Cushman HAULER 1000 2012 Technician'S Repair And Service Manual Download Page 30

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Page C-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 Front Body Components

Brush Guard

Front Basket

Glove Box Door

Splash Panel

Instrumental Panel

Front Fascia

Fender Flare

Cowl

Splash Panel

Floorpan

Summary of Contents for HAULER 1000 2012

Page 1: ...TECHNICIAN S REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLES REVISED AUGUST2012 625608 ISSUED MAY 2012...

Page 2: ...h the AC Drive motor must be towed with the Run Tow switch located under the passenger seat in the Tow position If the vehicle is to be used in a commercial environment signs similar to the ones illus...

Page 3: ...information contained in this Manual may be revised periodically E Z GO and therefore is subject to change without notice E Z GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL and E Z GO SPECIFICALLY DI...

Page 4: ...e United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self dischar...

Page 5: ...RMATION ROUTINE MAINTENANCE A SAFETY B BODY C WHEELS AND TIRES D FRONT SUSPENSION AND STEERING E ELECTRONIC SPEED CONTROL F MOTOR G BATTERIES AND CHARGING H ELECTRICAL SYSTEM J BRAKES K BATTERY CHARGE...

Page 6: ...Page iv Repair and Service Manual NOTES TABLE OF CONTENTS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

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: ...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 AND CARE A 2 VEHICLE CARE PRODUCTS A 3 SUN TOP AND WINDSHIELD A 3 HARDWA...

Page 12: ...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 an...

Page 13: ...quately secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehicle see GENERAL SPECIFICA TIONS for vehicle weight and load plus 1000 lbs 454 kg Lock t...

Page 14: ...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 check fill plug located on the bottom of...

Page 15: ...ended that the underbody be flushed occa sionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas should be loosened to ease its remov...

Page 16: ...RQUE 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 in ac...

Page 17: ...condition loose terminals corrosion hold down hardware CL CL CL CL Batteries check electrolyte level fill if required C A C A C A C A Brakes smooth operation of pedal Fluid stopping distance Brakes ag...

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: ...1 IMPORTANT SAFETY WARNING B 1 MODIFICATIONS TO VEHICLE B 1 GENERAL MAINTENANCE B 1 BEFORE SERVICING THE VEHICLE B 1 Additional Warnings B 2 BATTERY REMOVAL INSTALLATION B 3 LIFTING THE VEHICLE B 4 L...

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: ...rrosive explosive or 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 w...

Page 22: ...rks away from the batteries 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...

Page 23: ...hardware and lifting 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...

Page 24: ...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 crossmember Raise v...

Page 25: ...Page B 5 Repair and Service Manual Notes SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 26: ...Page B 6 Repair and Service Manual Notes SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 27: ...C 8 Minor Scratches C 8 Larger Scratches C 8 Complete Panel Repair C 8 LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Front Body Components C 2 Fig 3 Rear Body Components Hauler 800 C 3...

Page 28: ...Page C ii Repair and Service Manual Notes BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 29: ...ll provide additional protection In general body component replacement can be accom plished with a minimum of specialized tools Most body components are held in place with conventional remov able hard...

Page 30: ...this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 2 Front Body Components 48 Brush Guard Front Basket Glove Box Door Splash Panel Inst...

Page 31: ...on B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 Rear Body Components HAULER 800 Side Panel Floor Mat Rocker Panel Seat Wra...

Page 32: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 4 Rear Body Components HAULER 1000 Ashtray Side Panel Floor Mat Rocker Panel Seat...

Page 33: ...ttempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 5 Seating Seat Bottom Assembly Seat Back Assembly For Hauler 800 For Hauler 1000 Front of Vehicle 8 Seat B...

Page 34: ...Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 6 Plastic Bed Components Manual Lift A A B B C C Plastic B...

Page 35: ...y procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 7 Plastic Bed Components Power Actuator Actuator may be rotated 90 on some models UP DOWN ELECTRIC DUMP RED from Batte...

Page 36: ...lean the surface to be repaired with alco hol and dry 2 Mask the area to be painted common masking tape is adequate prior to repair and use aerosol type touch up paint 3 Apply spray touch up paint in...

