Cushman 632904 Service Manual Download Page 38

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Page D-2

Repair and Service Manual

BODY

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Fig. 2 Body Components (Front)

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Summary of Contents for 632904

Page 1: ...632904 REVISED JANUARY 2014 ISSUED MAY 2013 48V ELECTRIC POWERED UTILITY VEHICLE Repair Service Manual...

Page 2: ...UTIONS 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 unsaf...

Page 3: ...tained in this Manual may be revised periodically by E Z GO and therefore is subject to change without notice E Z GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and E Z GO SPECIFICALLY DISCLAIMS LIA...

Page 4: ...n applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and con...

Page 5: ...ECTION GENERAL INFORMATION ROUTINE MAINTENANCE A SAFETY B BATTERIES AND CHARGING C BODY D BRAKES E ELECTRICAL SYSTEM F ELECTRONIC SPEED CONTROL G FRONT SUSPENSION AND STEERING H MOTOR J REAR AXLE K RE...

Page 6: ...Page iv Repair and Service Manual NOTES TABLE OF CONTENTS...

Page 7: ...the information contained in this manual is subject to change without notice E Z GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result f...

Page 8: ...val of a battery wire Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Remove the batteries...

Page 9: ...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...

Page 10: ...Page viii Repair and Service Manual Notes SAFETY INFORMATION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 11: ...LOCATION A 1 TRANSPORTING VEHICLE A 1 Towing A 1 Hauling A 1 SERVICING THE ELECTRIC VEHICLE A 1 ROUTINE MAINTENANCE A 2 REAR AXLE A 2 BRAKES A 2 TIRES A 2 LIGHT BULB REPLACEMENT A 2 VEHICLE CLEANING...

Page 12: ...Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers GENERAL INFORMATION ROUTINE MA...

Page 13: ...dshield before transporting Maximum speed with sun top installed is 50 mph 80 kph If the vehicle is to be transported at highway speeds the sun top must be removed and the seat bottom secured When tra...

Page 14: ...and cause premature bearing failure REAR AXLE The only maintenance required for the first five years is the periodic inspection of the lubricant level The rear axle is provided with a lubricant level...

Page 15: ...d as fertilizers or for dust control can collect on the underbody of the vehicle These materials will accelerate corrosion of underbody parts It is recommended that the underbody be flushed occa siona...

Page 16: ...2 TORQUE SPECIFICATIONS Fig 3 Torque Specifications ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten all hardware...

Page 17: ...evel in master cylinder Brakes aggressive stop test C A C A C A C A Park Brake operation does it hold on a hill C A C A C A C A Accelerator smooth operation Charger Receptacle inspect charger connecto...

Page 18: ...Repair and Service Manual Notes GENERAL INFORMATION ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and...

Page 19: ...ttention to Notices Cautions Warnings and Dangers SAFETY NOTICES CAUTIONS WARNINGS AND DANGERS B 1 IMPORTANT SAFETY WARNING B 1 MODIFICATIONS TO VEHICLE B 1 GENERAL MAINTENANCE B 1 BEFORE SERVICING TH...

Page 20: ...Page B ii Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SAFETY...

Page 21: ...may produce high amperage or reach high temperatures Battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be...

Page 22: ...tteries 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...

Page 23: ...ing the retainer from the batteries Remove the batteries using a commercial battery carrier If the batteries have been cleaned and any acid in the battery rack area neutralized on a regular basis no c...

Page 24: ...ess When lifting the vehicle position jack stands only in the areas indicated To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 2 Center jack under the rear frame...

Page 25: ...ent C 4 Prolonged Storage C 4 Battery Charging C 5 AC Voltage C 5 TROUBLESHOOTING C 5 Hydrometer C 6 Using A Hydrometer C 6 BATTERY CHARGER C 7 Description C 7 Portable Charger Installation C 7 Charge...

Page 26: ...ge C ii Repair and Service Manual B BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Note...

Page 27: ...nd flushed with water Overfilling batteries may result in electro lyte being expelled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility...

Page 28: ...f the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas...

Page 29: ...ft on the batteries which is conductive and will contribute to the discharge of the batteries To prevent battery damage be sure that all battery caps are tightly installed The correct cleaning techniq...

Page 30: ...connect the battery wires as shown Ref Fig 5 Ensure that all battery terminals are installed crimp up Tighten the battery post hardware to 90 110 in lbs 10 12 5 Nm torque Protect the battery termi na...

