E-Z-GO MPT 800 Technician's Repair And Service Manual
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E-Z-GO MPT 800 Technician's Repair And Service Manual

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28838-G01
A Textron Company
TECHNICIAN'S
REPAIR AND SERVICE MANUAL
ELECTRIC POWERED UTILITY VEHICLES
REVISED DATE: OCT 2006

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Summary of Contents for E-Z-GO MPT 800

  • Page 1 28838-G01 A Textron Company TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLES REVISED DATE: OCT 2006...
  • Page 2 SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 E-Z-GO Division of Textron, Inc. 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 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE Safety ........................... Inside Covers Notes ..............................ii Safety Information ..........................v TITLE SECTION General Information & Routine Maintenance ...................A Safety ...............................B Body and Truckbed ..........................C Wheels and Tires ..........................D Front Suspension and Steering ......................E Electronic Speed Control (36V) ..................... F-1 Electronic Speed Control (48V) ....................

  • Page 6: Notes

    TABLE OF CONTENTS Notes: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    SAFETY INFORMATION 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. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle;...
  • Page 8 SAFETY INFORMATION Always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles. Always reduce speed in wet areas. Always use extreme caution when approaching sharp or blind turns. Always use extreme caution when driving over loose terrain.
  • Page 9 SAFETY INFORMATION VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air exchanges per hour is considered the minimum requirement.
  • Page 10 SAFETY INFORMATION Notes: Repair and Service Manual Page viii...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER PLATE LOCATION ....................A - 1 TRANSPORTING VEHICLE ......................A - 1 TOWING..........................A - 1 HAULING..........................A - 1 SERVICING THE ELECTRIC VEHICLE ..................A - 1 ROUTINE MAINTENANCE ......................A - 1 REAR AXLE .............................A - 2 BRAKES............................A - 2...
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Notes: Repair and Service Manual Page A-ii...

  • Page 13: Serial Number Plate Location

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings SERIAL NUMBER PLATE LOCATION tions and warnings in this manual. Any servicing requiring adjustments to be made The serial number and manufacture date code label are to the powertrain while the motor is running must on the vehicle.

  • Page 14: Light Bulb Replacement

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings This vehicle will give years of satisfactory service provid- For information on conducting a brake test, refer to ing it receives regular maintenance.

  • Page 15: Vehicle Care Products

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings • ally with plain water. Thoroughly clean any areas where Plexus plastic cleaner and polish removes minor mud or other debris can collect.

  • Page 16: Hardware

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings HARDWARE Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific Periodically the vehicle should be inspected for loose torque values.

  • Page 17: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ✓ Check ♦ Clean, Adjust, etc. ▲ Replace NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY BEFORE USE: ✓...

  • Page 18: Fig. 4 Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ✓ Check for unusual tire wear, align if required FRONT WHEEL ALIGNMENT ✓ Check for bent/binding linkage rod ✓...

  • Page 19: Safety

    SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. GENERAL (ASME/ANSI B56.8-1988 PART II) ................B - 1 NOTES, CAUTIONS AND WARNINGS ...................B - 5 IMPORTANT SAFETY WARNING....................B - 5 MODIFICATIONS TO VEHICLE ......................B - 5 GENERAL MAINTENANCE ......................B - 5 BEFORE SERVICING THE VEHICLE .....................B - 6 Additional Warnings.......................B - 6 BATTERY REMOVAL &...
  • Page 20 SAFETY Notes: Repair and Service Manual Page B-ii...

  • Page 21: General (Asme/Ansi B56.8-1988 Part Ii)

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, GENERAL manual without the manufacturer’s prior written authori- zation. Where authorized modifications have been made, The following text is provided as recommended by part II the user shall ensure that capacity, operation, warning, of ASME/ANSI B56.8-1988.
  • Page 22 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Control of Noxious Gases and Fumes (a) instructional material provided by the manufac- turer; 4.8.1 When equipment powered by internal com- (b) emphasis on safety of passengers, material loads, bustion engines is used in enclosed areas, the atmo- sphere shall be maintained within limits specified in the...
  • Page 23 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 5.4.8 Operators shall not add to, or modify, the car- 5.5.14 To negotiate turns, reduce speed to improve rier.
  • Page 24 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings trained personnel, and procedures shall be provided. (n) Fuel systems shall be checked for leaks and condi- Such facilities may be on or off the premises. tion of parts.

  • Page 25: Notes, Cautions And Warnings

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings NOTES, CAUTIONS AND WARNINGS MODIFICATIONS TO VEHICLE Throughout this manual, the following NOTES, CAU- To prevent personal TIONS and WARNINGS are used. For the protection of injury or death to the all personnel and the vehicle, be aware of and observe operator or passen-...

