E-Z-GO 2004 Hauler 800 Manuals

Manuals and User Guides for E-Z-GO 2004 Hauler 800. We have 1 E-Z-GO 2004 Hauler 800 manual available for free PDF download: Technician's Repair And Service Manual

E-Z-GO 2004 Hauler 800 Technician's Repair And Service Manual

E-Z-GO 2004 Hauler 800 Technician's Repair And Service Manual (212 pages)

ELECTRIC UTILITY VEHICLES

Brand: E-Z-GO | Category: Utility Vehicle | Size: 5 MB

Table of Contents

Table of Contents

5
- General Information
  4
- Notes
  6
- Safety Information
  7
  - General Operation
    7
General Information & Routine Maintenance

11
- List of Illustrations
  
  13
- Section Title
  
  13
  - Fig. 1 Initial Service Chart
    13
  - Routine Maintenance
    13
  - Serial Number Plate Location
    13
  - Servicing the Electric Vehicle
    13
  - Transporting Vehicle
    13
  - Care and Cleaning of the Vehicle
    14
  - Fig. 2 Lubrication Point
    14
  - Light Bulb Replacement
    14
  - Vehicle Care Products
    15
  - Fig. 3 Torque Specifications
    16
  - Hardware
    16
  - Torque Specifications
    16
  - Periodic Service Schedule
    17
  - Fig. 4 Periodic Service Schedule
    18
Safety

19
- General (Asme/Ansi B56.8-1988 Part II)
  21
- Section Title
  21
  - Wheels and Tires
    41
- General Maintenance
  25
- Important Safety Warning
  25
- Modifications to Vehicle
  25
- Notes, Cautions and Warnings
  25
- Additional Warnings
  26
- Before Servicing the Vehicle
  26
- Battery Removal & Installation
  27
- Lifting the Vehicle
  28
Front Suspension and Steering

45
- Maintenance
  48
  - Lubrication
    48
  - Wheel Bearing and King Pin Bushing Inspection
    48
  - Wheel Bearing Packing
    48
  - Wheel Bearing Adjustment
    49
  - Wheel Alignment
    49
- Section Title
  48
  - Electronic Speed Control (36V
    67
  - Electronic Speed Control (48V
    85
  - Motor
    103
- Front Suspension
  51
  - Front Shock Absorber Replacement
    51
  - Front Axle Replacement
    52
  - Axle Linkage Rod Replacement
    52
  - Front Spring Replacement
    52
  - Hub Replacement
    54
  - Wheel Bearing and Race Replacement
    54
- Steering
  56
Batteries and Charging

111
- Battery
  113
- Battery Maintenance
  113
  - At each Charging Cycle
    113
  - Electrolyte Level and Water
    114
  - Cleaning Batteries
    115
  - Battery Replacement
    115
  - Prolonged Storage
    116
  - Battery Charging
    117
  - AC Voltage
    117
- Safety
  113
- Section Title
  113
  - Electrical System
    121
- Troubleshooting
  117
  - Hydrometer
    118
  - Using a Hydrometer
    118
- Battery Charger
  119
  - Description
    119
  - Portable Charger Installation
    119
  - Charger Maintenance
    120
Brakes

131
- Section Title
  
  132
- Brakes - Rear Mechanical
  
  133
  - Brake System Overview
    133
    
    General Description
    133
    
    Equalizer Link
    133
    
    Automatic Adjuster Mechanism
    134
    
    How the Parking Brake Works
    134
    
    Compensator Assembly
    135
    
    Kick-Off Actuating Linkage
    135
  - Troubleshooting Flowchart
    136
  - Troubleshooting Table
    138
  - Troubleshooting and Inspection
    140
    
    New Vehicles
    140
    
    Troubleshooting and Inspection Procedures
    140
    
    Brake Pedal and Linkage Inspection
    140
    
    Periodic Brake Performance Test (PBPT)
    142
    
    Aggressive Stop Test
    143
    
    Wheel Brake Inspection
    144
  - Maintenance and Repairs
    146
    
    Parts Replacement Vs. Repair
    146
    
    Adjusting Brake Pedal Free Travel
    146
    
    Brake Drum Removal and Installation
    147
  - Brakes - Front Disc
    153
Battery Charger

157
- Battery Charger
  159
  - Description
    159
- Portable Charger Installation
  159
- Section Title
  159
  - Rear Suspension
    165
    
    Rear Axle
    167
  - Rear Axle
    169
  - Weather Protection
    175
    
    Top and Windshield
    177
  - Paint
    181
- On-Board Charger
  160
- Opening the Charger
  160
- Understanding the Charger
  160
- Component Replacement
  161
- Troubleshooting
  161
  - Continuity Checks
    161
  - Diode Test Procedure
    161
- Portable Charger
  164
Troubleshooting

185
- Section Title
  187
  - Electrical System
    187
  - Basic Electrical Power System Troubleshooting
    188
    
    Basic Electrical Troubleshooting for Accessories
    188
  - Suspension and Steering
    189
  - Lightning Protection and Grounding
    191
  - General Specifications
    197
    
    Industrial
    197
    
    Brakes
    199
    
    Tires
    199

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