Page 31: ...of the charger DC plug This rattle is caused by an inter nal magnet contained within the charger plug The magnet is part of the interlock system that prevents the vehicle from being driven when the ch...

Page 32: ...the temperature of the electrolyte and will include a conversion scale to cor rect the float reading It is important to recognize that the electrolyte temperature is significantly different from the a...

Page 33: ...ion rain and sun protection must be provided Fig 9 Charger Installation A dedicated circuit is required for the charger Refer to the charger manual for appropriate circuit protection The charger may r...

Page 34: ...it use of the vehicle The charger may remain plugged into the AC outlet To charge the vehicle refer to the instruction label on char ger Charger Maintenance The charging DC cord is equipped with a pol...

Page 35: ...l Replacement D 5 Front Seat Pod Replacement D 6 Rear Body Replacement D 6 Foot Rest Replacement D 7 Rear Bumper Replacement D 7 Front Seat Replacement D 7 Front Facing Rear Seat D 8 Rear Facing Rear...

Page 36: ...Page D ii Repair and Service Manual B BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 37: ...ll provide additional protection In general body component replacement can be accomplished with a minimum of specialized tools Most body components are held in place with conven tional removable hardw...

Page 38: ...Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 2 Body Components Front 15 6 4 16 1 19 3 17 13 12 14 18 22...

Page 39: ...of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 Body Components Seats and Rear Body 34 34 34 33 75 76 45 71 18 67...

Page 40: ...of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 4 Body Components Cargo Box Seat Foot Rest Seat Bed Seat Back Suppor...

Page 41: ...key switch plate and push it through the instrument panel opening freeing the panel for removal Reassembly is the reverse order of disassembly and will require new drive rivets Cowl Replacement Tool L...

Page 42: ...ONS in Section A for standard torque values unless otherwise noted in manual text To prevent possible injury or death from bat tery explosion The battery should always be removed before any servicing...

Page 43: ...eat back supports 36 Remove the screws 37 that secure the seat back sup port to the vehicle frame Remove the hardware 38 that secures the seat back support to the frame support 39 Remove each seat bac...

Page 44: ...jury it is strongly recommended that adequate help or a lifting device be used to remove the cargo bed from the vehicle Remove the hardware 35 from the cargo bed pivot Ref Fig 4 Unlatch the bed catch...

Page 45: ...vehicle and sur rounding area Minor Scratches For minor scratches the manufacturer suggests the fol lowing steps be taken to repair the Durashield body I Thoroughly clean the surface to be repaired w...

Page 46: ...with Carnauba base product avail able at any automotive parts distributor Complete Panel Repair In situations where large panels or areas must be painted touch up paint is not recommended In such cas...

Page 47: ...e E 4 Adjustment E 4 BRAKEDRUM REMOVAL AND INSTALLATION E 4 Wheel Brake Service E 5 Cleaning and Inspection E 7 ROUTINE MAINTAINCE E 7 REPLACEMENT OF WEAR ITEMS E 8 Brake Pad Replacement E 8 Spindle R...

Page 48: ...Page E ii Repair and Service Manual B BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 49: ...pistons by the upper shoe to shoe spring The wheel cylinders are of the double piston design permitting even distribution of force to each shoe There are no links Shoes rest directly on the piston en...

Page 50: ...aks along all lines and at brake assembly If no external leaks are apparent the problem is inside the master cylinder Do not allow brake fluid to contact painted surfaces Wipe off immediately After ma...

Page 51: ...emove flexible brake hose from branch tee Remove brake light switch from branch tee Remove plug from branch tee Do not reuse existing branch tee on new master cylinder Install new branch tee on new ma...

Page 52: ...g 4 At this position the push rod on opposite arm of bellcrank should be against piston in master cylinder but should not be applying any force If push rod is not against piston or is applying force l...

Page 53: ...total of 2 to obtain required spacing If two inner brake drum washers do not provide the required spacing the brake drum is incorrect and must be replaced with a new drum Do not back off nut to insta...

Page 54: ...heel Brake Component Wheel Cylinder Spindle Cap Cotter Pin Castellated Nut Outer Brake Drum Washer Drum Cup and Spring Brake Shoe Lower Shoe to Shoe Spring Inner Brake Drum Washer Upper Shoe to Shoe S...

Page 55: ...is contacted by the brake shoes Be sure shoe ledges are smooth and free of rough edges Replace both wheel brake assemblies if any gouges or galling is found Measure the brake shoe thickness Measure at...