  • Page 26: Before Servicing The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BEFORE SERVICING THE VEHICLE To prevent battery explosion that could Before attempting to inspect or service a vehicle, be sure result in severe per- to read and understand the following warnings: sonal injury or death, keep all smoking...

  • Page 27: Battery Removal & Installation

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings and flushed with water. the vehicle batteries. Remove the battery hold down by removing the hardware and lifting the retainer from the Wrap wrenches with batteries.

  • Page 28: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE Tool List Qty. Required BL + Floor jack ..............1 Front of Vehicle Jack stands..............4 Chocks.................4 BL - Some servicing operations may require the vehicle be raised.
  • Page 29 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings To raise the entire vehicle, install chocks in front and behind each front wheel (Ref Fig. 3 on page B-8). Center jack under the rear frame crossmember.
  • Page 30 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page B-10...
  • Page 31 BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY .............................. C - 1 General..........................C - 1 BODY COMPONENT REPLACEMENT..................C - 1 LIST OF ILLUSTRATIONS Fig. 1 Drill Out Metal Rivet ......................C - 1 Fig. 2 Body Components (Front) ....................C - 2 Fig.
  • Page 32 BODY Notes: Repair and Service Manual Page C-ii...
  • Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BODY drilling into the head with a sharp drill bit that is slightly larger than the shank of the rivet (Ref Fig. 1 on page C- In the following text, there are references to 1).
  • Page 34 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...
  • Page 35 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 3 Body Components (Rear) Repair and Service Manual Page C-3...
  • Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 4 Battery Rack Components Repair and Service Manual Page C-4...
  • Page 37 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Vehicle Rear Bumper Fig. 5 Ashtray and Hitches Repair and Service Manual Page C-5...
  • Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Part of Truckbed Metal Bed Fig. 6 Metal Truckbed Repair and Service Manual Page C-6...
  • Page 39 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 7 Plastic Truckbed Repair and Service Manual Page C-7...
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Actuator may be rotated 90˚ on some models Fig. 8 Electric Dump Repair and Service Manual Page C-8...

  • Page 41: Wheels And Tires

    WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ......................D - 1 Tire Repair..........................D - 1 Wheel Installation ......................... D - 1 LIST OF ILLUSTRATIONS Fig. 1 Wheels and Tires ......................... D - 2 Repair and Service Manual Page D-i...
  • Page 42 WHEELS AND TIRES Notes: Repair and Service Manual Page D-ii...
  • Page 43 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings WHEEL AND TIRE SERVICE inflation pressure should be in the higher allowable range, but under no condition should inflation pressure Tools List Qty.
  • Page 44 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wheel and/or Tire style may vary Fig. 1 Wheels and Tires Repair and Service Manual Page D-2...

  • Page 45: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE ..........................G - 2 Lubrication ..........................G - 2 Wheel Bearing and King Pin Bushing Inspection ..............G - 2 Wheel Bearing Packing ......................G - 2 Wheel Bearing Adjustment ....................
  • Page 46 FRONT SUSPENSION AND STEERING Notes: Repair and Service Manual Page E-ii...
  • Page 47 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...

  • Page 48: Maintenance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE In the following text, there are references to removing/installing bolts etc. Additional hard- Front of Vehicle ware (nuts, washers etc.) that is removed must always be installed in its original position unless otherwise specified.

  • Page 49: Wheel Bearing Adjustment

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings the bearing is removed for inspection. It is recommended that a bearing packer attached to a grease gun be used; however, manual packing is acceptable if done correctly.
  • Page 50 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings To adjust wheel alignment, loosen tie rod jam nuts (1) and turn tie rod (2) until correct alignment is achieved. Tighten jam nuts to 36 - 40 ft.

  • Page 51: Front Suspension

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

  • Page 52: Front Axle Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Front Axle Replacement washer (22) and remove it from end of bolt. Remove nut (21), 3 1/2" long bolt (20), spring plate (24) and spacer 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 all Notes, Cautions and Warnings side spring must be mounted to the axle with the hardware (20 - 23) installed in its original location (Ref Fig. 6 on page E-5). Driver side spring installation is the reverse order of dis- assembly making sure to install the long bolt (20), spring plate (24), spacer (23), nut (21) and washer (22) in their...

  • Page 54: Hub Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Replace upper portion of floor mat in plastic trim retain- ers. Install front wheels per WHEELS AND TIRES sec- tion and lower vehicle per SAFETY section.
  • Page 55 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Front of Vehicle Fig. 11 Wheel Bearing Replacement Install inner wheel bearing (4) and new grease seal in hub and mount hub to spindle.

  • Page 56: Steering

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 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 SAFETY Tool List Qty.

  • Page 57: Tie Rod Inspection/Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 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 58: Bellows Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Remove lock nut (10) until tie rod ball joint (6) threads are protected. Using a ball joint separator as a lever, apply pressure to ball joint and tap nut with plastic faced hammer to release tie rod from spindle arm.

