Cushman HAULER PRO 2014 Service Manual Download

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TROUBLESHOOTING

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

111

Repair and Service Manual

634756

TROUBLESHOOTING

ELECTRICAL SYSTEM

Basic Electrical Power System Trouble-
shooting

To diagnose electrical problems in the electrical power

system, refer to the ELECTRONIC SPEED CONTROL

section.

Basic Electrical Troubleshooting for Acces-
sories

To diagnose elecrical problems in the vehicle electrical

wiring system, refer to the ELECTRICAL SYSTEM sec-

tion.

Condition

Possible Cause

Correction

VEHICLE WILL NOT MOVE
See ELECTRONIC SPEED CONTROL
section.

VEHICLE SPEED ERRATIC

Faulty ESC system

Test and replace components as
indicated by test procedure

NO REDUCED SPEED IN REVERSE

Faulty ESC system

Test and replace components as
indicated by test procedure

MOTOR NOISY

Damaged bearing

Replace bearing

Raised commutator bar(s)

Replace motor

Loose motor mounting hardware

Tighten

BATTERIES WILL NOT CHARGE

Charger not functioning correctly

Repair or replace charger

Vehicle charging wiring faulty

Repair or replace wiring

Vehicle/charger connector damaged

Replace connector

Battery case damaged

Replace battery

Low electrolyte level

Maintain correct electrolyte level

Battery capacity deficient

Hydrometer/load test
Replace battery if required

Damaged battery

Replace battery

Summary of Contents for HAULER PRO 2014

Page 1: ...TECHNICIAN S REPAIR AND SERVICE MANUAL 72V Electric Powered Utility Vehicle 634756 ISSUED MAY 2014 ...

Page 2: ... and will not be covered under warranty For towing transporting vehicle refer to TRANSPORTING VEHICLE section If the vehicle is to be used in a commercial environment signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition NOTICES CAUTIONS WARNINGS AND DANGERS Observe the NOTICES CAUTIONS WARNINGS and DAN GERS be aware that servicing a ve...

Page 3: ... AND CONSE QUENTIAL DAMAGES resulting from the use of the information and materials in this Manual These are the original instructions as defined by 2006 42 EC CONTACT US E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 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 80...

Page 4: ...order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE Batteries self discharge over time The rate of self discharge varies depending on the ambi ent temperature the age and condition of the batteries Fully charged batteries will not freeze in winter temperatures unless the temperature falls below 75 F...

Page 5: ...nce requirements This vehicle is designed and manufactured for off road use It does not conform to Federal Motor Vehicle Safety Stan dards and is not equipped for operation on public streets Some communities may permit these types of vehicles to be operated on their streets on a limited basis and in accordance with local ordinances Ensure all electrical accessories are grounded to the DC to DC con...

Page 6: ...sing wheel chocks and safety stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated Test drive vehicle after repairs or...

Page 7: ...REAR AXLE 2 BRAKES 2 TIRES 2 Recommended Tire Pressures 2 LIGHT BULB REPLACEMENT 2 VEHICLE CLEANING AND CARE 3 VEHICLE CARE PRODUCTS 3 SUN TOP AND WINDSHIELD 3 HARDWARE 4 SAFETY NOTICES CAUTIONS WARNINGS AND DANGERS 5 IMPORTANT SAFETY WARNING 5 MODIFICATIONS TO VEHICLE 5 GENERAL MAINTENANCE 5 BEFORE SERVICING THE VEHICLE 6 Additional Warnings Specific to Electrical System 6 BATTERY REMOVAL AND INS...

Page 8: ...7 Tire Repair 17 Wheel Installation 18 FRONT SUSPENSION AND STEERING MAINTENANCE 20 Lubrication 20 Wheel Bearing and King Pin Bushing Inspection 20 Wheel Bearing Packing 20 Wheel Bearing Adjustment 21 Wheel Alignment 21 FRONT SUSPENSION 23 Front Shock Absorber Replacement 24 Front Axle Replacement 24 Axle Linkage Rod Replacement 24 Front Spring Replacement 25 Hub Replacement 26 Wheel Bearing and R...

Page 9: ...SOR 39 CONTROLLER 39 CONTROLLER REPLACEMENT 39 SOLENOID REPLACEMENT 40 MOTOR GENERAL 43 Motor Replacement 43 Motor Tests 44 BATTERIES AND CHARGING SAFETY 45 BATTERY 45 BATTERY MAINTENANCE 46 At Each Charging Cycle 46 Monthly 46 Electrolyte Level and Water 46 Cleaning Batteries 47 Battery Replacement 48 Prolonged Storage 48 Battery Charging 49 AC Voltage 49 FAULT DIAGNOSIS 49 Hydrometer 50 Using A ...

Page 10: ...juster Mechanism 66 How the Park Brake Works 66 Kick Off Actuating Linkage 66 Compensator Assembly 66 FAULT DIAGNOSIS FLOWCHART 67 FAULT DIAGNOSIS TABLE 69 FAULT DIAGNOSIS AND INSPECTION 70 New Vehicle 70 Fault Diagnosis and Inspection Procedures 70 Brake Pedal and Linkage Inspection 71 Periodic Brake Performance Test PBPT 73 Aggressive Stop Test 74 Wheel Brake Inspection 74 MAINTENANCE AND REPAIR...

