh water to rinse the whole battery. All devices for battery cleaning and rinsing are stored inside the FAIRPLAY battery maintenance kit. Cleaning should be conducted once a month, or more frequently in case of harsh environment.

  • Page 131: Battery Replacement

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Fig. J 4: Preparing Acid Neutralizer Battery Replacement Before attempting to carry out any electric service of the vehicle equipped with program controlled guidance system, the Run-Tow/Maintenance switch must be set to its 'Tow/Maintenance' position.

  • Page 132: Prolonged Storage

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Connect the battery wires with care as shown in the figure (Ref Fig. J5). Tighten the battery binding posts to torque of 1bs. Protect the battery terminals and battery cable terminals with a commercially available protective coating.

  • Page 133: Charging Battery

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Specific Gravity Electrolyte Freezing Point Fig. J 6: Electrolyte Freezing Point Charging Battery Battery charger is designed for fully charge of battery pack. In case of severe deep circulation of battery, some electronic micromodules of battery charger will not be activated such that the battery charger may not work;...

  • Page 134: Ac Voltage

    Different manufacturers have different requirements. Seek advice from battery manufacturer or FAIRPLAY representative to find out about specific requirements. The second type of case is to determine the cause why the vehicle fails to run normally. Any problem of vehicle performance may result in slow vehicle running or failure of running in some cases.

  • Page 135: General

    Read section A and B completely prior to operation or repair of golf car GENERAL The FAIRPLAY battery charger is automatic and is designed specifically for charging electric vehicle batteries. The battery charger can be connected to a vehicle that has been driven any distance and will charge the batteries fully before shutting itself off.

  • Page 136: Understanding Charger

    The power (AC) wire is equipped with a grounding plug; be sure not to unplug, cut off, or bend the grounding posts. If vehicle is to be charged with a non FAIRPLAY charger, refer to the instructions supplied with the charger.

  • Page 137: Battery Charger Maintenance

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car method is reverse to the removal procedures. Fig. J 10: Opening the Charger BATTERY CHARGER MAINTENANCE The only maintenance required for the charger is the periodic cleaning of the DC connector auxiliary contact.

  • Page 138: Continuity Check

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Continuity Check Before attempting to perform a continuity check, disconnect the battery charger from both AC and DC power sources. To check for continuity, set the DVOM (digital volt ohm meter) to KQ setting and select “Continuity”. The meter will give an audible signal when it detects continuity.
  • Page 139 BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Activate START, charger OFF; Plug DC cable into vehicle Insert the AC Transformer Unplug AV wire sounds wire into and DV wire receptacle Relay Opening the closing...