  • Page 59: Spindle Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings page E-15. Anchor in vice by clamping on the mounting The spindle bearings are designed to be used "dry".

  • Page 60: Rack And Pinion Unit Disassembly And Inspection

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Remove rack and pinion unit from vehicle. See ‘Rack and Pinion Unit Replacement’ on page E-15. Anchor in vice by clamping on the mounting ears of the unit.

  • Page 61: Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ion unit until instructed to do so after setting proper rack Replace rack and pinion unit in reverse order of removal. extension-to-rack and pinion unit clearance.

  • Page 62: Steering Wheel Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings To maintain correct orientation when replacing steering wheel, first turn wheels straight ahead. To prevent damage to the clipboard, Front of Vehicle perform the following removal proce-...

  • Page 63: Steering Shaft And Column Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings hammer. Internal damage to rack and pinion unit can result. When steering wheel is loosened, remove retaining nut and remove steering wheel.
  • Page 64 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Install with arch Small up as shown Retaining Ring Steering Shaft Bearing Groove Fig. 25 Small Retaining Ring Orientation Repair and Service Manual Page E-18...
  • Page 65 ELECTRONIC SPEED CONTROL (36V AND 48V) TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. 36 VOLT SYSTEM VEHICLES GENERAL ..................F - 1 Pedal Box ..........................F - 1 Controller ..........................F - 1 GENERAL TROUBLESHOOTING ....................F - 1 Symptoms..........................F - 2 Testing...........................F - 2 Testing Battery Voltage ......................F - 2 Continuity Check ........................F - 3...
  • Page 66 ELECTRONIC SPEED CONTROL (36V AND 48 V) TABLE OF CONTENTS FOR SECTION ‘F’ (CONT.) SECTION TITLE PAGE NO. Testing a Solenoid for Continuity..................F - 23 TROUBLESHOOTING DIAGRAMS ....................F - 24 INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT........F - 32 CONTROLLER REPLACEMENT ....................F - 35 SOLENOID REPLACEMENT ......................F - 35 LIST OF ILLUSTRATIONS Fig.

  • Page 67: Electronic Speed Control (36V

    ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL The pedal box and controller are connected by a four pin connector that is located under the seat within the black The Electronic Speed Control system consists of two plastic environmental cover.
  • Page 68 A typical DVOM is shown in illustrations. A recom- mended DVOM is available through the E-Z-GO Service Parts Department as P/N 27481-G01. Any DVOM may be used; however, the accuracy, controls, displays and features may vary depending on the make and model.
  • Page 69 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Continuity Check To prevent possible inju- ry or death r esulting from a battery explo- sion, use an insulated wrench and remove the BL- wire from the battery to disconnect electrical power to vehicle.
  • Page 70 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings TROUBLESHOOTING DIAGRAMS numbers to the information in the detailed troubleshoot- ing diagram. The simplified troubleshooting diagram is a quick ESC It is vital to the safety of the technician and assistants diagnosis (Ref Fig.
  • Page 71 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Electronic Speed Control Diagnostic Procedure 1206 Controller Key OFF Direction Selector in N * Below 36 Volts: Battery B- to B+ = Charge batteries before proceding "Reference Voltage"...
  • Page 72 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Key ON, Direction Selector in F Voltage Between Battery Depress B- & Direction Pedal Selector Microswitch Terminal with Red Wire Solenoid Verify Continuity -...
  • Page 73 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Disconnect Key Switch Harness Green Wire From Control Harness The 4-pin connector is a Key On, Direction Selector in F very difficult item to check.
  • Page 74 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Key ON, Direction Selector in F Pedal Depressed Voltage Between Battery B- & Controller Pin 4 Key ON, Direction Selector in F Pedal Depressed Until Solenoid Clicks Voltage Between...
  • Page 75 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Key ON, Direction Selector in F Disconnect Battery Wire; Pedal Fully Depressed Disconnect 6 Pin Connector from Controller Voltage Between Battery B- &...
  • Page 76 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Return to Remove B+ Wire From Battery Resistance Between Controller Pin 1 & Controller B- Pull Up Floor Mat Remove Pedal Box Cover Verify Plunger...
  • Page 77 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Key ON, Direction Selector in F Voltage Between Battery B- & Motor S2 Key ON, Direction Selector in F .5 - 2.5 Volt Voltage Between Less Than...
  • Page 78 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Remove Orange Wire from Controller Key ON, Direction Selector in F Pedal Fully Depressed Voltage Between Controller B+ &...
  • Page 79 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT Tool List Qty. Required Phillips screwdriver ............. 1 Wrench, 7/16"...
  • Page 80 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 17/64"...
  • Page 81 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 1.5 - 1.7 volts 0.4 - 0.6 volts Fig. 18 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page F-15...
  • Page 82 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings CONTROLLER REPLACEMENT SOLENOID REPLACEMENT Tool List Qty. Required Tool List Qty. Required Socket, 3/8", 3/8" drive ..........1 Socket, 3/8", 3/8"...
  • Page 83 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Ignition Interlock Key Switch Charger Receptacle Pedal Direction Selector Switch Solenoid Motor Controller 1206 Wires indicated are contained in power harness All other wires are control wiring MS2 is closed when direction selector switch is in forward or reverse...
  • Page 84 ELECTRONIC SPEED CONTROL (36V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page F-18...