Page 11: ...IONAL FRONT HYDRAULIC BRAKES SYSTEM DESCRIPTION 85 MASTER CYLINDER REPLACEMENT 85 Remove Master Cylinder 85 Install Master Cylinder 85 BRAKE MASTER CYLINDER FLUID 86 Flush Hydraulic Brake System 86 Check Brake Fluid 86 ROUTINE MAINTENANCE 86 REPLACEMENT OF WEAR ITEMS 86 Brake Pad Replacement 86 Rotor Replacement 87 Spindle Replacement 87 Actuator Linkage Bushings 87 Actuator Pivot Bushings 87 BLEE...

Page 12: ...ent 97 WEATHER PROTECTION SUN TOP AND WINDSHIELD 101 Transporting Vehicle 101 SUN TOP 101 Rear Support Installation 101 Front Struts 101 Sun Top 101 SPLIT WINDSHIELD 103 FULL WINDSHIELD 104 HANDHELD DIAGNOSTICS HOW TO USE THE HANDHELD PROGRAMMER 105 Primary Connection 4 Pin Tyco 105 Alternate Connection 4 Pin Molex 105 Navigation 106 Changing Data Value 106 Bookmark 106 TROUBLESHOOTING ELECTRICAL ...

Page 13: ...B TABLE OF CONTENTS xi Repair and Service Manual 634756 VEHICLE DIMENSIONS 116 INCLINE AND TURNING CLEARANCE 117 PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE 119 APPENDIX A DELTA Q USER S GUIDE A ...

Page 14: ...xii Repair and Service Manual TABLE OF CONTENTS Notes 634756 ...

Page 15: ... and cracks at sun top mounting points Always check that the vehicle and contents are adequately secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehicle see GENERAL SPECIFICATIONS for vehicle weight and load plus 1000 lbs 454 kg Lock park brake and secure vehicle using ratchet tie downs SERVICING THE ELECTRIC VEHICLE To prevent severe injury or ...

Page 16: ... vehicle has been put into service it is recom mended that the brakes be checked daily by performing a brake test To prevent 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 with regard for the safety of all personnel For information on conducting ...

Page 17: ...ted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody These materials will accel erate corrosion of underbody parts It is recommended that the underbody be flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas can be loosened to ease removal but take care not to chip or ...

Page 18: ...s specified in the Repair and Service Manual for this vehi cle Fig 2 Torque Specifications and Bolt Grades 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 accordance with this chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered...

Page 19: ... nosing removing or replacing any components that are not operating correctly take the time to consider the safety of yourself and others around you if the compo nent should move unexpectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach high temperatures Battery acid and hydrogen gas could result in serious bodily injury to the technicia...

Page 20: ...epair or maintenance To prevent battery explosion that could result in severe personal injury or death keep all smoking materials open flame or sparks away from the batteries Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4 Because hydro gen gas is lighter than air it will collect in the ceiling of buildings necessitating proper venti lati...

Page 21: ...gative cable first the positive cable and then all other cables from the vehicle batteries Remove the battery hold down by removing the 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 regular basis corrosion to the battery racks or surrounding area ...

Page 22: ...nt and behind the wheels not being raised 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 crossmember Raise vehicle and locate a jack stand under outer ends of rear axle Lower the jack and test the stability of the vehicle on the two jack stands Place...

Page 23: ...9 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SAFETY 634756 ...

Page 24: ...10 Repair and Service Manual SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 25: ...p will also 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 hardware Some components are mounted with pop rivets which require the rivet head be removed in order to push out the shank of the rivet The rivet head is easily removed by drilling into the head...

Page 26: ...ving the cowl or may be removed as part of the cowl To prevent personal injury disconnect nega tive battery cables before servicing vehicle Pull front of floor mat 3 up to expose rivets 4 that secure instrument panel 1 to floor Ref Fig 4 Drill out rivets 4 that attach the instrument panel to floor and rivets 6 that attach instrument panel to the cowl 1 Pry out four ratchet fasteners 5 located with...

Page 27: ...an also be removed along with the front fenders To prevent personal injury disconnect nega tive battery cables before servicing vehicle Remove brush guard See Brush Guard Replacement on page 13 Drill out seven rivets 6 across top of instrument panel 1 that secure the instrument panel to the cowl 11 Ref Fig 4 Drill out six rivets 12 three on each side that secure the cowl to the front fenders Raise...

Page 28: ...ivet Gun 1 Torque Wrench ft lbs 1 Remove rocker panel on side of vehicle that side panel is to be replaced See Rocker Panel Replacement on page 14 Remove four bolts 25 washers 26 and nuts 27 securing side panel 21 to rear fender 28 Ref Fig 7 Retain hardware for reuse Drill out rivets 24 securing side panel to seat support panel 22 Drill out rivets 23 securing side panel to frame Reverse steps to i...

Page 29: ...m vehicle Reverse steps to install replacement fender Use new riv ets 43 Tighten hardware 43 to torque specified below Fig 8 Rear Fender Replacement Rear Body Panel Replacement Tool List Qty Socket 7 16 1 Ratchet 1 Wrench 7 16 1 Remove two rivets 43 securing rear body panel 47 to the rear fender 41 Ref Fig 9 Carefully remove two ratchet fasteners 42 securing rear body panel 47 to the frame Ref Fig...

Page 30: ...lean the surface to be repaired with alcohol 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 light even overlapping strokes Multiple coats may be applied to provide adequate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best c...

Page 31: ...e low volume of these small tires overinflation can occur in a matter of seconds Overinflation could cause the tire to separate from the 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 Recommended Tire Pressures on page 2 for recommended tire inflation pressure For outdoor applications with major u...