Page 37: ...Page C 9 Repair and Service Manual B 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 38: ...Page C 10 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 39: ...S FOR SECTION D SECTION TITLE PAGE NO Page D i Repair and Service Manual WHEELS AND TIRES WHEEL AND TIRE SERVICE D 1 TIre Repair D 1 Wheel Installation D 2 LIST OF ILLUSTRATIONS Fig 1 Wheel and Tire I...

Page 40: ...Page D 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 41: ...rim or cause the tire to explode either of which could cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire...

Page 42: ...85 ft lbs 115 Nm torque It is important to follow the 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 moun...

Page 43: ...Page D 3 Repair and Service Manual B 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 44: ...Page D 4 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 45: ...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 46: ...ints Do not use more than three 3 pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Wheel B...

Page 47: ...in 2 and loosen castellated nut 3 If performing a wheel bearing adjustment as part of another procedure make sure wheel is mounted to hub hand tight with lug nuts 4 and hub is loosely retained on spin...

Page 48: ...e flat area on the threaded tube has left hand threads clock wise to loosen while the end without the flat has conventional right hand threads counter clockwise to loosen To adjust wheel alignment loo...

Page 49: ...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 50: ...t 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 long...

Page 51: ...e 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 t...

Page 52: ...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 spindle and fill the area between the two wheel bearin...

Page 53: ...e 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 of hub Clean spindle 2 and pack new bearings with gre...

Page 54: ...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 55: ...ion Check front wheel alignment and adjust if necessary Wheel Alignment on page E 3 Tie Rod Inspection Replacement Tool List Qty Tape Measure 1 Wrench 3 4 1 Wrench 9 16 1 Needle Nose Pliers 1 Wrench 1...

Page 56: ...e 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 10 Cut...

Page 57: ...l List 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 use...

Page 58: ...hey are found to be damaged or excessively worn a new rack and pinion unit must be installed Secure rack and pinion unit in vice by the mounting ears only The rack and pinion unit is made of aluminum...

Page 59: ...6 1 Torque Wrench in lbs 1 To remove rack and pinion unit 12 Ref Fig 12 loosen front wheels and lift and support front of vehicle per SAFETY section Remove front wheels Remove bolt 13 and washer 14 se...

Page 60: ...te the 1 8 gap Tighten jam nut 5 to 35 45 ft lbs 47 61 Nm torque Secure bellows to rack and pinion unit with new wire tie 14 Steering Wheel Replacement Tool List Qty Socket 15 16 1 Ratchet 1 2 drive 1...

Page 61: ...pres ent replace clipboard Install by carefully pressing first the top two then the bottom two retaining tabs into the matching slots in steering wheel Steering Shaft and Column Replacement Tool List...

Page 62: ...of seal in bushing 12 at top of column and press steering shaft and bearing assem bly into column base Secure with large retaining ring making sure it is fully seated in groove of column Place steerin...

Page 63: ...19 Repair and Service Manual B B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 64: ...E 20 Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 65: ...RAMS F 6 1206HB 5201 Controller Faults and Troubleshooting F 6 INDUCTIVE THROTTLE SENSOR ITS TESTING AND REPLACEMENT F 10 CONTROLLER REPLACEMENT F 13 SOLENOID REPLACEMENT F 13 LIST OF ILLUSTRATIONS Fi...

Page 66: ...LLER REPLACEMENT F 32 SOLENOID REPLACEMENT F 32 LIST OF ILLUSTRATIONS Fig 14 Run Tow Maintenance Switch F 17 Fig 15 Access to Pedal Box F 18 Fig 16 Controller and Solenoid F 19 Fig 17 Battery Referenc...

Page 67: ...agnotic tool 4 The Freedom performance option This option includes all of the driving features of the Golf Coastal option except that the flat ground and downhill com pression braking speeds are 18 5...

Page 68: ...s The system functions in all key switch positions The TCT system is not a substitute for the ser vice brake which should be used to control speed and reduce possibility of injury If all of the follow...

Page 69: ...to the armature shaft of the motor Magnetic pulses are converted into electri cal signals which the controller uses to determine the motor speed Controller The controller is a solid state unit that a...

Page 70: ...adequacy of the battery set charge the batteries and perform a load test using a discharge machine following manufacturer s instructions If batteries are satisfactory recharge bat tery set Fig 4 Batte...