  • Page 85: Electronic Speed Control (48V

    ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 48 VOLT SYSTEM VEHICLES GENERAL Performance options of the Precision Drive System include: 48 Volt vehicles are operated in one of four modes or •...
  • Page 86 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings At monthly intervals, test the 48 volt system by allowing 48 volt vehicles operate only in the ‘RUN’ posi- tion.
  • Page 87 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings The electrical power to the motor will be interrupted inter- Speed Sensor mittently allowing the vehicle to roll a short distance, The speed sensor uses a sealed sensor to read the thereby allowing the internal components of the motor to impulses of a ring magnet attached to the armature shaft...
  • Page 88 A typical DVOM is shown in illustrations. A recom- mended DVOM is available through the E-Z-GO Service Parts Department as P/N 27481-G01. Any DVOM may be used; however, the accuracy, controls, displays and Repair and Service Manual...
  • Page 89 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings lated wrenches when working on batteries. To check for continuity, set the DVOM to the KΩ setting and select ‘Continuity’.
  • Page 90 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings TROUBLESHOOTING DIAGRAMS The following diagrams will assist in servicing the vehi- cle. By utilizing the Fault Codes, considerable time will be saved in determining the probable vehicle operating malfunction.
  • Page 91 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fault Fault Vehicle Operation Corrective Action Code Change - - - Direction Selector Fault Vehicle Operates in •...
  • Page 92 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 4 - 1 Current sense fault Vehicle will not run • Replace controller 4 - 3 M- fault Vehicle will not run •...
  • Page 93 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 48 Volt Battery Pack Pedal Box Charging Connector 1264 Controller Reed Switch To Hand Solenoid Held Motor Motor...
  • Page 94 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Pedal Box Charging Connector 1264 Controller Reed Switch Solenoid WHT / YEL Switch ORN / RED SPARE WHT / BLK RED / YEL...
  • Page 95 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 96 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 1264 Controller Motor Speed Sensor SPARE SPARE SPARE All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 97 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 48 Volt Battery Pack Charging Connector 1264 Controller Motor Solenoid This test will verify secondary circuit voltage. Please reference the chart for probe connections. If not/ Then Probe Connection Voltage...
  • Page 98 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings INDUCTIVE THROTTLE SENSOR (ITS) Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the plastic TESTING AND REPLACEMENT pedal box studs.
  • Page 99 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 7/32"...
  • Page 100 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ± ± 0.5 volts 0.3 volts Fig. 16 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page F-34...
  • Page 101 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings CONTROLLER REPLACEMENT SOLENOID REPLACEMENT Tool List Qty. Required Tool List Qty. Required Socket, 10mm, 3/8" drive ..........1 Socket, 3/8", 3/8"...
  • Page 102 ELECTRONIC SPEED CONTROL (48V) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings #10 Black #4 Black From Motor F2 From Motor A1 (Power Harness) (Power Harness) #4 Black From Motor A2 (Power Harness) #18 Yellow...

  • Page 103: Motor

    MOTOR TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. GENERAL ............................G - 1 Motor Removal ........................G - 1 Motor Disassembly ....................... G - 3 Bearing Replacement ......................G - 3 Field Coil Replacement ......................G - 3 Brush Replacement ......................
  • Page 104 MOTOR Notes: Repair and Service Manual Page G-ii...
  • Page 105 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL Remove battery cable Do not hold vehicle on hill by using from (-) battery terminal accelerator and motor. Leaving the motor in a stalled condition for more than 3-4 seconds will raise the commutator bars resulting in unacceptable noise and accel- erated brush wear and cause permanent damage to motor.
  • Page 106 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 48V ONLY Fig. 3 Motor Components Repair and Service Manual Page G-2...
  • Page 107 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Motor Disassembly Press the new bearing into the commutator end cover using heat again to aid installation. Tool List Qty.
  • Page 108 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Motor Assembly Tool List Qty. Required Socket, 3/8", 3/8" drive ..........1 Torque wrench, in. lbs., 3/8" drive ....... 1 Align the commutator end cover with the holes in the 1.30"...
  • Page 109 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings MOTOR WIRING 36V Motor Wire Terminal Marker From Direction Selector "B" Direction Selector "D" Controller "B+" Controller "A2" Fig.
  • Page 110 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Repair and Service Manual Page G-6...