Page 32: ... approved safety equipment when mounting demounting tires Follow all instructions and safety warnings provided by the mounting demounting machine manufacturer Wheel Installation Do not tighten lug nuts to more than 85 ft lbs 115 Nm torque It is important to follow the cross sequence pattern when installing lug nuts to ensure even seating of the wheel against the hub Fig 1 Wheel and Tire Installati...

Page 33: ...angers 19 Repair and Service Manual 634756 FRONT SUSPENSION AND STEERING Fig 1 Axle Mounted Steering and Front Suspension Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate Shaft with U Joints Rack and Pinion King Pin Tube Thrust Washer Spindle and King Pin Bushing Axle Tie Rod Rack Ball Joint Rack Extension Spacer ...

Page 34: ...at could damage components Wheel Bearing and King Pin Bushing Inspection Lift the front of the vehicle and support on jack stands as instructed in SAFETY section Observe all warnings Rotate the front wheel and feel for any roughness While holding spindle with one hand grasp bottom of tire with other hand and rock tire back and forth on spindle Some minor rocking movement of tire is normal If exces...

Page 35: ... the wheel two to three more turns to displace excess grease If required tighten castellated nut 3 again until slight resistance is felt If the cotter pin hole in the spindle 5 aligns with a slot in the castellated nut insert a new cotter pin 2 If the hole does not align loosen the castellated nut to align with the closest avail able slot in the nut Check for smooth and free rotation of the wheel ...

Page 36: ... on the threaded tube has left hand threads clockwise to loosen while the end without the flat has conventional right hand threads counter clock wise to loosen To adjust wheel alignment loosen tie rod jam nuts 1 and turn tie rod 2 until correct alignment is achieved Ref Fig 5 Tighten jam nuts to 36 40 ft lbs 49 54 Nm torque Test drive vehicle to confirm steering wheel is correctly centered If it i...

Page 37: ...articular attention to Notices Cautions Warnings and Dangers 23 Repair and Service Manual 634756 FRONT SUSPENSION Fig 7 Front Suspension Components NOTE Tie Rod Not Shown for Clarity Part of Frame Part of Frame 2 30 5 4 1 7 9 11 12 24 20 10 6 8 18 26 27 17 25 24 28 18 13 3 29 16 15 15 21 23 22 19 17 14 14 ...

Page 38: ...he steering system The intermediate shaft is assembled with the universal joints set 90 out of phase with each other Remove hardware 13 14 15 securing rack and pinion unit 16 to front axle Discard lock nuts 15 Move rack and pinion unit back to rest on top of front springs 17 Secure rack and pinion unit to spring with wire to prevent pulling apart intermediate shaft Remove three 1 3 4 long bolts 18...

Page 39: ...a set The following procedure will replace one spring at a time Loosen front wheels Lift and support front of vehicle as instructed in SAFETY section Observe all warnings Remove front wheels To detach driver side spring Fully loosen the two rack and pinion unit lock nuts 15 one near the bellows and one on the rear side of the rack and pinion unit until only one thread is engaged Ref Fig 7 Remove t...

Page 40: ... center bolt at rear left spring to cen ter bolt at front right spring must be equal distance as center bolt at rear right spring to center bolt at front left spring Ref Fig 10 Tighten the spring hardware 21 19 27 first and rack and pinion unit hardware 15 next to 35 50 ft lbs 50 70 Nm torque Fig 10 Front Axle Alignment Replace upper portion of floor mat in plastic trim retainers Install front whe...

Page 41: ...of hub the bearing race with a hammer and soft non ferrous punch Tap race in a circular pattern while moving from side to side to avoid damaging bore of hub Clean outer wheel bearing 6 inner wheel bearing 4 hub and dust cap 7 in solvent and dry thoroughly Inspect for signs of damage Pitting or a blue coloration of the rollers indicates bearing replacement is required If the roller portion of the b...

Page 42: ...front wheel and lift and support front of vehicle per SAFETY section Ref Fig 14 Remove passenger side front wheel and turn steering wheel fully to the left Remove the cotter pin 2 and loosen the castellated 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 passeng...

Page 43: ...ure 1 Wrench 3 4 1 Wrench 9 16 1 Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hammer 1 Socket 11 16 1 Torque Wrench ft lbs 1 Crowfoot Socket 3 4 1 Grasp the tie rod 8 at ball joints 6 and check for any vertical motion which would indicate a worn condition and necessitate replacement Ref Fig 14 To remove tie rod loosen wheels and lift and support front of vehicle per SAF...

Page 44: ...AFETY 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 See Rack Ball Joint Replacement on page 28 Cut wire ties 5 6 and slide bellows off rack extension Install new bellows aligning small end over groove in rack extension and secure with new wire tie 5 Leave large end loose until rack extension to rack ...

Page 45: ...n Unit Replacement on page 33 Spindle Replacement Tool 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 used dry Lubrication attracts dirt and will ruin the bearings Do not apply grease to the spindle bearings Loosen front wheel Lift and support front of...

Page 46: ...d or excessively worn a new rack and pinion unit must be installed To avoid damage to the aluminum rack and pinion unit secure unit in vice by the mounting ears only Remove rack and pinion unit from vehicle Anchor in vice by clamping on the mounting ears of the unit Disassemble rack and pinion unit 1 by removing screw 13 and tensioner 2 to relieve pressure on rack 3 and pinion 4 Ref Fig 21 Loosen ...