Page 71: ...indicate 0 when it detects continuity Testing a Switch for Continuity Place one probe on one contact of the switch place the second probe on the second terminal of the switch Ref Fig 5 on Page F 5 Act...

Page 72: ...mmanded to be closed 3 9 Throttle reapplied 1 Contactor opened 2 Contactor coil or wiring opened MAIN DRIVER OFF Main Driver FET detected as not turning ON Throttle applied to cause Contactor to close...

Page 73: ...ler powers up with Key Direction and Throttle applied OR Throttle applied before Key and Direction switch applied KSI ON Forward or Reverse ON 8 Throttle 25 1 Incorrect sequence of Vehicle input contr...

Page 74: ...ttempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 8 Controller Connectors and Connections RU N TO W C From Motor 4AWG A1 From Motor 4AWG CB To Solenoid 4AWG...

Page 75: ...s Cautions Warnings and Dangers Fig 9 Controller Wiring Diagram KSI WHT WHT WHT YEL BLU MAIN COIL BLU RED RED RED RED RUN TOW ORG RED ORG GRN GREY WHT YEL WHT RED RED GRN BLK BLK BLK BLK BLK A1 A A2 F...

Page 76: ...0V 0 3V when the solenoid clicks and 2 7V 0 5 volts at full pedal 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 st...

Page 77: ...Warnings and Dangers Fig 11 ITS Adjustment Sheet 1 of 2 Use 7 32 drill to measure gap between plunger and ITS Micro switch disengaged Micro switch disengaged Pedal bracket rest against front of pedal...

Page 78: ...o Notices Cautions Warnings and Dangers Fig 12 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 SOLE...

Page 79: ...to 120 144 in lbs 13 5 16 3 Nm torque Replace the environmental cover and tighten the mount ing bolts to 35 44 in lbs 4 5 Nm torque Reconnect the BL battery cable and replace the seat SOLENOID REPLACE...

Page 80: ...d this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 13 Solenoid Wiring SOL Red Wire Ring Terminal From Main Wire Harness SOL From Contr...

Page 81: ...Repair and Service Manual Notes ELECTRONIC SPEED CONTROL HAULER 800 TCT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings an...

Page 82: ...Repair and Service Manual Notes ELECTRONIC SPEED CONTROL HAULER 800 TCT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings an...

Page 83: ...y 2 mph 3 kph and the warning beeper will sound When the accelerator pedal is depressed the electronic brak ing and warning beeper will be overridden and normal vehicle operation resumes Any unusual s...

Page 84: ...me the 48 volt system should be disconnected from the bat teries by selecting the TOW MAINTENANCE position on the Run Tow Maintenance switch located under the passenger seat The Electronic Speed Contr...

Page 85: ...8 drive 1 Torque wrench ft lbs 3 8 drive 1 Extension 6 3 8 drive 1 Insulated wrench 9 16 1 Wrench 1 2 1 Wrench 7 16 1 Phillips screwdriver large 1 Phillips screwdriver small 1 Shop towel 1 Allen wrenc...

Page 86: ...voltage test If there is any doubt as to the adequacy of the bat tery set charge the batteries and perform a load test using a discharge machine following manufacturer s instructions If batteries are...

Page 87: ...the probes are attached without activating switch The audible indicator will stop and the meter dis play will indicate a value greater than 0 when the switch is activated Fig 18 Continuity Check of Sw...

Page 88: ...g Replace 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 conne...

Page 89: ...uxiliary contact 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 wirin...

Page 90: ...1 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 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 Sw...

Page 91: ...J 1 Pin Connector 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 Swit...

Page 92: ...ro wiring 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 Perform...

Page 93: ...the negative 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 th...

Page 94: ...erform battery discharge test Verify the chrager process Negative probe on BL and positive probe on battery side of solenoid BRF Verify wire connection quality Positive probe on B and negative probe o...

Page 95: ...he solenoid clicks and 2 7V 0 5 volts at full pedal Ref Fig 29 on Page F 31 If the reading is out of specification the ITS sensor must be replaced The ITS attaches to the plastic pedal box using two p...