  • Page 111: 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 - 1 Monthly ..........................H - 2 Electrolyte Level and Water....................
  • Page 112 BATTERIES AND CHARGING Notes: Repair and Service Manual Page H-ii...

  • Page 113: Safety

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, SAFETY and storage facility. Aerosol containers of battery terminal Always observe the following warnings when working on protectant must be used with extreme or near batteries: care.

  • Page 114: Electrolyte Level And Water

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings charger to a vehicle that is to be unattended A battery being charged will ‘gas’ with the majority of the beyond the normal charging cycle.

  • Page 115: Cleaning Batteries

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ate (baking soda) and water. This solution is best applied with a quart sized hand sprayer. The solution should con- Watering gun similar to the type included in the Battery Maintenance Kit sist of 2 teaspoons (10 ml) of sodium bicarbonate (bak-...

  • Page 116: Prolonged Storage

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings sion to the battery racks or surrounding area should be present. Any corrosion found should be immediately removed with a putty knife and a wire brush.

  • Page 117: Battery Charging

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings that may result from personnel running over or tripping over the cord set. • The charger is automatically turned off during the connect/disconnect cycle and therefore no electri- cal arc is generated at the DC plug/receptacle contacts.

  • Page 118: Hydrometer

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Hydrometer Do not perform a hydrometer test on a battery that has just been watered. The battery must A hydrometer (P/N 50900-G1) is used to test the state of go through at least one charge and discharge cycle in order to charge of a battery cell (Ref Fig.

  • Page 119: Battery Charger

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings and replaced with a good battery of the same brand, type Portable Charger Installation and approximate age. Portable chargers must be mounted on a platform above the...

  • Page 120: Charger Maintenance

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 10 Polarized Receptacle Charger Maintenance The charging (DC) cord is equipped with a polarized con- nector which fits into a matching receptacle on the vehi- cle.

  • Page 121: 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 ACCESSORY WIRING ........................J - 4 LIGHT BULB REPLACEMENT ......................J - 4 LIST OF ILLUSTRATIONS Fig.
  • Page 122 ELECTRICAL SYSTEM Notes: Repair and Service Manual Page J-ii...
  • Page 123 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings DIGITAL VOLT OHM METER TROUBLESHOOTING A typical digital volt ohm meter (DVOM) is shown (Ref In order to effectively troubleshoot the circuits that Fig.
  • Page 124 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Driver Side Passenger Side Turn Marker Headlight Headlight Marker Turn Solenoid Hour Meter BLU/WHT Horn + 12V ORN /WHT 15 AMP 15 AMP...
  • Page 125 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Driver Side Passenger Side Marker Headlight Headlight Marker Turn Turn BLU/WHT Horn + 12V ORN /WHT 15 AMP Fuse 15 AMP Brake...
  • Page 126 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings POWER SUPPLY ACCESSORY WIRING Tool List Qty. Required After determining that there is power to the fuse panel, and the fuse is good, continue checking the circuit using DVOM................
  • Page 127 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVERSE BUZZER GRN/ Control Accessory Harness Harness DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER, LABEL AND PLATE KEY SWITCH AND KEY SET Fig.
  • Page 128 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings FUSE BLOCK HORN FLOOR MOUNTED HORN BUTTON HOUR METER DETAIL Floormat Floorboard Fig. 5 Horn, Fuse Block, Hour Meter Repair and Service Manual Page J-6...
  • Page 129 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings HEADLIGHT Rear Fender TAILLIGHT TURN SIGNAL Fig. 6 Turn Signal, Headlight, Tail Light Repair and Service Manual Page J-7...
  • Page 130 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Repair and Service Manual Page J-8...
  • Page 131 BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. BRAKES - REAR MECHANICAL BRAKE SYSTEM OVERVIEW ......................K - 1 General Description.......................K - 1 How the Service Brake Works....................K - 2 Equalizer Link ........................K - 2 Automatic Adjuster Mechanism .....................K - 2 How the Parking Brake Works....................K - 2 Compensator Assembly ......................K - 3 Kick-Off Actuating Linkage ....................K - 3...

  • Page 132: Section Title

    BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO. Fig. 19 Check Clevis Pins......................K - 15 Fig. 20 Checking Parking Brake Latching Pressure ..............K - 15 Fig. 21 Brake Assembly........................ K - 15 Fig. 22 Wheel Brake Lubrication Points ..................K - 16 Fig.

  • Page 133: Brakes - Rear Mechanical

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Parking Brake Pedal Torsion Springs Push Nut Identification Hole Hinge Pin Pedal Latch Service Brake Pedal Kick Off Spacer Catch Bracket...