  • Page 140: Description Of Charger Indicator Implication

    BATTERY AND CHARGER Read section A and B completely prior to operation or repair of golf car Fig. J 14: Diode Test Procedure DESCRIPTION OF CHARGER INDICATOR IMPLICATION Color Implication Remarks Orange Charge ongoing - Main charge mode Orange/yellow Charge finished - Finished charge mode Orange/yellow Precharge mode flickering...
  • Page 141 BODY Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS BODY----------------------------------------------------------------------------------------------------------------------------K-2 BODY COMPONENT REPLACEMENT--------------------------------------------------------------------------------K-2 LIST OF ILLUSTRATIONS Fig. K1: Drill Out Metal Rivet-----------------------------------------------------------------------------------------------K-2 Fig. K2: Body Components (Front) --------------------------------------------------------------------------------------K-3 Fig. K3: Bottom Plate and Rocker Panel-------------------------------------------------------------------------------K-4 Fig.
  • Page 142 BODY Read section A and B completely prior to operation or repair of golf car In the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in original position unless otherwise specified.
  • Page 143 BODY Read section A and B completely prior to operation or repair of golf car If the instrument panel is to be replaced, the serial number plate must be removed and reinstalled on the instrument panel (Ref Fig. K2). Fig. K2: Body Components (Front)
  • Page 144 BODY Read section A and B completely prior to operation or repair of golf car Fig. K3: Bottom Plate and Rocker Panel...
  • Page 145 BODY Read section A and B completely prior to operation or repair of golf car Fig. K4: Seat Frame and Battery Rack...
  • Page 146 BODY Read section A and B completely prior to operation or repair of golf car Fig. K5: Rear Body Components...
  • Page 147 BODY Read section A and B completely prior to operation or repair of golf car Fig.K6: (6P) Body Components (Middle) Fig.K7: (6P) Rear Body Components...
  • Page 148 ACCESSORY WIRINGS Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS DVOM-------------------------------------------------------------------------------------------------L-2 TROUBLESHOOTING--------------------------------------------------------------------------------------------L-2 POWER SUPPLY--------------------------------------------------------------------------------------------L-4 CHECK FOR LOOSE OR BARE WIRES--------------------------------------------------------------------L-4 CHECK FOR BATTERY CONDITION--------------------------------------------------------------------------------L-4 CHECK POWER WIRE--------------------------------------------------------------------------------------------L-4 CHECK FUSE--------------------------------------------------------------------------------------------L-4 ACCESSORY WIRINGS--------------------------------------------------------------------------------------------L-5 LIST OF ILLUSTRATIONS Fig.
  • Page 149 A typical DVOM (digital volt ohm meter) is shown (Ref Fig. L1). A recommended model is available through the FAIRPLAY Service Parts Department. For the purpose of this section, the red probe (+) and black probe (-) are used. Any DVOM may be used; however, the control, display, accuracy, and features may vary depending on the make and model.
  • Page 150 ACCESSORY WIRINGS Read section A and B completely prior to operation or repair of golf car Example 2: If a problem occurs in the lighting circuit that results in only one of the headlights not working, there is no reason to check battery wiring or the fuse since it is obvious that voltage is present. Since bulbs will burn out over time, the obvious place to start is at the headlight that is not functioning.
  • Page 151 ACCESSORY WIRINGS Read section A and B completely prior to operation or repair of golf car POWER SUPPLY Tool List Qty. Required DVOM..............1 1. CHECK FOR LOOSE OR BARE WIRES Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame.
  • Page 152 ACCESSORY WIRINGS Read section A and B completely prior to operation or repair of golf car ACCESSORY WIRINGS After determining that there is power to the fuse panel, and the fuse is good/continue checking the circuit using the procedures previously used to check the power supply, i.e. loose or rusted connections, bare wires, continuity of the wiring from terminal to terminal, operating condition of switch, etc.
  • Page 153 PAINT Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS PAINTING-----------------------------------------------------------------------------------------------------------------M-2 MINOR SCRATCHES-------------------------------------------------------------------------------------------------M-2 LARGER SCRATCHES----------------------------------------------------------------------------------------------M-2 COMPLETE PANEL REPAIR------------------------------------------------------------------------------------------M-3...
  • Page 154 Provide protective practices so as to avoid painting that exceeds the vehicle and neighboring range. Minor scratches: For minor scratches, FAIRPLAY suggests the following steps be taken to repair the FAIRPLAY vehicle body. Clean thoroughly the surfaces with ethanol and dry.
  • Page 155 ‘TPE’ panels. The finish will include an application of a primer coat, a base color coat and a clear coat. FAIRPLAY does not supply these materials in a variety of paint colors.
  • Page 156 TROUBLESHOOTING Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS ELECTRICAL SYSTEM------------------------------------------------------------------------------------------N-2 ELECTRICAL SYSTEM BASIC TROUBLESHOOTING--------------------------------------------------------N-2 ACCESSORY BASIC ELECTRIC TROUBLESHOOTING---------------------------------------------------------N-2 FRONT SUSPENSION AND STEERING----------------------------------------------------------------------------N-3...
  • Page 157 TROUBLESHOOTING Read section A and B completely prior to operation or repair of golf car Electrical System Condition Possible Cause Correction Key ‘OFF’ or no direction selected Turn key ‘ON’ and select direction Batteries discharged Charge battery Load test and replace batteries that cannot be Batteries unable to be charged charged Clean and tighten the battery connecting wires, and...
  • Page 158 TROUBLESHOOTING Read section A and B completely prior to operation or repair of golf car WIRING section. Front Suspension and Steering Condition Possible Cause Correction Incorrect tire pressure Inflate to recommended pressure Uneven tire attrition Incorrect alignment (incorrect toe-in) Align front tires Remove steering column, pinion and bearing and Water has entered steering box and may remove water before adding grease...
  • Page 159 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car TABLE OF CONTENTS VEHICLE PARAMETERS--------------------------------------------------------------------------------------------------O-2 PRECAUTIONS---------------------------------------------------------------------------------------------------------------O-9 LIST OF ILLUSTRATIONS Fig. O1 Vehicle Dimensions (2P) ----------------------------------------------------------------------------------------O-4 Fig. O2 Incline Specifications and Turning Clearance Diameter (2P) -------------------------------------------O-5 Fig.
  • Page 160 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car VEHICLE PARAMETERS (4P) WEIGHT (without batteries)(2P)-----------------------------------749.57lbs (340kg) WEIGHT (without batteries)(6P)-----------------------------------881.85bs (400kg) TIRES (4 ply rated) ---------------------------------------------------205/50-10 TIRE PRESSURE-----------------------------------------------------30-33 psi (200-220 KPa) LOAD CAPACITY (including operator, passenger, cargo and accessories)(2P)--- ---------------------800 Ibs.
  • Page 161 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car ELECTRICAL SYSTEM（2P）------------------------------------48 volt DC, six, 8 volt deep cycle storage batteries ELECTRICAL SYSTEM（6P）------------------------------------48 volt DC, eight, 6 volt deep cycle storage batteries SPEED CONTROL--------------------------------------------------Solid State continuously variable speed controller TRANSAXLE------------------------------------------------------------High efficiency differential with helical gears, 12.49:1 ratio...
  • Page 162 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car Specifications are subject to change without further notice. 74.02 inches (1880mm) 47.24 inches (1200mm) 66.54 inches 33.86 inches (1690mm) (860mm) 95.67 inches (2430mm) 38.58 inches (980mm) 47.24 inches (1200mm)
  • Page 163 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car DIAMETER 21ft (6.4m） Fig. O2 Incline Specifications and Turning Clearance Diameter （2P）...
  • Page 164 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car Fig. O3 Vehicle Dimensions(6P)
  • Page 165 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car 2 Vehicle Dimensions, Incline Specifications and TuPning CleaPance DiameteP Fig. O4 Incline Specifications and Turning Clearance Diameter （6P）...
  • Page 166 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car Read and understand the following warnings before attempting to operate the vehicle: To prevent personal injury or death, observe the following: When vehicle is to be left unattended, engage parking (PARK) brake, move direction selector to neutral, turn key to ‘OFF’...
  • Page 167 GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car Read and understand the following text and warnings before attempting to service a vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

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