Page 56: ...re is no need to bleed the system For Hub Replacement Wheel Bearing and Race Replacement Wheel Bearing Packing and Wheel Bear ing Adjustment procedures see FRONT SUSPENSION AND STEERING Spindle Replac...

Page 57: ...Add fluid if the level has fallen below 1 4 from the top of the reservoir and inspect for visible fluid leaks PARKING BRAKE The rear brake includes a parking feature consisting of a wheel brake lever...

Page 58: ...a ble Cable replacement consists of first loosen jam nut which holds the brake cable through clamp then remove the washer cotter and clevis pin that securing the cable to the connecting link and side...

Page 59: ...1 POWER SUPPLY F 3 Check For Loose Or Bare Wires F 3 Check battery Condition F 3 Check Green Power Wire F 3 Check Fuse F 3 ACCESSORY WIRING F 3 LIGHT BULB REPLACEMENT F 3 FUSE REPLACEMENT F 4 DC TO DC...

Page 60: ...Page F ii Repair and Service Manual B ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 61: ...hting circuit 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 th...

Page 62: ...BLU WHT Light Switch Part of Key Switch RED RED Inline Fuse RED WHT RED RED BRN BLK YEL Turn Signal Switch GRN WHT YEL WHT BLK Flasher YEL BLU WHT BLK BRN BRN BRN WHT BRN WHT WHT RED RED Turn Signal T...

Page 63: ...nd the red probe to the terminal on the side of the fuse block where the green wire is con nected A reading of battery voltage indicates that the green wire is in good condition The green wire supplie...

Page 64: ...horized Branch or the Service Parts Department Fig 4 Tail Brake Light Bulb Replacement FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace...

Page 65: ...Fig 6 DC to DC Converter Fig 7 Horn Front of Vehicle Mounting Plate Screw Harness Nut DC converter Washer Washer Fuse Block GREEN Red Black Front of Vehicle Harness For Models before 2 Oct 2013 DC co...

Page 66: ...Page F 6 Repair and Service Manual B ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 67: ...ting a Switch for Continuity G 5 Testing a Solenoid for Continuity G 5 TROUBLESHOOTING DIAGRAMS G 6 INDUCTIVE THROTTLE SENSOR ITS TESTING AND REPLACEMENT G 14 CONTROLLER REPLACEMENT G 17 SOLENOID REPL...

Page 68: ...G ii Repair and Service Manual ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 16...

Page 69: ...l slow the vehicle the warning beeper will not sound until either the vehicle speed is reduced to 8 mph 13 kph at which it freely coasts between 8 and 3 mph 5 kph or the accelerator pedal is applied W...

Page 70: ...lerator pedal has been released for more than one second c the vehicle begins to roll above 2 mph 3 kph The electronic braking will limit speed to approximately 2 mph 3 kph and the warning beeper will...

Page 71: ...ssed by removing the four screws and top cover from the enclosed pedal box Fig 2 Access to Pedal Box Speed Sensor The speed sensor uses a sealed sensor to read the impulses of a ring magnet attached t...

Page 72: ...ions and instructions for the use and care of the meter To assure accurate readings be sure to set the meter to the closest voltage reading above the expected voltage To prevent injury resulting from...

Page 73: ...for continuity set the DVOM to the KW setting and select Continuity The meter will give an audible signal when it detects continuity If the meter does not have a continuity setting set it to KW the m...

Page 74: ...s failed and the solenoid must be replaced Fig 6 Continuity Check of Solenoid TROUBLESHOOTING DIAGRAMS The following diagrams will assist in servicing the vehi cle By utilizing the Fault Codes conside...

Page 75: ...ce controller 1 2 Throttle fault 1 Vehicle will not run Check pedal box adjustment connections Replace ITS 1 3 Speed sensor fault Vehicle runs slowly Check speed sensor magnet wire sensor connector co...

Page 76: ...ct did not close Vehicle will not run Replace controller 4 5 Welded auxiliary con tact Vehicle runs slowly Replace controller 5 1 Keyswitch SRO Vehicle will not run Check keyswitch wiring Replace keys...

Page 77: ...14 15 16 17 18 19 20 21 22 23 24 J1 1 2 3 4 5 6 J2 1 2 3 4 J3 F2 To Hand Held Diagnostic MAIN Charger Interlock Switch Optional Walkaway Fuse 20A RUN STORE SWITCH 20 A B M B F1 F R N A2 Key Switch For...