Page 96: ...CONTROL HAULER 1000 Fig 28 ITS Adjustment Sheet 1 of 2 Use 17 64 drill to measure gap between plunger and ITS Micro switch disengaged Micro switch disengaged Pedal bracket rest against front of pedal...

Page 97: ...Warnings B B ELECTRONIC SPEED CONTROL HAULER 1000 Fig 29 ITS Adjustment Sheet 2 of 2 Micro switch activated Plunger enters ITS Plunger fully activated Pedal bracket rests on rear of pedal frame openi...

Page 98: ...2 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 vehicle Replace and tighten...

Page 99: ...r A1 Power Harness 4 Black From Motor A2 Power Harness 18 Yellow From J1 Pin 5 Control Harness 18 Blue From J1 Pin 17 Control Harness 18 Red From Tow Switch and Reverse Buzzer Control Harness 10 White...

Page 100: ...Repair and Service Manual NOTES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings ELECTRONIC SPEED CONTROL HA...

Page 101: ...1 Fig 2 Mark Axle and Motor G 1 Fig 3 Motor Components G 2 Fig 4 Brush Wear G 3 Fig 5 Securing Brushes G 4 Fig 6 Motor Wiring G 4 HAULER 1000 GENERAL G 7 Motor Removal G 7 Motor Disassembly G 7 Beari...

Page 102: ...Page G ii Repair and Service Manual Notes MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 103: ...on the TCT model vehicle the Run Tow Maintenance switch must be left in the Tow Maintenance position for at least 30 seconds after the circuit is restored Disconnect the negative BL battery cable wit...

Page 104: ...B MOTOR HAULER 800 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 Motor Components Speed Sensor 13 5 4 3...

Page 105: ...sting against the side of the brush This keeps the brushes out of the way during bearing replacement Ref Fig 5 on Page G 4 Remove internal snap ring 8 and heat the commutator end cover again Press bea...

Page 106: ...ap ring Ref Fig 3 on Page G 2 Motor Tests The armature and motor housing are not available as individual parts No testing is recommended to deter mine the specific area of failure When a test of the p...

Page 107: ...Page G 5 Repair and Service Manual Notes MOTOR HAULER 800 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 108: ...Page G 6 Repair and Service Manual Notes MOTOR HAULER 800 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 109: ...anual 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 Using an insulated wrench disc...

Page 110: ...aring Proper support must be given to the commutator end cover during press operations Inadequate and or uneven support will cause the end cover to fracture To aid disassembly heat only the commutator...

Page 111: ...e field coil retainers 11 to motor housing 4 Remove the field coils Replacement field coils are installed in reverse order of disassembly Brush Replacement Tool List Qty Wrench 1 2 1 Ratchet 1 Socket...

Page 112: ...the system is operating correctly and the vehicle either does not run or runs poorly the motor is the only remaining component and must be replaced Motor Installation Tool List Qty Socket 7 16 3 8 dr...

Page 113: ...Page G 11 Repair and Service Manual B B MOTOR HAULER 1000 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 114: ...Page G 12 Repair and Service Manual B MOTOR HAULER 1000 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 115: ...TING H 6 Hydrometer H 6 Using A Hydrometer H 7 LIST OF ILLUSTRATIONS Fig 1 Correct Electrolyte Level H 2 Fig 2 Watre Purity Table H 2 Fig 3 Automatic Watering Gun H 3 Fig 4 Preparing Acid Neutralizing...

Page 116: ...age H ii Repair and Service Manual Notes BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 117: ...ter 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 Aerosol container...

Page 118: ...age A battery being charged will gas with the majority of 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...

Page 119: ...Preparing Acid Neutralizing Solution Allow the solution to sit for at least three minutes use a soft bristle brush or cloth to wipe the tops of the batteries in order to remove any residue that could...

Page 120: ...event battery explosion that could result in severe personal injury or death extreme care must be used with aerosol containers of battery terminal protectant Insulate the metal container to prevent th...

Page 121: ...e the battery For portable chargers disconnect the charging plug from the vehicle receptacle For on board chargers disconnect the charging harness from the batteries The batteries must be cleaned and...

Page 122: ...battery must mature before it will develop its maximum capacity Maturing may take up to 100 charge discharge cycles After the maturing phase the older a battery gets the lower the capacity The only w...