  • Page 134: Automatic Adjuster Mechanism

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings requires enough cable travel at the wheel brake to work reliably. When the brake is released, there must be slack Brake Lever in the system so the brakes will release fully and the adjusters will function.

  • Page 135: Compensator Assembly

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Compensator Assembly Older The compensator assembly contains a spring, which is Models compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref Fig.

  • Page 136: Troubleshooting Flowchart

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace...
  • Page 137 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Disassemble Adjuster Tries Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.

  • Page 138: Troubleshooting Table

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings TROUBLESHOOTING TABLE Test (PBPT), and Aggressive Stop Test is performed (Ref Fig. 6 on page K-6). Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Condition...
  • Page 139 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Condition Possible Cause Correction Neither wheel locks when park brake Incorrect compensator spring adjust- Return to factory specification ment is latched.

  • Page 140: Troubleshooting And Inspection

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings TROUBLESHOOTING AND INSPECTION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes.
  • Page 141 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 6. Inspect the brake cable equalizer linkage. Inspect for signs of corrosion, damage, wear or Measured Amount of Free Travel excessive misalignment (Ref Fig.

  • Page 142: Periodic Brake Performance Test (Pbpt)

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings and bushings should move freely and be free of cor- rosion. The kick-off cam should rotate when the Hinge Torsion accelerator pedal is depressed.

  • Page 143: Aggressive Stop Test

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings times as described below, then repeat the Periodic Brake Performance Test three more times (second set of three). If the vehicle passes two of three Periodic Brake Perfor- mance Tests, check that the clevis pins at the brake levers are loose.

  • Page 144: Wheel Brake Inspection

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wheel Brake Inspection Inspect the brake lever for damage or wear. Test the adjuster function as follows: Wear a dust mask and Push the front brake shoe in the direction of the rear eye protection whenever...
  • Page 145 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 9. Measure the brake shoe thickness. 10. Inspect the brake shoe springs. Measure at the most worn area. Brake shoe thick- Be sure that they are not broken or damaged and are correctly installed.

  • Page 146: Maintenance And Repairs

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE AND REPAIRS depressed enough to remove slack from the compensa- tor and cables. Correct adjustment of free travel is Tool List Qty.

  • Page 147: Brake Drum Removal And Installation

    BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings At the spherical nut, adjust the free travel as noted above. Use a 'bathroom' scale to confirm the latching force Drive again and brake aggressively 10 times.
  • Page 148 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Pay particular attention to the location of the Clean backing plate with a commercial brake cleaner. inner brake drum washer (6) inside the brake Allow to dry completely.
  • Page 149 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Be sure that the adjusting screw is pin (4) and compress and rotate the shoe clamp (5) 90° screwed into the star wheel nut until to release it from the shoe clamp pin.
  • Page 150 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Install adjuster mechanism (driver side silver, passenger Remove the cotter pins and clevis pins connecting the side gold).
  • Page 151 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ing a thin blade screwdriver between the small hook and Adjust the brake pedal free travel. See ‘Adjusting Brake the bracket.
  • Page 152 BRAKES - REAR MECHANICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings To prevent serious injury or death resulting from the use of worn parking brake components, to not attempt to re-new worn components.

  • Page 153: Brakes - Front Disc

    BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings SYSTEM DESCRIPTION brake line to new master cylinder and tighten to 15 in. lbs. (1.7 Nm) torque. To assure correct braking performance, all peri- Latch the brake pedal.
  • Page 154 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ROUTINE MAINTENANCE over the rotor. Secure the caliper to the spindle and tighten both bolts to 25 - 30 ft. lbs (33 - 40 Nm) torque. Tool List Qty.
  • Page 155 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings actuator pivot and the linkage rod (See Actuator linkage Attach a short length of clear hose to the caliper bleed bushings).
  • Page 156 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page K-24...

  • Page 157: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. 48 V BATTERY CHARGER ......................L - 1 Description..........................L - 1 36V BATTERY CHARGER ......................L - 1 DESCRIPTION ........................L - 1 PORTABLE CHARGER INSTALLATION..................L - 1 ON-BOARD CHARGER ........................
  • Page 158 BATTERY CHARGER Notes: Repair and Service Manual Page L-ii...

  • Page 159: Battery Charger

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 48 VOLT BATTERY CHARGER Refer to the charger manual for appropriate circuit pro- tection. Description The battery charger accompanying this vehicle is 120 volt AC, 60 Hz input with 48 volt DC output.

  • Page 160: On-Board Charger

    Do not attempt to pull out, cut or bend the ground post. To prevent electrical If vehicle is to be charged with a non E-Z-GO s h o c k o r a r c , w h i c h charger, refer to the instructions supplied with the charger.