Page 78: ...onnector Diagnostics 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 J1 1 2 3 4 5 6 J2 1 2 3 4 J3 F2 Charger Interlock Switch Optional Walkaway Fuse 20A B M B F1 F R N Key Switch Forwar...

Page 79: ...ng and pin 8 voltage J1 3 BRV Verify tow switch and aux power wiring J1 7 BRV Verify wire connections Possible controller failure J1 8 BRV Verify wiring Possible faulty controller J1 20 Performance op...

Page 80: ...tive side of battery pack voltage The positive lead of the DVOM is used to probe the controller connections Leave connections plugged in the controller Armature will need to be rotated for this test J...

Page 81: ...battery discharge test Verify the chrager process Negative probe on BL and positive probe on battery side of solenoid BRV Verify wire connection quality Positive probe on B and negative probe on B BRV...

Page 82: ...s and 2 7V 0 5 volts at full pedal Ref Fig 17 If the reading is out of specification the ITS sensor must be replaced The ITS attaches to the plastic pedal box using two plas tic studs and two speed nu...

Page 83: ...and Dangers Fig 15 ITS Adjustment Sheet 1 of 2 Use 7 32 drill bit to measure gap between plunger and ITS Micro switch disengaged Micro switch disengaged Pedal bracket rest against front of pedal frame...

Page 84: ...es Cautions Warnings and Dangers Fig 16 ITS Adjustment Sheet 2 of 2 Micro switch activated Plunger enters ITS Plunger fully activated Pedal bracket rests on rear of pedal frame opening 3 4 SOLENOID AC...

Page 85: ...mounting bolts to 108 132 in lbs 12 15 Nm torque and the M6 F1 and F2 bolts to 80 90 in lbs 9 10 Nm torque and M8 B M B bolts to 120 130 in lbs 14 15 Nm torque Replace controller mount assembly in ve...

Page 86: ...ness 4 Black From Motor A1 Power Harness 18 Red From Tow Switch and Reverse Buzzer Control Harness 10 White From Charger Receptacle 4 Black From Battery Power Harness 4 Black From Charger Charger Harn...

Page 87: ...Inspection Replacement H 11 Bellows Replacement H 12 Pinion Seal Replacement H 12 Spindle Replacement H 13 Rack and Pinion Unit Disassembly and Inspection H 14 Rack and Pinion Unit Replacement H 15 Ch...

Page 88: ...rnings and Dangers Fig 15 Bellows Replacement H 12 Fig 16 Pinion Seal Replacement H 13 Fig 17 Removing Brake Caliper H 13 Fig 18 Spindle Replacement H 14 Fig 19 Rack and Pinion Unit Disassembly H 14 F...

Page 89: ...icular attention to Notices Cautions Warnings and Dangers Fig 1 Axle Mounted Steering and Front Suspension Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate...

Page 90: ...ut of rubber boot Fig 2 Lubrication Points Do not use more than three pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas...

Page 91: ...the inner and outer wheel bearings about 1 2 3 4 full with grease Wheel Bearing Adjustment Tool List Qty Socket 1 1 2 1 Ratchet 1 If performing a wheel bearing adjustment only lift and support front...

Page 92: ...ld be 0 1 8 0 3 mm less than the rear Fig 4 Wheel Alignment To hold threaded tube while loosening jam nut use a wrench on the center flat section of tube The tie rod has different threads on each end...

Page 93: ...List Qty Wrench 9 16 1 Remove the nut 1 from the bottom of the shock absorber 2 at the front axle 3 Ref Fig 6 Compress shock absorber to clear the mounting bracket Loosen the nut securing the top of t...

Page 94: ...event pulling apart intermediate shaft Remove the three 1 3 4 long bolts 18 two 1 1 2 long bolts 28 spring plate 24 and five lock nuts 19 secur ing axle to springs and discard lock nuts At the 3 1 2 l...

Page 95: ...25 27 securing rear of spring 17 to vehicle frame and discard lock nuts 27 To prevent stress and possible damage to the rack and pinion unit the driver side spring must be mounted to the axle with th...

Page 96: ...seal 8 so the flange side of the seal is facing into the bore Tap gently into place until seal is flush with end of hub Lubri cate lips of seal and spindle with grease Ref Fig 10 Place new hub onto s...