Page 123: ...electrolyte temperature is above or below 80 F 27 C Adjust the reading to conform with the electrolyte temperature e g if the reading indicates a specific gravity of 1 250 and the electrolyte tempera...

Page 124: ...age H 8 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 125: ...1 TROUBLESHOOTING J 1 POWER SUPPLY J 5 MAIN ACCESSORY WIRING J 5 LIST OF ILLUSTRATIONS Fig 1 DVOM J 1 Fig 2 Accessory Wiring Diagram HAULER 800 J 2 Fig 3 Main Harness Wiring Diagram HAULER 800 J 3 Fig...

Page 126: ...Page J ii Repair and Service Manual Notes ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 127: ...ot the lighting 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...

Page 128: ...dicates butt connection within wiring harness Brake Switch RED BRN WHT BLK BLK NO C Driver Side Passenger Side Driver Side Passenger Side State of Charge Meter Solenoid Hour Meter Turn Turn Marker Mar...

Page 129: ...9 10 11 12 13 14 15 16 S 1 1 1 1 S 1 1 PURPLE GREEN WHITE 1 2 3 4 GRAY 1 3 4 2 A5 1 1 1 2 2 4 4 3 3 W17 W8 W7 W14 W13 W11 W10 W12 W6 W18 W16 1 W21 W19 W20 W9 W5 W4 W3 W2 W1 W15 W23 W22 W25 W24 RUN TOW...

Page 130: ...Switch Part of Key Switch RED 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 Turn Signal Taillight Taillight YEL BRN...

Page 131: ...e readings may be somewhat lower than battery volt age A reading of 1 volt below battery voltage is acceptable 3 Check Converter Supply Firmly attach the black probe to the most negative battery post...

Page 132: ...ion before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers B ELECTRICAL SYSTEM Fig 5 Electrical Accessories RED GRN BLK REVERSE BUZZER DASH MOUNTED DIRECTION...

Page 133: ...this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers B B ELECTRICAL SYSTEM Fig 6 Electrical Accessories ON OFF KEY SWITCH AND KEY SET GRN HORN...

Page 134: ...l Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers B ELECTRICAL SYSTEM Fig 7 Electrical Accessories Rear Fender...

Page 135: ...Page J 9 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 ELECTRICAL SYSTEM...

Page 136: ...Page J 10 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 ELECTRICAL SYSTEM...

Page 137: ...nd Installation K 15 Wheel Brake Service K 16 Backing Plate Entire Wheel Brake Assembly Removal and Installation K 17 Brake Shoe Removal K 17 Brake Shoe Installation K 18 Brake Cable and Equalizer Ass...

Page 138: ...Removal and Installation K 17 Fig 24 Brake Shoe 17L K 18 Fig 25 Brake Shoe 17T K 18 Fig 26 Brake Shoes and Springs K 19 Fig 27 Brake Cable Equalizer and Compensator K 19 Fig 28 Brake Pedal Removal and...

Page 139: ...cables is governed by the brake pedal If the cables can not travel far enough to absorb the slack free travel in the system and still apply the shoes to the drums the braking effort at the wheel brake...

Page 140: ...oing so will cause permanent damage to the adjuster assem bly and result in a gradual loss of brakes The wheel brakes are equipped with an automatic adjuster mechanism that is designed to compensate f...

Page 141: ...top tube within the spring is engaged and the linkage becomes solid Ref Fig 3 on Page K 3 The brake compensator assembly applies a spring load to the parking brake system and insures that the parking...

Page 142: ...ght Providing free travel is correctly adjusted the clevis pins will not be under tension by the brake cables Test Result Fails 2 out of 3 Fails 2 out of 3 Perform the Periodic Brake Performance Test...

Page 143: ...lling Do this by first verifying that some braking function exists Then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start d...

Page 144: ...rovided that shoes have 06 1 5 mm min material System not adjusted properly Check and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace Starti...

Page 145: ...r glazed Check again when shoes are dry Rusted or sticky brake pivot hardware Replace Neither wheel locks Brake system requires complete adjustment Adjust entire system Brake pedal not returning Check...