Page 47: ...en castellated 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 passenger side spindle arm Remove nut from ball joint and ball joint from spindle arm Remove the three lock nuts 18 securing rack and pinion unit to front axle and discard nuts Remove rack and pin io...

Page 48: ...ompound 1 Torque Wrench ft lbs 1 To maintain correct orientation when replacing steering wheel turn wheels straight ahead To prevent damage to the clipboard perform the fol lowing removal procedure Do not use a screwdriver to push or pry the retaining tabs From the front side of the steering wheel 4 remove the clipboard 5 by pulling straight up on the bottom of the clipboard to release the two bot...

Page 49: ...ue Wrench in lbs 1 Wheel Bearing Grease AR To remove steering shaft 4 Ref Fig 25 remove the steering wheel See Steering Wheel Replacement on page 34 Loosen front wheels Lift and support front of vehicle per SAFETY section and remove front wheels Remove the bolt 1 and washer 2 that secures the intermediate shaft 3 to the steering shaft 4 Remove the four bolts 5 and washers 6 that secure the steerin...

Page 50: ... Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 634756 Fig 27 Small Retaining Ring Orientation Install with arch up as shown Small Retaining Ring Groove Bearing Steering Shaft ...

Page 51: ... Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers FRONT SUSPENSION AND STEERING 634756 ...

Page 52: ... Repair and Service Manual FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 53: ... is wired to the batteries and develops a regulated power supply for the throttle position sensor As the pedal is pressed the magnitude of deflection in the throttle position sensor varies the voltage which in turn is fed back to the controller The controller interprets the change in voltage and supplies the appropriate power to the motor The throttle position sensor unit and the controller are bo...

Page 54: ... REPLACEMENT Tool List Qty Socket 7 16 1 Socket 3 8 1 Ratchet 1 Insulated Wrench 1 2 1 Torque Wrench ft lbs 1 To prevent electrical shock the BL wire must be removed before discharging the controller by shorting the B and B terminals of the con troller with a large screwdriver Be sure to hold screwdriver by the insulated portion Note the location of the wiring before disconnecting from solenoid Us...

Page 55: ...41 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRONIC SPEED CONTROL 634756 ...

Page 56: ...42 Repair and Service Manual ELECTRONIC SPEED CONTROL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 57: ...e battery Ref Fig 1 Mark both the axle and motor housings to assist with realignment during reassembly of motor to rear axle Ref Fig 2 Disconnect the motor wires from the controller terminals U V and W Fig 2 Mark Axle and Motor Be careful not to damage the splines when remov ing and reassembling the motor to the rear axle housing Remove the connector at the speed sensor 7 Ref Fig 4 Remove the six ...

Page 58: ...as individual parts No testing is recommended to determine the specific area of failure When a test of the power wiring system indicates that the system is operating correctly yet the vehicle either does not run or runs poorly the motor is the only remaining component and must be replaced Fig 4 Motor Components Item Torque Specification 5 9 72 78 in lbs 8 9 Nm Motor Terminal Wire Marker From Contr...

Page 59: ...of 1 4 cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and flushed with water Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aerosol containers of battery terminal protec tant must be used with caution Insulate metal container to p...

Page 60: ...rtance is too much water which will result in electrolyte being forced out of the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle Do not overfill batteries The charging cycle will expel electrolyte and result in component damage Fig 1 Correct Electrolyte Level A battery being charged will gas with the majority of the gassing taking place at...

Page 61: ...ich 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 technique is to spray the top and sides of the batteries with a solution of sodium bicarbon ate baking soda and water This solution is best applied with a garden type sprayer equipped with a non metallic spray wand The solution s...

Page 62: ...5 Ensure that all battery terminals are installed with crimp facing up Tighten the battery post hardware to 90 100 in lbs 6 8 Nm torque Do not overtighten the ter minal nut causing a mushroom effect on the battery post and preventing the terminal nut from being properly tightened Protect the battery terminals and battery wire terminals with a commercially available protective coat ing Fig 5 Batter...

Page 63: ...ble chargers there will be a rattle present in the body of the charger DC plug This rattle is caused by an internal magnet contained within the charger plug The magnet is part of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the vehicle charging receptacle AC Voltage Battery charger output is directly related to the input volt age If vehicle ...

Page 64: ...orrect the float reading It is important to recognize that the electro lyte temperature is significantly different from the ambient temperature if the vehicle has been operated Using A Hydrometer 1 Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading Examine the color of the electrolyte A brown or gray coloration...

Page 65: ...ion 160 71 1 032 030 150 65 6 028 026 140 60 0 024 022 130 54 4 020 018 120 48 9 016 014 110 43 3 012 010 100 37 8 008 006 90 32 2 004 002 80 26 7 0 002 70 21 1 004 006 60 15 6 008 010 50 10 012 014 40 4 4 016 018 30 1 1 020 022 20 6 7 024 026 10 12 12 028 EXAMPLE 1 Electrolyte Temperature Above 80 F 27 C Electrolyte temperature 90 F 32 C Hydrometer reading 1 250 1 250 004 1 254 corrected specific...

Page 66: ...52 Repair and Service Manual BATTERIES AND CHARGING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 67: ...LK WHT RED WHT PNK BLU ORN BLK BLK BLK BLK BLK BLK BLK YEL WHT BLK RED BLK BLK BLU BLU BRAKE SWITCH FUSE BLOCK FUSE BLOCK FUSE BLOCK HDL T SWITCH USB 12V BRAKE SWITCH HDLT SWITCH USB 12V BLU BLU YEL YEL GRN WHT GRN WHT BLU WHT BLU WHT BLU WHT BLU WHT BLU WHT GRN WHT BRN BRN BRN GRN RED TURN SIGNAL TURN SIGNAL RED RED WHT RUN TOW MAIN CONTACTOR MAIN CONTACTOR MAIN CONTACTOR RED BLU RED BLU BLU BLK ...

