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E-Z-GO ST SHUTTLE 4/6 2009, Technician'S Repair And Service Manual

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E-Z-GO ST SHUTTLE 4/6 2009 Technician'S Repair And Service Manual Download Page 134

Page K-22

MECHANICAL BRAKES

Repair and Service Manual

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

cables to the brake levers using new clevis pins and new 

cotter pins.
Adjust the brake pedal free travel. “Adjusting Brake Pedal 

Free Travel” on page J 17

Compensator Assembly, Removal and 

Installation 

Disconnect the compensator assembly from the brake 

pedal by removing the cotter pin and clevis pin (Ref Fig. 

28).
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. “Adjusting Brake Pedal 

Free Travel” on page J 17

Brake Pedal Removal and Installation

Disconnect the compensator assembly (1) from the 

brake pedal by removing the cotter pin (2) and the clevis 

pin (3). Unplug the wiring harness on models equipped 

with brake lights. Unhook the torsion spring (4) by insert-

ing a thin blade screwdriver between the small hook and 

the bracket. Move the hook back and to the side to 

release the torsion spring (Ref Fig. 29).   
Remove the lock nut (5), the shoulder bolt (6) and 

remove the brake pedal. 
Inspect the shoulder bolt for corrosion that could cause 

binding. This bolt and both bushings (7) must be 

replaced with new ones if corrosion or wear is found.
Brake pedal installation is in the reverse order of disas-

sembly. Tighten the nut (5) to 25 - 29 ft. lbs. (34 - 39 Nm) 

torque and use a new cotter pin when installing the com-

pensator assembly. Connect brake light wiring harness, 

if equipped.
Adjust the brake pedal free travel. “Adjusting Brake Pedal 

Free Travel” on page J 17
Check for proper brake light operation if equipped.

Parking Brake Catch Bracket Removal and 

Installation

Remove the driver side front wheel to gain access to the 

brake pedal release mechanism.

To prevent serious injury or death resulting 
from the sue of worn parking brake compo-

Fig. 28  Brake Cable, Equalizer and Compensator

Spherical

Nut

Jam

Lock

Nut

Equalizer

Bracket

Compensator
Assembly

Cotter
Pin

Clevis
Pin

Brake

Cables

Compensator

Rod

Fig. 29  Brake Pedal Removal and Installation

6

7

7

3

2

1

4

5

8

8

9

10

9

Pedal
Latch

No Hole in

Models Prior

to 2001

Older

Models

2001

and

Later

Summary of Contents for ST SHUTTLE 4/6 2009

Page 1: ...ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR TECHNICIAN S REPAIR AND SERVICE MANUAL 612342 ISSUED APRIL 2009 REVISED JULY 2011...

Page 2: ...with 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 il...

Page 3: ...nual is subject to change without notice E Z GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in t...

Page 4: ...ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batte...

Page 5: ...ITLE SECTION GENERAL INFORMATION ROUTINE MAINTENANCE A SAFETY B BODY C WHEELS AND TIRES D FRONT SUSPENSION E ELECTRONIC SPEED CONTROL F MOTOR G BATTERIES CHARGING H BATTERY CHARGER J BRAKES K ELECTRIC...

Page 6: ...Page iv Repair and Service Manualal TABLE OF CONTENTS Notes...

Page 7: ...s manual or for incidental or consequential damages that result from the use of the material in this manual This vehicle conforms to the current applicable standard for safety and performance requirem...

Page 8: ...y of each battery terminal and be sure to rewire the batteries correctly Always use specified replacement parts Never use replacement parts of lesser quality Always use recommended tools Always determ...

Page 9: ...eiling of buildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement Never charge a vehicle in an area that is subject to flame or spark Pay particula...

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

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 HARDW...

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

Page 13: ...ately 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 the...

Page 14: ...l is in the REAR AXLE section BRAKES After the 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 result...

Page 15: ...colors for use on TPE plastic bodies P N 28140 G and 28432 G Multi purpose Battery Protectant formulated to form a long term flexible non tacky dry coating that will not crack peel or flake over a wid...

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

Page 17: ...es items listed in previous table the following BATTERIES Clean battery terminals 3 Check charge condition and all connections WIRING 3 Check all wiring for loose connections and broken missing insula...

Page 18: ...g BATTERIES Clean batteries terminals DIRECTION SELECTOR 3 Check for wear and smooth movement lubricate shaft with light oil if required KING PINS 3 Check for excessive play and tightness of retaining...

Page 19: ...AL ASME ANSI B56 8 1988 B 4 NOTES CAUTIONS AND WARNINGS B 9 IMPORTANT SAFETY WARNING B 9 MODIFICATIONS TO VEHICLE B 9 GENERAL MAINTENANCE B 9 BEFORE SERVICING THE VEHICLE B 9 Additional Warnings B 10...