Page 146: ...eliminate the need for routine brake testing and inspection as shown on the Periodic Service Schedule in Section A Continued proper brake operation depends on periodic mainte nance Brake Pedal and Lin...

Page 147: ...ee motion when the pedal is applied and released Inspect the brake cable sup ports to be sure the cables are properly secured If any of these conditions are found replace both cables and equalizer as...

Page 148: ...severe injury or death resulting from operating a vehicle with improperly oper ating brake system the braking system must be properly maintained All driving brake tests must be done in a safe location...

Page 149: ...avel Adjusting Brake Pedal Free Travel on page 14 Then repeat the Periodic Brake Performance Tests If vehicle fails remove from service and refer to Wheel Brake Inspection to evalu ate the reason for...

Page 150: ...icantly worn and leaving a ledge of unworn drum Inspect the splines for galling wear and corrosion If any of these problems are found the drum must be replaced 3 Remove any accumulated brake dust from...

Page 151: ...es to show more wear at the leading and trailing edges Ref Fig 14 on Page K 12 If the brake shoe thickness is approaching 06 1 5 mm it is recommended that the shoes be replaced It is recommended that...

Page 152: ...ke cables start to move the brake levers This should not be confused with the light resistance that is felt as the brake pedal is depressed enough to remove slack from the compensa tor and cables Corr...

Page 153: ...ing Parking Brake Latching Pressure Brake Drum Removal and Installation Remove the dust cap 1 to gain access to the castel lated nut 2 and the cotter pin 3 Ref Fig 21 on Page K 15 Fig 21 Brake Assembl...

Page 154: ...ic Service Schedule in Section A The wear rate of brake shoes and required service intervals will vary based on usage terrain and other conditions It is recommended that wheel brake service be perform...

Page 155: ...re replaced the adjusters and springs also be replaced It is good practice to do one side at a time using the other side for reference Using a pair of pliers compress the brake shoe retainer springs 1...

Page 156: ...shoe retainer springs and brake shoe return springs Clean the axle shaft to remove grease dirt and all for eign matter Fig 25 Brake Shoe 17T Insert a straight blade screwdriver between the adjusting l...

Page 157: ...the spherical nut on the equalizer link Ref Fig 27 on Page K 19 Inspect the hardware and replace if needed Remove the brake cable and equalizer assembly and discard Slide the equalizer link of the new...

Page 158: ...and to the side to release the torsion spring Ref Fig 28 on Page K 20 Remove the lock nut 5 the shoulder bolt 6 and remove the brake pedal Inspect the shoulder bolt for corrosion that could cause bin...

Page 159: ...the reverse order of disassembly Use a new push nut or push nuts If required adjust the kick off cam 3 Parking Brake Kick Off Cam Removal Replacement and Installation on page 22 Pedal Bumper Adjustmen...

Page 160: ...ove the cam pivot 7 cam and spacer 8 Ref Fig 31 on Page K 21 Inspect the bushings 9 10 and spacer If they are worn replace them with new ones Installation is in the reverse order of disassembly With t...

Page 161: ...Page K 23 Repair and Service Manual NOTES MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 162: ...Page K 24 Repair and Service Manual NOTES MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 163: ...remove the master cylinder Remove the bolts securing the brake actuator assembly housing cover and remove cover The clevis pin joining the brake cylinder clevis and the upper actuator pivot must be re...

Page 164: ...que NOTE Unless fluid is lost or a brake line is discon nected there is no need to bleed the system Rotor Replacement The rotor disc brake hub is not designed to be trued turned If the rotor has deep...

Page 165: ...automotive DOT 3 brake fluid Never reuse any excess fluid or return to the original container Dispose of brake fluid prop erly Brake fluid should never be returned to the original con tainer and reus...

Page 166: ...Page K 28 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 BRAKES FRONT DISC...

Page 167: ...Service Manual BATTERY CHARGER CHARGER DESCRIPTION L 1 PORTABLE CHARGER INSTALLATION L 1 UNDERSTANDING THE CHARGER L 2 LED DISPLAY INFORMATION L 2 LED Operation Codes L 2 LED Fault Codes L 2 MAINTENA...