Page 97: ...must also be replaced To install race 5 make sure bore of hub 1 is clean and place new race over bore of hub Evenly tap with hammer and bearing driver to drive race fully in bore Repeat on other side...

Page 98: ...t 11 16 1 To remove rack ball joint 1 loosen passenger side front wheel and lift and support front of vehicle per SAFETY section Ref Fig 12 Remove passenger side front wheel and turn steering wheel fu...

Page 99: ...section Check front wheel alignment and adjust if necessary Wheel Alignment on page H 3 Tie Rod Inspection Replacement Tool List Qty Tape Measure 1 Wrench 3 4 1 Wrench 9 16 1 Needle Nose Pliers 1 Wren...

Page 100: ...le per SAFETY section Remove passenger side front wheel and turn steering wheel fully to the left Remove rack ball joint 2 and jam nut 3 from rack extension 4 Rack Ball Joint Replacement on page H 10...

Page 101: ...st Qty Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hammer 1 Wrench 3 4 1 Socket 3 4 1 Socket 11 16 1 Torque Wrench ft lbs 1 The spindle bearings are designed to be used dr...

Page 102: ...vice by the mounting ears only The rack and pinion unit is made of aluminum and can be damaged if held otherwise Remove rack and pinion unit from vehicle Anchor in vice by clamping on the mounting ea...

Page 103: ...astellated nut 3 until rack ball joint 1 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 ball joint from pas...

Page 104: ...ion unit with new wire tie 14 Steering Wheel Replacement Tool List Qty Socket 15 16 1 Ratchet 1 2 drive 1 Plastic Faced Hammer 1 Ball Peen Hammer 1 Anti seize Compound 1 Torque Wrench ft lbs 1 To main...

Page 105: ...the vehicle wheels in the straight ahead position align the steering wheel on the steering shaft and slide wheel on shaft Tighten the steering wheel nut 6 to 15 20 ft lbs 20 27 Nm torque Inspect the f...

Page 106: ...ning ring fully into groove Slide wave washer into base of steering column To install steering shaft and bearing assembly apply wheel bearing grease to lip of seal in bushing 12 at top of column and p...

Page 107: ...s Cautions Warnings and Dangers GENERAL J 1 Motor Removal J 1 Motor Disassembly J 1 Bearing Replacement J 2 Field Coil Replacement J 3 Brush Replacement J 3 Motor Assembly J 3 Motor Tests J 4 Motor In...

Page 108: ...Page J ii Repair and Service Manual B MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 109: ...in SAFETY section of this manual The shorting of motor wires could cause an explosion Tool List Qty Insulated wrench 9 16 1 Chalk or paint pen 1 Socket 7 16 1 Ratchet 1 Internal snap ring pliers 1 Usi...

Page 110: ...the armature Once heated place the commutator end cover armature assembly in press giving as much support to the end cover as possible and press the armature out of the bearing Push back each brush un...

Page 111: ...move brush terminal hardware 12 at A1 and A2 Ref Fig 3 Remove screws 13 securing brush plate 14 Remove brushes rigging and brush plate Pull back each brush until each of the springs 15 rest against th...

Page 112: ...Tool List Qty Socket 7 16 3 8 drive 1 Torque wrench in lbs 3 8 drive 1 Be sure that a bumper spline is installed between the motor input pinion shaft and splines Apply a small quan tity of molybdenum...

Page 113: ...K 1 REAR AXLE DISASSEMBLY K 1 Axle Shaft Removal and Disassembly K 1 Axle Shaft Seal Removal and Replacement K 2 Axle Shaft Replacement K 3 LIST OF ILLUSTRATIONS Fig 1 Add Check and Drain Rear Axle Lu...

Page 114: ...Page K ii Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers REAR AXLE...

Page 115: ...Drain Rear Axle Lubricant REAR AXLE DISASSEMBLY The rear axle is a precision assembly and therefore any repair or replacement of parts must be done with extreme care in a clean environment Before att...

Page 116: ...axle shaft Ref Fig 4 Fig 4 Pressing Bearing from Axle Shaft Axle Shaft Seal Removal and Replacement Tools List Qty Internal snap ring pliers 1 Seal puller 1 Seal installer P N 18739 G1 1 Ball peen ham...

Page 117: ...the outer snap ring Coat the outboard spline of the axle with a commer cially available anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 8 Fig 7 Installi...

Page 118: ...Page K 4 Repair and Service Manual Notes REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 119: ...Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers REAR SUSPENSION L 1 General L 1 Shock Absorber Removal L 1 Shock Absorber I...