  • Page 161: Troubleshooting

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Continuity Good fuse (-) Probe "Beep" Blown fuse (+) Probe Fig. 4 Opening the Charger (Fuse shown as typical "Beep"...
  • Page 162 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings START With Charger CLOSED Plug in DC cord to Vehicle Plug AC Cord Relay Transformer Unplug into Known Clicks Hums? AC &...
  • Page 163 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Low Resistance High Resistance Select Select Forward Bias Reverse Bias DVOM's shown are for reference only. Refer to manufacturer's Users Manual for specific instructions.

  • Page 164: Portable Charger

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Heat Sink Ammeter Diode Transformer Battery Fuse Capacitor AC Input Power Input Board Line Cord Relay Diode Battery Control Board Relay +...

  • Page 165: 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 166 REAR SUSPENSION Notes: Repair and Service Manual Page M-ii...

  • Page 167: Rear Axle

    REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of In the following text, there are references to removal except that the shock absorber nuts (2,5) must removing/installing bolts etc.
  • Page 168 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 1 Rear Suspension Repair and Service Manual Page M-2...

  • Page 169: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. Rear Axle Removal ......................... N - 1 Rear Axle Installation......................N - 1 REAR AXLE DISASSEMBLY......................N - 1 Axle Shaft Removal and Disassembly.................. N - 2 Axle Shaft Seal Removal and Replacement................. N - 2 Axle Shaft Replacement .......................
  • Page 170 REAR AXLE Notes: Repair and Service Manual Page N-ii...
  • Page 171 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Rear Axle Removal 36 VOLT MOTOR WIRING The rear axle assembly is top heavy. To reduce the MOTOR WIRE possibility of personal...
  • Page 172 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Axle Shaft Removal and Disassembly Tool List Qty. Required Arbor press..............1 Bearing Bearing separator............1 Separator Needle nose pliers............
  • Page 173 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Washer Spline Cotter Pin Inner Snap Ring Lock Washer Seal Axle Nut Fig. 7 Removing Seal Bearing Outer Snap Ring Brake Drum...
  • Page 174 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Repair and Service Manual Page N-4...

  • Page 175: Weather Protection

    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 ..........................P - 1 SPLIT WINDSHIELD........................P - 3 ONE-PIECE WINDSHIELD ......................P - 3 LIST OF ILLUSTRATIONS...
  • Page 176 WEATHER PROTECTION Notes: Repair and Service Manual Page P-ii...

  • Page 177: Top And Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings TOP AND WINDSHIELD Front Strut 1. Remove and discard the four bolts from the front cowl. The top does not provide protection from roll over 2.
  • Page 178 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Front of Vehicle Front of Vehicle Front of Vehicle (FRONT) (REAR) Fig. 1 Sun Top Repair and Service Manual Page P-2...
  • Page 179 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings SPLIT WINDSHIELD Place bottom section of windshield on rubber grommets and press the sash, starting at the bottom, onto the front Remove protective covering from the windshield (item 3 strut so that it snaps into place.
  • Page 180 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Strut Front of Vehicle Fig. 3 One Piece Windshield Repair and Service Manual Page P-4...

  • Page 181: Paint

    PAINT TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. PAINTING ............................Q - 1 Minor Scratches........................Q - 1 Larger Scratches ........................Q - 1 Complete Panel Repair ......................Q - 1 Repair and Service Manual Page Q-i...
  • Page 182 PAINT Notes: Repair and Service Manual Page Q-ii...
  • Page 183 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PAINTING III. Apply spray touch up paint in light even overlapping strokes. Multiple coats may be applied to provide Follow the paint manufacturer’s recommendations for adequate coverage and finish.
  • Page 184 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page Q-2...

  • Page 185: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. ELECTRICAL SYSTEM ......................... R - 1 Basic Electrical Power System Troubleshooting ..............R - 2 Basic Electrical Troubleshooting for Accessories..............R - 2 SUSPENSION AND STEERING ....................R - 3 Repair and Service Manual Page R-i...
  • Page 186 TROUBLESHOOTING Notes: Repair and Service Manual Page R-ii...

  • Page 187: Electrical System

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ELECTRICAL SYSTEM Condition Possible Cause Correction VEHICLE WILL NOT MOVE Key ‘OFF’ or no direction selected Turn key ‘ON’ and select direction (36VOLT VEHICLES) Batteries discharged Charge batteries...

  • Page 188: Basic Electrical Power System Troubleshooting

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Condition Possible Cause Correction BATTERIES WILL NOT CHARGE Vehicle/charger connector damaged Replace connector (Continued) Battery case damaged Replace battery Low electrolyte level Maintain correct electrolyte level Battery capacity deficient...

  • Page 189: Suspension And Steering

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings SUSPENSION AND STEERING Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment (Incorrect toe in) Align front tires STIFF STEERING Water has entered steering box and...
  • Page 190 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Condition Possible Cause Correction STEERING PULLS TO ONE SIDE Incorrect tire pressure Inflate to recommended pressure Dragging wheel brake Service brake system Suspension component failure Repair...