Page 168: ...Page L ii Repair and Service Manual Notes BATTERY CHARGER Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 169: ...any way refer all repair work to qualified personnel Not for use by children Portable chargers are shipped with the vehicle Prior to vehicle or charger operation chargers must be removed and mounted...

Page 170: ...harged RED FLASH fault code LED Fault Code RED FLASH Light turns on briefly but does not flash after that check for valid AC voltage ONE RED FLASH One flash a pause and then again one flash and a paus...

Page 171: ...Page L 3 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 BATTERY CHARGER...

Page 172: ...Page L 4 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 BATTERY CHARGER...

Page 173: ...Service Manual REAR SUSPENSION 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 M 1 REAR AXLE REMOVAL M 3 Re...

Page 174: ...Page M 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 175: ...the shock absorber Shock Absorber Installation Shock absorber installation is in the reverse order of dis assembly except that the shock absorber nuts 1 3 must be tightened until the shock absorber b...

Page 176: ...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 177: ...supporting the differential to the engine frame Remove the U bolts holding axle to engine frame Remove the drive belt and driven clutch see CLUTCHES section Remove the F R shifter bracket nut and loo...

Page 178: ...Page M 4 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 179: ...1 Axle Shaft Seal Removal and Replacement N 2 Axle Shaft Replacement N 3 LIST OF ILLUSTRATIONS Fig 1 Add Check and Drain Rear Axle Lubricant N 1 Fig 2 Removing Installing Outer Snap Ring N 1 Fig 3 Rem...

Page 180: ...Page N ii 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 181: ...le is a precision assembly and therefore any repair or replacement of parts must be done with extreme care in a clean environment Before attempting to perform any service on the axle read and understa...

Page 182: ...ment Tools List Qty Internal snap ring pliers 1 Seal puller 1 Seal installer P N 18739 G1 1 Ball peen hammer 1 Use care to prevent damage to the inner surface of the axle tube at the sealing area Remo...

Page 183: ...ter snap ring Coat the outboard spline of the axle with a commercially available anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 8 on Page N 3 Fig 7 Ins...

Page 184: ...Page N 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 185: ...ervice Manual WEATHER PROTECTION 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 FULL WINDSHIELD P 4 LIST OF ILLUSTRATI...

Page 186: ...Page P ii Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 187: ...ench 9 16 2 Hex wrench 7 32 1 Straight blade screwdriver 1 Rear Support Installation At driver side of vehicle align the holes in the rear strut 5 with the holes in the seat back support bracket being...

Page 188: ...re Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Sun Top B A C D Front of Vehicle D Bumper Front of Vehicle A seat back support seat Front of Vehicle C Front of Vehicle B 3 2...

Page 189: ...ts and 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 t...

Page 190: ...eld Using 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...

Page 191: ...Page P 5 Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 192: ...Page P 6 Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 193: ...ON TITLE PAGE NO Page Q i Repair and Service Manual HANDHELD DIAGNOSTICS HOW TO USE THE HANDHELD PROGRAMMER Q 1 Primary Connections 4 PIN TYCO Q 1 Alternate Connection 4 PIN MOLEX Q 1 Navigation Q 1 C...

Page 194: ...age Q ii Repair and Service Manual B HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 195: ...ow position and also when the battery charger is con nected to the vehicle The main menu appears after the data is uploaded from the unit controller charger etc the main menu will not be displayed if...

Page 196: ...the value of the parame ter BOOKMARK To set a position in the Menu hold a Book mark Key down for four seconds until the Bookmark set screen is displayed To jump to a selected Bookmark position press...

Page 197: ...mph Accel Selection 1 3 2 Braking Selection 1 3 3 5 Freedom Speed 14 5 19 5 18 5 mph Accel Selection 1 2 1 Braking Selection 1 2 1 Monitor Battery Amp Hours 0 100000 AmpHr Battery Voltage 0 100 V Elas...

Page 198: ...Speed Sensor Fault 0 100000 Hrs Main Driver On 0 100000 Hrs Main Coil Open 0 100000 Hrs Main Dropout 1 0 100000 Hrs Motor Stall 0 100000 Hrs Main Driver Off 0 100000 Hrs Main Dropout 2 0 100000 Hrs C...

Page 199: ...r Fault History YES NO Information OEM Info Display OEM information Reconfigured Display reconfigure status Model Number Display handheld model number Serial Number Display handheld serial number Manu...