Page 120: ...Page L ii Repair and Service Manual B REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 121: ...shock absorber 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 bushin...

Page 122: ...REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Rear Suspension Front of the Vehicle 4 4...

Page 123: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TOP AND WINDSHIELD M 1 Trailering M 1 SHUTTLE 8 SUN TOP M 1 Rear Support Installation M 1 Front Struts M 1 Su...

Page 124: ...Page M ii Repair and Service Manual B WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 125: ...ool List Qty Plastic faced mallet 1 Wrench 1 2 2 Wrench 9 16 2 Hex wrench 7 32 1 Straight blade screwdriver 1 Rear Support Installation Using a plastic faced hammer tap end caps 5 into the top of the...

Page 126: ...n before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Shuttle 8 Sun Top Driver Side Shown Front Of Vehicle A 3 6 7 7 8 9 21 4 Sun Top 11 18 20 Front...

Page 127: ...nd press the sash starting at the bottom onto the front strut so that it snaps into place See Details B and C Repeat for opposite side of windshield Position top grips 8 as shown See Detail D at top h...

Page 128: ...a plastic faced mallet gently tap sash to ensure wind shield seats properly See Detail A Insert screw 4 through washer 5 rubber grommet 6 and existing hole in front strut Secure with washer 5 and loc...

Page 129: ...nual WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers WHEEL AND TIRE SERVICE N 1 Tire Repair N...

Page 130: ...Page N ii Repair and Service Manual B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 131: ...could cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor applications with...

Page 132: ...e cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts 1 Finger tigh...

Page 133: ...HOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRICAL SYSTEM P 1 Basic Electrical Power System Tro...

Page 134: ...Page P ii Repair and Service Manual B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 135: ...h or motor Clean tighten or replace faulty wiring Solenoid has failed Replace solenoid Key switch has failed Replace key switch Micro switch at direction selector switch has failed Replace micro switc...

Page 136: ...C SPEED CONTROL section Basic Electrical Troubleshooting for Accessories To diagnose electrical problems in the vehicle electrical wiring system refer to the ELECTRICAL SYSTEM section BATTERIES WILL N...

Page 137: ...eeler gauge will pass under the rack the rack must be replaced PLAY IN STEERING Steering wheel loose Inspect splines replace steering wheel if required Tighten steering wheel nut Steering components w...

Page 138: ...Page P 4 Repair and Service Manual B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 139: ...dure Pay particular attention to Notices Cautions Warnings and Dangers Grounding Requirements Q 1 Ground Systems Q 1 Lightning Protection Requirements Q 1 Equipment Fault and Personal Safety System Q...

Page 140: ...i Repair and Service Manual B LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Danger...

Page 141: ...ms cannot be obtained due to high soil resistivity rock formations or other abnormal conditions alternate methods for reducing the resistance to earth must be considered Chemical Treatments No salt co...

Page 142: ...east 24 below grade and be at least 24 away from the structure All bends in the conductor shall have a minimum radius of 8 and be no less than 90 degrees Ground Mats In areas where electrodes cannot b...

Page 143: ...or to all pull boxes junction boxes and power panels In existing facilities where an existing conduit is not large enough to accommodate an additional ground conductor or where a conduit section is in...

Page 144: ...4 Repair and Service Manual B Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES LIGHTNING PROTECTION AND GR...

Page 145: ...GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SHUTTLE 8 R 1 LIST OF ILLUSTRATIONS Fig...

Page 146: ...ge R ii Repair and Service Manual B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Note...

Page 147: ...mph 0 5 mph 21 kph 0 8 kph Towing Capacity N A Steering Suspension Steering Self compensating rack and pinion Front Suspension Leaf springs with hydraulic shock absorbers Rear Suspension Leaf springs...

Page 148: ...ny procedure Pay particular attention to Notices Cautions Warnings and Dangers 46 0 in 116 8 cm 149 0 in 3178 5 cm 167 5 in 425 5 cm 123 5 in 313 7 cm 45 5 in 115 6 cm 75 6 in 192 0 cm Center Rear Whe...

Page 149: ...NS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURNING CLEARANCE DIAMETER 33 ft 10 1 m RECOMMENDED MAX SIDE...

Page 150: ...age R 4 Repair and Service Manual B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Note...

Page 151: ...properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle...

Page 152: ...of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Service Parts Manuals as well as Repair and Service Manuals ar...

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