Page 68: ...K BLK BLK BLK BLK BLK BLK BLK BLK BLU BLK BLK BLK BLK BLK BLK BLK BLK RED BLK BLK BLK BLK BLK BLK BLK BLK BLK YEL RED BRN BLU BLU GRN RED RED GRN WHT GRN WHT BLU WHT WHT BLU WHT BLU WHT BLK WHT BLK WHT BLK WHT YEL YEL BLU SOC BLU BLK WHT BLK WHT BLK WHT SPEED ENCODER HOUR METER TEMP SENSOR PROGRAMMING PORT BLK WHT BLK WHT BLK WHT BLK WHT RED BLU RED BLU BLU RED GRN GRN WHT WHT BLK BRN SWITCH BLU W...

Page 69: ...r and Service Manual 634756 Fig 3 Electrical Schematic On Board Charger BLU BLK BLK BLK WHT WHT RED BRN 1 1 1 1 1 1 2 3 4 5 7 8 6 2 WHT GRY WHT WHT RED BLU BLK GROUND WHT 12V SWITCHED RED 12V UNSWITCHED DC DC 2 PIN PLUG DC DC 3 PIN PLUG A A A B C B A B B C CHARGER 2 PIN PLUG CHARGER 8 PIN PLUG BATTERY TEMP SENSOR RECEPTICAL LED 72V B FUSE FUSE BLU SWITCH ENABLE ...

Page 70: ...ove If the reading is below 12 volts the bat tery requires either charging or replacement MAIN HARNESS Power Supply Tool List Qty DVOM 1 1 Check for loose or bare wires Check for loose wires at each terminal connection Check for worn insulation or bare wires touching the frame Bare wires may cause a short circuit If any DVOM readings indicate a faulty wire it is recom mended that the condition of ...

Page 71: ...attach the black probe to the battery post with the black wire attached and the red probe to the power white wire terminal at the fuse block A reading of battery voltage indicates that the power wire is in good condition The power wire supplies power to the entire fuse block 4 Check fuse Place the red probe to each wire terminal on the fuse block A reading of battery voltage indicates that the fus...

Page 72: ...rrect components and secured to the harness bundle with a wire tie The faulty wire should be cut back close to the harness and the ends protected with vinyl electrical tape Headlight Replacement Following procedure is applicable for vehicles with halo gen headlights For vehicles equipped with halogen headlights mounted in the cowl locate bulb socket 1 on backside of light and turn bulb socket a qu...

Page 73: ...756 Fig 6 Headlights Taillight Replacement To replace the taillight bulb or the brake light bulb roll the rubber bezel from around the edge of the taillight and remove lens Ref Fig 7 Install replacemnet bulb and replace lens Headlight taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department Fig 7 Taillights 4 2 1 Rubber Bezel ...

Page 74: ...re no voltage is detected and the last place that voltage was detected In circuits where no voltage is expected the same procedure may be used except that the DVOM is set to continuity Place the nega tive probe on a wire terminal at the beginning of the cir cuit and work towards the device that is not working with the positive probe When continuity is no longer indi cated a failed conductor or dev...

Page 75: ...ttached without activating switch The audible indicator will stop and the meter display will indicate a value greater than 0 when the switch is acti vated The change in display or audible indicator shows that the switch is functioning Fig 8 Continuity Check of Switch Testing a Solenoid for Continuity Place one probe on one of the large terminals and the other probe on the second large terminal Ref...

Page 76: ...62 Repair and Service Manual ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 77: ...B ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 63 Repair and Service Manual 634756 ...

Page 78: ...B 64 Repair and Service Manual ELECTRICAL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 634756 ...

Page 79: ...rake will not be adequate The self adjusting mechanism in the wheel brakes requires enough cable travel at the wheel brake to work reliably When the brake is released there must be slack in the system so the brakes will release fully and the adjusters will function Free pedal travel pedal force shoe to drum clearance and braking capability are closely related It is very important to maintain the p...

Page 80: ...er pedal which extends across the top of the service brake pedal It is spring loaded and attached to the service brake pedal with a hinge pin Ref Fig 2 Pressing the park brake pedal moves the latch arm against the catch bracket attached to the chassis As the park brake is pressed the service brake is applied until the notch in the latch arm engages with the catch bracket The service brake pedal is...

Page 81: ...roviding 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 PBPT 3 Times 3 Aggressive Stop Test 10 times 4 2 Bad Seal and Thrust Washer Condition Good Remove Excess Brake Dust from Brake Components 8 Yes Return To Service Go to 2 Go to 6 Remove Both Drums Don t Dis...

Page 82: ...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 driving at maximum speed and brake aggressively 10 times At the spherical nut readjust the free travel Drive and brake aggressively 10 more times Repeat until the pedal free travel stabilizes within the spec...

Page 83: ...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 In excess of 1 1 8 2 9 cm free pedal travel Soft Pedal Low pedal force at park brake latch Adjust per manual Brake cables damaged Replace Brake return bumper out of adjustment Adjust per manual End of brake cable loose from anchor bracke...