Page 200: ...Page Q 6 Repair and Service Manual Notes HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 201: ...GE NO TROUBLESHOOTING TROUBLESHOOTING HAULER 800 1206HB 5201 Controller Faults and Troubleshooting R 1 TROUBLESHOOTING HAULER 1000 ELECTRICAL SYSTEM R 5 Basic Electrical Power System Troubleshooting R...

Page 202: ...Page R ii Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 203: ...plied to cause Contactor to close 3 8 Condition clears 1 Controller defective MOTOR STALL High Armature Current when no Speed Pulses detected Contactor closed 6 Speed Pulses appear 1 Motor is stalled...

Page 204: ...on and Throttle applied OR Throttle applied before Key and Direction switch applied KSI ON Forward or Reverse ON 8 Throttle 25 1 Incorrect sequence of Vehicle input controls 2 Defective Throttle devic...

Page 205: ...ge R 3 Repair and Service Manual Notes TROUBLESHOOTING HAULER 800 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dange...

Page 206: ...ge R 4 Repair and Service Manual Notes TROUBLESHOOTING HAULER 800 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dange...

Page 207: ...tion F Electronic Speed Control HAULER 1000 for HAULER 1000 vehicle VEHICLE SPEED ERRATIC Faulty ESC system Test and replace components as indicated by test procedure NO REDUCED SPEED IN REVERSE Fault...

Page 208: ...in the bellows Remove the bellows and remove excess grease Insufficient lubricant in king pins rod ends idler bushing or steering box Add one pump of lubricant to each grease fitting and operate stee...

Page 209: ...e R 7 Repair and Service Manual Notes TROUBLESHOOTING HAULER 1000 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dange...

Page 210: ...e R 8 Repair and Service Manual Notes TROUBLESHOOTING HAULER 1000 Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dange...

Page 211: ...NG GROUNDING REQUIREMENTS S 1 GROUND SYSTEMS S 1 LIGHTINIG PROTECTION REQUIREMENTS S 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM S 1 GROUND NETWORK REQUIREMENTS S 1 EXTERNAL GROUNDING REQUIREMENTS S...

Page 212: ...ii Repair and Service Manual Notes LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and D...

Page 213: ...ohms 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...

Page 214: ...below grade and be at least 24 away from the struc ture 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 be driv...

Page 215: ...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 insulat...

Page 216: ...4 Repair and Service Manual Notes LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and D...

Page 217: ...AGE NO Page T i Repair and Service Manual GENERAL SPECIFICATIONS HAULER 800 T 1 HAULER 1000 T 2 LIST OF ILLUSTRATIONS Fig 1 Vehicle Dimensions T 3 Fig 2 Incline Specifications and Turning Clearance Di...

Page 218: ...ge T 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 219: ...2 cm Rear Axle Ratio 12 44 1 Overall Width 49 5 in 128 cm Performance Overall Height No Canopy 46 5 in 118 cm Top of steering wheel Seating Capacity 2 Person Overall Height With Canopy 70 0 in 178 cm...

Page 220: ...9 5 in 128 cm Performance Overall Height No Canopy 46 5 in 118 cm Top of steering wheel Seating Capacity 2 Person Overall Height With Canopy 70 0 in 178 cm Dry Weight 810 lb 367 kg Without Batteries W...

Page 221: ...ons Warnings and Dangers 7 5 in 19 0 cm 65 5 in 166 0 cm 103 5 in 262 0 cm 48 6 in 123 0 cm Rear 38 0 in 97 0 cm Front 37 0in 94 0 cm HAULER 800 44 5 in 113 0 cm 30 5 in 77 0 cm 10 5 in 27 0 cm 18 0 i...

Page 222: ...e attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURNING CLEARANCE DIA HAULER 800 19 0 ft 5 8 m HAULER 1000 22 0 ft 6 7 m RECOMMENDED MAX RAMP GRADE 25 or 1...

Page 223: ...Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 6 3 16 cm 1 8 4 5 cm 1 4 3 5cm 7 8 19 8 cm 11 4 28 9 cm 4 8 12 2 cm 10 5 26...

Page 224: ...age T 6 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 225: ...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 226: ...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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