Table Of Contents - E-Z-GO TXT 48V Repair And Service Manual

Table of Contents

Safety2
Notices, Cautions And Warnings2
General Information4
Battery Prolonged Storage4
Table Of Contents5
Safety Information7
General Operation7
Maintenance8
Ventilation9
General Information & Routine Maintenance11
Serial Number Label Location13
Servicing The Electric Vehicle13
Transporting Vehicle13
Towing13
Hauling13
Rear Axle14
Brakes14
Tires14
Light Bulb Replacement14
Routine Maintenance14
Vehicle Cleaning And Care14
Vehicle Care Products15
Sun Top And Windshield15
Hardware16
Torque Specifications16
Periodic Service Schedule17
Notes, Cautions And Warnings21
Important Safety Warning21
Modifications To Vehicle21
General Maintenance21
Before Servicing The Vehicle21
Additional Warnings22
Battery Removal & Installation23
Fig. 1 Battery Connections23
Fig. 2 Lifting The Vehicle23
Lifting The Vehicle24
Body27
Body Component Replacement29
Drill Out Metal Rivet29
Instrument Panel Replacement29
General29
Body Components (Front)30
Body Components (Rear)31
Front Shield Replacement32
Rocker Panel Replacement32
Cowl Replacement32
Body Replacement33
Rear Bumper Replacement33
Wheels And Tires35
Wheel And Tire Service37
Tire Repair37
Wheel Installation37
Electronic Speed Control - Tct39
Trucourse Technology (Tct) System41
Changing Performance Options41
Trucourse Technology System™ Performance Options & Diagnostics41
Run-Tow/Maintenance Switch42
Trucourse Technology (Tct) System™ Operation42
Pedal Box43
Speed Sensor43
Controller43
Access To Pedal Box43
General Troubleshooting44
Testing Battery Voltage44
Continuity Check44
Symptoms44
Testing A Switch For Continuity45
Testing A Solenoid For Continuity45
Continuity Check Of Switch45
Continuity Check Of Solenoid45
Troubleshooting Diagrams46
1206Hb-5201 Controller Faults And Troubleshooting46
Controller Fault Responses47
Controller Faults And Troubleshooting47
Inductive Throttle Sensor (Its) Testing And Replacement50
Its And Plunger50
Its Adjustment51
Controller Replacement53
Solenoid Replacement53
Front Suspension And Steering57
Fig. 2 Lubrication Point57
Axle Mounted Steering And Front Suspension59
Lubrication60
Wheel Bearing And King Pin Bushing Inspection60
Wheel Bearing Packing60
Wheel Bearing Adjustment61
Wheel Alignment61
Front Suspension63
Front Shock Absorber Replacement63
Front Suspension Components63
Front Axle Replacement64
Front Spring Replacement64
Front Axle Alignment65
Hub Replacement65
Wheel Bearing And Race Replacement66
Seal Installation66
Steering67
Steering Components67
Rack Ball Joint Replacement67
Rack Ball Joint Installation68
Tie Rod Inspection/Replacement68
Tie Rod Replacement68
Bellows Replacement69
Pinion Seal Replacement69
Spindle Replacement70
Rack And Pinion Unit Disassembly71
Rack And Pinion Unit Replacement72
Spindle Contact With Front Axle72
Steering Wheel Replacement73
Checking Gap73
Clipboard Removal73
Steering Replacement73
Steering Shaft And Column Replacement74
Small Retaining Ring Orientation74
Steering Shaft And Column74
Motor77
Motor Removal79
Disconnect Battery Cable79
Mark Axle And Motor79
Motor Disassembly79
Motor Components80
Bearing Replacement81
Brush Replacement81
Brush Wear81
Motor Tests82
Motor Installation82
Securing Brushes82
Motor Assembly82
Batteries And Charging85
Battery Maintenance87
At Each Charging Cycle88
Monthly88
Electrolyte Level And Water88
Correct Electrolyte Level88
Cleaning Batteries89
Battery Replacement89
Automatic Watering Gun89
Preparing Acid Neutralizing Solution89