Page 84: ...l are described in detail under MAINTENANCE AND REPAIRS on page 76 Satisfactory brake performance does not eliminate the need for routine brake testing and inspection as indicated in the Periodic Service Schedule in Sec tion A Continued proper brake operation depends on periodic maintenance Unequal braking one wheel locks while other rotates Wheel not locking is not adjusting Check brake operation...

Page 85: ...st to the point at which the brake shoes first contact the brake drums This should not be confused with the light resistance that is felt as the brake pedal is pressed enough to remove slack from the compensator and cables Too much free travel may indicate wheel brakes not adjusting wear in the cables and linkages or initial break in of components Not enough free travel may indicate improper adjus...

Page 86: ...essary as the spring assembly is factory calibrated With the park brake disengaged check that the compensator spring length is 3 15 16 10 cm Ref Fig 12 If an adjustment is required it should be made at the nuts at the spring facing the front of the vehicle Tighten the jam nut firmly after adjusting 8 Inspect park brake pedal hinge Check for broken or rusted springs and correct retention of the hin...

Page 87: ... performance over time and as part of fault diagnosing a problem vehicle Before performing this test inspect the brake pedal and linkage and correct any problems found including adjust ing the brake pedal free travel if required The purpose of this test is to compare the braking perfor mance of the vehicle to the braking performance of new or known to be good vehicles or to an established acceptab...

Page 88: ...ssive Stop Test To prevent serious injury or death all brake tests must be done in a safe location with regard for the safety of all personnel Always conduct a visual inspection and evaluate pedal travel before operating a vehicle to verify braking function is present The purpose of this test is to attempt to fully expand and release the brake adjusters on a vehicle which has failed the first set ...

Page 89: ...ster arm and note if the arm engages the star wheel and attempts to rotate it Ref Fig 17 If the adjuster arm engages and turns the star wheel proceed If the arm fails to engage the star wheel it has been damaged and both wheel brake assemblies must be replaced If the adjuster arm engages the star wheel but fails to rotate it the adjuster assemblies must be replaced with new color coded adjusters N...

Page 90: ...dal Free Travel on page 77 This includes all linkage and wheel brake components Fig 18 Brake Shoe Wear Top Pull Fig 19 Orientation of Brake Shoe Springs MAINTENANCE AND REPAIRS Tool List Qty Hydraulic Floor Jack 1 Scale 1 Jack Stands 4 Wheel Chocks 4 Socket 1 2 1 Socket 3 4 1 Socket 11 16 1 Socket 15 16 1 Socket 1 1 8 1 Socket 1 4 1 Torque Wrench ft lbs 1 Torque Wrench in lbs 1 Extension 6 1 Ratch...

Page 91: ...e brake pedal aggressively four to six times to establish known free travel All brake tests must be done in a safe location with regard for the safety of all personnel In a safe location free from people and vehicles drive the vehicle at reduced speed and apply the brakes aggres sively As the brakes adjust and stop the vehicle effec tively start driving at maximum speed and brake aggressively 10 t...

Page 92: ...r brake drum washer 6 inside brake drum It may be on the axle shaft or attached to the rear of the drum hub This washer must be reinstalled when brake is reassembled To install the brake drum clean the axle shaft and the splines on the brake drum to remove debris and grease Apply a small amount of anti seize compound to the axle spline Install the inner brake drum washer 6 and slide the brake drum...

Page 93: ...lubricant Ref Fig 24 Install actuator components adjuster components and brake shoes See Brake Shoe Installation on page 81 If brake shoes and drum are not to be replaced sand the friction surfaces lightly with emery cloth to remove any debris Ensure the adjusting screw is screwed into the star wheel nut until only 1 2 threads are exposed If brake shoes are replaced replace brake springs and adjus...

Page 94: ... them out ward and away from the back mounting plate This will release the tension in the brake springs 4 Remove the brake springs and remove the brake shoes Inspect brake shoes If a brake shoe has less than 0 40 lining material thickness AT ANY POINT on either shoe then both shoes MUST be replaced Check for free lateral front and back movement of the adjusting mechanism and for free movement of t...

Page 95: ...ean the axle shaft to remove debris and grease that may have accumulated Fig 28 Brake Shoe 17T Insert a straight blade screwdriver between the adjusting lever and the adjusting mechanism Rotate the star wheel counter clockwise until the shoes have retracted sufficiently to allow installation of brake drum Install washer 5 brake drum 6 washer 8 and castel lated nut 9 Tighten the castellated nut to ...

Page 96: ...sconnect the compensator assembly from the brake pedal by removing the cotter pin and clevis pin Ref Fig 29 Loosen and remove the jam nut and the spherical nut connecting the compensator rod to the equalizer link Remove the compensator assembly Installation is the reverse of removal Use new cotter pins in the clevis pin Adjust the brake pedal free travel See Adjusting Brake Pedal Free Travel on pa...

Page 97: ...moval and Installation Note the location and orientation of the two torsion springs 8 for reassembly purposes Remove the push nut s 9 and pin 10 Ref Fig 30 and remove the park brake pedal To prevent serious injury or death resulting from the use of worn park brake components do not attempt to re new worn components The park brake arm latch is a hardened part Do not grind or file it as doing so wil...

Page 98: ...d Kick Off Cam Removal and Installation Park Brake Kick Off Cam Removal Replace ment and Installation Disconnect the park brake release linkage as described above Loosen the two set screws 5 from the cam 6 and remove the cam pivot 7 cam and spacer 8 Ref Fig 33 Inspect the bushings 9 10 and spacer Replace any that show signs of wear Install in reverse order of removal With the park brake engaged an...