  • Page 191: Lightning Protection And Grounding

    LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. Grounding Requirements ........................S - 1 Ground Systems ..........................S - 1 Lightning Protection Requirements ....................S - 1 Equipment Fault and Personal Safety System ................S - 1 Ground Network Requirements .......................S - 1 External Grounding Requirements ....................S - 2 Materials ............................S - 2 Earth Electrode System ........................S - 2...
  • Page 192 LIGHTNING PROTECTION AND GROUNDING Notes: Repair and Service Manual Page S-ii...
  • Page 193 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 1.
  • Page 194 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding SUPERCEDES: EFFECTIVE: Rev -, ECN 027194 10/19/92 6.
  • Page 195 LIGHTING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding SUPERCEDES: EFFECTIVE: Rev -, ECN 027194 10/19/92 9.
  • Page 196 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding SUPERCEDES: EFFECTIVE: Rev -, ECN 027194 10/19/92 Notes: Repair and Service Manual...

  • Page 197: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. MPT™ 800 ............................T - 1 MPT™ 1000 .............................T - 2 INDUSTRIAL™ 800 .........................T - 3 INDUSTRIAL™ 1000 ........................T - 4 Commander™ 280 ...........................T - 5 Commander™ 2100 .........................T - 6 Jacobsen Hauler™...
  • Page 198 GENERAL SPECIFICATIONS Notes: Repair and Service Manual Page T-ii...

  • Page 199: Brakes

    GENERAL SPECIFICATIONS ™ STANDARD EQUIPMENT: WEIGHT (without batteries) 675 lbs. (306 kg) TIRES 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 800 lbs. (362 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 200 GENERAL SPECIFICATIONS ™ 1000 STANDARD EQUIPMENT: WEIGHT (without batteries) 809 lbs. (374 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 1000 lbs. (454 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 201 GENERAL SPECIFICATIONS ™ INDUSTRIAL STANDARD EQUIPMENT: WEIGHT (without batteries) 675 lbs. (306 kg) TIRES 18 x 5.70 x 8 (4 ply rated) TIRE PRESSURE 35 - 45 psi (241 - 310 kPa) LOAD CAPACITY 800 lbs. (362 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 202 GENERAL SPECIFICATIONS ™ INDUSTRIAL 1000 STANDARD EQUIPMENT: WEIGHT (without batteries) 809 lbs. (374 kg) TIRES (4 ply rated) 18 x 5.70 x 8 (4 ply rated) TIRE PRESSURE 35 - 45 psi (241 - 310 kPa) LOAD CAPACITY 1000 lbs. (454 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 203 GENERAL SPECIFICATIONS ™ Commander STANDARD EQUIPMENT: WEIGHT (without batteries) 675 lbs. (306 kg) TIRES 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 800 lbs. (362 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 204 GENERAL SPECIFICATIONS ™ Commander 2100 STANDARD EQUIPMENT: WEIGHT (without batteries) 809 lbs. (374 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 1000 lbs. (454 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 205 GENERAL SPECIFICATIONS ™ Jacobsen Hauler STANDARD EQUIPMENT: WEIGHT (without batteries) 675 lbs. (306 kg) TIRES 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 800 lbs. (362 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 206 GENERAL SPECIFICATIONS ™ Jacobsen Hauler 1000 STANDARD EQUIPMENT: WEIGHT (without batteries) 809 lbs. (374 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 1000 lbs. (454 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 207 GENERAL SPECIFICATIONS 10 in (25 cm) 47 in (119 cm) 66 in (168 cm) (Front) 38 in (97 cm) 103 in (262 cm) (Rear) 35 in (89 cm) 38 in (97 cm) 47 in MPT ™ 800 (119 cm) INDUSTRIAL ™ 800 CUSHMAN ™...
  • Page 208 GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER MPT ™ 800 19 ft (5.8 m) MPT ™ 1000 22 ft (6.7 m) INDUSTRIAL ™ 800 19 ft (5.8 m) INDUSTRIAL ™...
  • Page 209 GENERAL SPECIFICATIONS FRONT SIDE PowerWise Only 1 in. (2.5 cm) 9 1/8 in. (23 cm) 6 3/4 in. 4 7/8 in. 10 ft. DC 7 ft. AC (17 cm) (12 cm) Cord Cord (3 m) (2 m) 10 7/8 in. 8 3/16 in.
  • Page 210 GENERAL SPECIFICATIONS Repair and Service Manual Page T-12...
  • Page 211 Read and understand the following warnings Read and understand the following text and before attempting to operate the vehicle: warnings before attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. prevent personal It is virtually impossible to anticipate all possible compo-...
  • Page 212 E-Z-GO Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material...

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