Prolonged Storage90
Ac Voltage91
Battery Charging91
Troubleshooting91
Freezing Point Of Electrolyte91
Hydrometer92
Using A Hydrometer92
Hydrometer Temperature Correction93
Battery Charger95
Portable Charger Installation97
Charger Description97
Charger Installation97
Understanding The Charger98
Led Fault Code98
Maintenance Instructions98
Led Display Information98
Mechanical Brakes101
Brake System Overview103
Mechanical Brake System103
How The Service Brake Works104
Equalizer Link104
Parking Brake And Kick-Off Mechanism104
How The Parking Brake Works104
Compensator Assembly105
Kick-Off Actuating Linkage105
Troubleshooting Flowchart106
Troubleshooting And Inspection Procedures110
Brake Pedal Bumper Inspection110
Brake Pedal Inspection110
Brake Pedal And Linkage Inspection110
Check For Excessive Free Travel111
Equaliser And Compensator111
Parking Brake Pedal Hinge Inspection112
Kick-Off Cam Inspection112
Periodic Brake Performance Test (Pbpt)112
Periodic Brake Performance Test113
Aggressive Stop Test113
Wheel Brake Inspection114
Equally Loaded Vehicle114
Adjuster Mechanism114
Brake Shoe Wear115
Orientation Of Brake Shoe Springs115
Maintenance And Repairs116
Parts Replacement Vs. Repair116
Adjusting Brake Pedal Free Travel116
Free Travel Adjustment116
Check Clevis Pins117
Brake Assembly117
Brake Drum Removal And Installation117
Checking Parking Brake Latching Pressure117
Wheel Brake Service118
Wheel Brake Lubrication Points118
Backing Plate Removal And Installation119
Brake Shoe Installation119
Brake Shoe Removal119
Brake Cable, Equaliser And Compensator120
Brake Pedal Removal And Installation121
Brake Shoes And Springs121
Catch Bracket And Latch Arm122
Pedal Bumper Adjustment122
Direction Selector125
Replacing The Reverse Warning Buzzer127
Direction Selector Switch127
Replacing The Direction Selector Switch127
Direction Selection Switch Replacement128
Direction Selector Switch Connections128
Electrical System131
Digital Volt Ohm Meter133
Accessory Wiring Diagram134
Main Harness Wiring Diagram135
Power Supply136
Main & Accessory Wiring136
Check For Loose Or Bare Wires136
Check Battery Condition136
Electrical Accessories137
Rear Suspension141
Shock Absorber Installation143
Rear Spring Removal143
Rear Spring Installation143
Rear Axle Assembly Removal143
Rear Axle Installation144
Motor Wiring144
Rear Axle Maintenance149
Checking The Lubricant Level149
Axle Shaft Removal And Disassembly149
Rear Axle Disassembly149
Removing/Installing Axle Shaft150
Removing/Installing Inner Snap Ring150
Axle Shaft Seal Removal And Replacement150
Removing Seal150
Axle Shaft Replacement151
Installing Seal151
Cut Away Of Outer Bearing And Brake Drum151
Weather Protection153
Top And Windshield155
Front Strut155
Trailering155
Sun Top155
Golf Car Sun Top156
Split Windshield157
One-Piece Front Windshield158
Front Windshield158
Rear Windshield159
Handheld Diagnostics161
How To Use The Handheld Programmer161
Curtis Handheld Programmer161
Navigation161
Main Menu Definitions162
Changing Data Value162
Bookmark162
Lightning Protection And Grounding173
Grounding Requirements175
Ground Systems175
Lightning Protection Requirements175
Equipment Fault And Personal Safety System175
External Grounding Requirements176
Materials176
Earth Electrode System176
Lightning Protection System176
Paint179
Painting181
Minor Scratches181
Complete Panel Repair181
Larger Scratches181
General Specifications183
Product Specification185
Configuration Highlights185
Product Overview185