Page 99: ... rest position With the mas ter cylinder no longer applying hydraulic pressure to the brake pistons the piston seals retract the pistons permit ting the brake pads to float freely against their guide pins while removing all pressure against the rotors MASTER CYLINDER REPLACEMENT When this procedure is preformed it is likely that brake fluid will leak from the master cylinder Use care to avoid brak...

Page 100: ... 3 4 1 Jack 1 Jack Stands 4 Brake Adjusting Tool 1 Plastic Faced Hammer 1 Never work on a vehicle supported by a jack alone To prevent possible personal injury the vehicle must be supported on jack stands dur ing procedures that require lifting REPLACEMENT OF WEAR ITEMS Wear a dust mask and eye protection working on wheel brakes Do not use pressurized air to blow dust from brake assemblies Brake P...

Page 101: ...ot also is fitted with a nylon bush ing between it and the brake cylinder clevis To replace any of these bushings the actuator linkage must be removed from the lower actuator pivot and the linkage rod See Actuator Linkage Bushings on page 87 Remove the cotter pin and clevis pin securing the upper actuator pivot and master cylinder clevis Remove lock nut and shoulder bolt to remove pivot com ponent...

Page 102: ...move to the driver side rear brake bleed the brakes using the follow ing procedure The bleeder valve at the caliper must be closed at the end of each stroke and before the brake pedal is released to ensure that air cannot enter the system It is also important that the brake pedal be returned to full up position 1 Open the bleeder valve and have an assistant depress brake pedal gently until fluid f...

Page 103: ...ard portable charger option has been selected a portable charger is shipped with the vehicle Prior to charger use remove charger from packing mate rials and place in an area that permits maximum air flow around and underneath the charger For optimum perfor mance and shortest charge times place the charger in an area with adequate ventilation The charger should also be placed in an area that will b...

Page 104: ...90 Repair and Service Manual BATTERY CHARGER Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 105: ...n ual and support the rear of the vehicle on the outer ends of the rear bumper Remove the bottom shock absorber nut 1 Ref Fig 3 Compress the shock absorber 2 and remove the top shock absorber nut 3 Remove shock absorber Shock Absorber Installation Reverse removal process to install new shock absorber Tighten shock absorber nuts 1 3 until the shock absorber bushings 4 expand to the diameter of the ...

Page 106: ...that is supported by a jack alone Turn vehicle key to OFF and remove it from vehicle Ensure all optional electrical accessories are turned OFF Place the Run Tow Maintenance switch in the Tow Main tenance position Using an insulated wrench remove the negative cable first the positive cable and then all other cables from the vehicle batteries Ref Fig 1 Fig 1 Battery Connections Raise the rear of the...

Page 107: ...ttention to Notices Cautions Warnings and Dangers 93 Repair and Service Manual 634756 Tighten the battery post hardware to 90 110 in lbs 10 12 Nm Place the Run Tow Maintenance switch in the Tow Main tenance position Fig 3 Rear Suspension Front of the Vehicle 4 5 1 3 5 4 5 4 5 4 10 10 11 6 9 9 7 2 7 8 9 ...

Page 108: ...94 Repair and Service Manual REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 109: ...h the check fill hole See Fig 1 Fig 1 Add Check and 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 attempting to perform any service on the axle read and understand all of the following text and illustra tions before disassembling the unit Handle all ...

Page 110: ...ft Remove the bearing by supporting the inner race of the bearing on an arbor press bed and apply pressure to the threaded end of the 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 Hammer 1 Use care to prevent damage to the inner surface of the axle ...

Page 111: ... seal damage lightly coat the axle shaft with bearing grease and support the shaft during installation Install the inner snap ring Ref Fig 5 Fig 7 Installing Seal Axle Shaft Replacement Carefully insert the axle shaft and bearing through the oil seal Rotate the shaft until the spline engages with the dif ferential side gears Install the outer snap ring Coat the outboard spline of the axle with a c...

Page 112: ...s and Dangers 634756 Tighten the castellated axle nut to 70 ft lbs 95 Nm torque minimum 140 ft lbs 190 Nm torque maximum Continue to tighten until the slot in the nut aligns with the cotter pin hole Fig 8 Cut Away of Outer Bearing and Brake Drum Thin Thrust Washer Inner Snap Ring Bearing Outer Snap Ring Brake Drum Axle Nut Cotter Pin Thick Thrust Washer Spline ...

Page 113: ...99 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers REAR AXLE 634756 ...

Page 114: ...100 Repair and Service Manual REAR AXLE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 115: ...ardware and cracks in sun top at mount ing points SUN TOP Tool 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 At driver side of vehicle align the holes in the rear strut 5 with the holes in the seat back support bracket being sure that the open end of the strut faces the front of the vehicle as shown See Detail C ...

Page 116: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 634756 Fig 1 Sun Top A C D Front of Vehicle D Bumper Front of Vehicle A Seat Back Support Seat Front of Vehicle C 18 3 5 3 9 1 5 11 10 6 4 7 6 16 15 17 18 19 ...

Page 117: ...ets 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 top hole on each side of front strut Secure with top grip fasteners 9 Fig 2 Split Windshield It may be necessary on early production sun tops to drill a 9 32 hole in front face of both sides of front ...

Page 118: ...d Using a plastic faced mallet gently tap sash to ensure windshield 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 lock nut 7 See Detail B Do not over tighten or squeeze grommet Place bottom section of windshield on rubber grommets and press the sash starting at the bottom onto the front strut so that it snaps ...

Page 119: ...nterface circuits may result in perma nent damage to the programmer The handheld programmer will not function when the Run Tow switch is in the Tow position The handheld programmer will not function when the battery charger is connected to the vehicle The main menu appears only after data is uploaded from unit controller charger etc the main menu will not be displayed if there are no entries withi...

Page 120: ...ss the left arrow once or more on the navigation key to display the main menu Changing Data Value Press the up or down arrow on the data value key to change the value of the parameter Bookmark Press a bookmark key for four seconds until the bookmark set screen is dis played to set a position in the menu Press the appropriate bookmark key to jump to a selected bookmark position Main Menu Definition...

Page 121: ...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 Elasped Meters Amp Hours Trip 0 100000 AmpHr Vehicle Speed 0 25 mph Odometer 0 100000 miles Hour Meter 0 100000 Hrs I O Throttle 0 100 Speed Pulses ON OFF Pers Input 0 ON OFF Pers Input 1 ON OFF Foot Inpu...

Page 122: ...s 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 Curent Sense Fault 0 100000 Hrs M Shorted 0 100000 Hrs Field Missing 0 100000 Hrs Hardware Failsafe 0 100000 Hrs Faults System Faults Display active faults Fault History Display non active past faults...

Page 123: ...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 Manufacture Date Display handheld manufacture number Software Version Display handheld software version Hardware Version Display handheld hardware version MC Protocol Ver Display MC Protocol version ES Pr...

Page 124: ...110 Repair and Service Manual HANDHELD DIAGNOSTICS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 125: ...EHICLE WILL NOT MOVE See ELECTRONIC SPEED CONTROL section VEHICLE SPEED ERRATIC Faulty ESC system Test and replace components as indicated by test procedure NO REDUCED SPEED IN REVERSE Faulty ESC system Test and replace components as indicated by test procedure MOTOR NOISY Damaged bearing Replace bearing Raised commutator bar s Replace motor Loose motor mounting hardware Tighten BATTERIES WILL NOT...

Page 126: ...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 steering from lock to lock Do not over grease If steering does not return to acceptable condition proceed to next step Bent rack Remove rack and place on flat surface with rack teeth up If a 015 381 mm feeler...

Page 127: ...113 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TROUBLESHOOTING 634756 ...

Page 128: ...114 Repair and Service Manual TROUBLESHOOTING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 129: ... 191 cm Vehicle Load Capacity 1000 lb 450 kg Front Wheel Track 37 0 in 94 cm Outside Clearance Circle 22 1 ft 6 7 m Rear Wheel Track 38 8 in 99 cm Intersecting Aisle Clearance N A Ground Clearance at Differential 5 5 in 14 cm Speed Level Ground 13 mph 0 5 mph 21 kph 0 8 kph Cargo Box Width inside 44 0 in 112 cm Towing Capacity 1262 lb 5614 N Max Drawbar Cargo Box Length inside 36 0 in 91 cm Steeri...

Page 130: ...before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 634756 VEHICLE DIMENSIONS Fig 2 Vehicle Dimensions 36 0 in 91 0 cm 49 8 in 126 0 cm 10 5 in 27 0 cm 75 3 in 191 3 cm 111 0 in 281 0 cm Rear 38 8 in 98 6 cm Front 37 0 in 94 0 cm 44 5 in 113 0 cm ...

Page 131: ...lar attention to Notices Cautions Warnings and Dangers 117 Repair and Service Manual 634756 INCLINE AND TURNING CLEARANCE Fig 3 Incline Specifications and Turning Clearance Diameter TURNING CLEARANCE DIA Approx 22 1 ft 6 7 m RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX ...

Page 132: ...118 Repair and Service Manual GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 133: ...oose terminals corro sion hold down and hardware C CL CL CL CL Batteries check electrolyte level fill if required C A C A C A C A Brakes smooth operation of pedal stopping distance C C C C C Brakes aggressive stop test does brake hold on a hill C C C C Accelerator smooth operation C C C C C Wiring loose connections broken or missing insulation C C C C Charger Receptacle clean connections CL CL CL ...

Page 134: ...120 Repair and Service Manual PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 634756 ...

Page 135: ...PPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers A Repair and Service Manual APPENDIX A DELTA Q USER S GUIDE ...

Page 136: ...er près de la batterie et éviter toute étincelle ou flamme nue à proximité des batteries Fournissez une ventilation adéquate du chargement Ne jamais charger une batterie gelée Prendre connaissance des mesures de précaution spécifiées par le fabricant de la batterie p ex vérifier s il faut enlever les bouchons des cellules lors du chargement et les taux de chargement Danger Risque de chocs électriq...

Page 137: ...EC 60320 C14 plug rated 250V 13A minimum or b for all other countries a safety approved detachable cord 3 conductor 1 5mm minimum rated appropriately for industrial use The cord set must be terminated on one end with a grounding type input connector appropriate for use in the country of destination and on the other end an output grounding type IEC 60320 C14 plug 3 The enclosure of the charger has ...

Page 138: ...Notes D APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Repair and Service Manual ...

Page 139: ... prop erly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible component failures or the manner in which they may fail A vehicle requiring repair indicates that it is no longer function ing as designed and therefore should be considered poten tially hazardous Use extreme care when working on vehicle When diagnosing removing or replacing any component...

Page 140: ... 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine E Z GO Parts Accessories Department or at www shopezgo com Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc...

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