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

Page 21: ...m a safety survey period ically and as conditions warrant to their premises to identify areas where golf cars should not be operated and to identify possible hazards 5 2 1 Steep Grade In areas where s...

Page 22: ...ndition of the batteries the output rate of the battery charger and the amount of time the batter ies are on charge Hydrogen emissions are generally con sidered to be in the area of 10 to 20 cubic lit...

Page 23: ...l ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 6 2 8 As required under paragraphs 6 2 6 and 6 2 7 the manufacturer shall be contacte...

Page 24: ...dance with the owner s manual without the manufacturer s prior written authorization Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance...

Page 25: ...tirety to all new operators and not condensed for those claiming previous experience 8 1 65 2 3The user should include in the operators training program the following a instructional material provided...

Page 26: ...ibility is obstructed at other locations 8 1 225 5 6Ascend or descend grades slowly 8 1 235 5 7Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up...

Page 27: ...th the manufacturer s recommendations and the following practices a A scheduled preventive maintenance lubrication and inspection system shall be followed b Only qualified and authorized personnel sha...

Page 28: ...onformance with manufacturers recommended proce dures q Carriers shall be kept in a clean condition to mini mize fire hazards and facilitate detection of loose or defective parts r Modifications and a...

Page 29: ...ce high amperage or reach high temperatures Battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with utmost cau tion Be careful...

Page 30: ...rom the batteries Hydrogen gas is generated in the charging cycle of batteries and is explosive in con centrations as low as 4 Because hydro gen gas is lighter than air it will collect in the ceiling...

Page 31: ...by removing the hardware and lifting the retainer from the batteries Remove the batteries using a commercial battery car rier If the batteries have been cleaned and any acid in the battery rack area...

Page 32: ...ess When lifting the vehicle position jack stands only in the areas indicated To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 2 Center jack under the rear frame...

Page 33: ...Page B 13 Repair and Service Manual Notes Read all of Section A and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings SAFETY...

Page 34: ...Page B 14 Repair and Service Manual Notes SAFETY Read all of Section A and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 35: ...placement C 6 Rear Body Replacement C 6 Foot Rest Replacement C 7 Rear Bumper Replacement C 7 Front Seat Replacement C 8 Front Facing Rear Seat C 8 Rear Facing Rear Seat C 8 Cargo Bed Replacement C 8...

Page 36: ...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 all Notices Cautions Dangers and Warnings...

Page 37: ...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 hardwa...

Page 38: ...Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 2 Body Components Front Frame 1 52 54 53 56 55...

Page 39: ...nd this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 3 Body Components Seats and Rear 44 43 A A B SHUTTLE 4 MODEL ONLY B 52 51 54 5...

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

Page 41: ...e reverse order of disassembly and will require new drive rivets Cowl Replacement Tool List Qty Electric air drill 1 Drill bit 7 32 1 Wrench 5 16 1 Phillips screwdriver 1 Rivet gun 1 Duct tape 1 Allen...

Page 42: ...R for more information Disconnect the four pin connector from the Speed control at connection near the floor Remove the hardware 26 securing the seat pod to the floor and remove the pod Installation o...

Page 43: ...y component remove or install seat support brackets by sliding to the open end of the molded channel Do not force the seat support brackets into or out of the channels from above Remove rear valance p...

Page 44: ...lacement is in the reverse order of removal Cargo Bed Replacement Tool List Qty Wrench 1 2 2 The cargo bed is heavy and awkward to han dle To prevent possible personal injury it is strongly recommende...

Page 45: ...s be taken to repair the Durashield body 1 Thoroughly clean 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 aeros...

Page 46: ...Page C 10 Repair and Service Manual Notes BODY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 47: ...ONTENTS FOR SECTION D SECTION TITLE PAGE NO WHEELS AND TIRES Page D i Repair and Service Manual WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 1 LIST OF ILLUSTRATIONS Fig 1 Wheels and...

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

Page 49: ...jury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor applications with major use on grassy ar...

Page 50: ...attern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten lug nuts as show...

Page 51: ...ring Wheel Replacement E 16 Steering Shaft and Column Replacement E 17 LIST OF ILLUSTRATIONS Fig 1 Axle Mounted Steering and Front Suspension E 1 Fig 2 Lubrication Points E 2 Fig 3 Bearing Adjustment...

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

Page 53: ...lar attention to all Notices Cautions Dangers and Warnings B B Fig 1 Axle Mounted Steering and Front Suspension Front of Vehicle Rack Pinion Unit King Pin Tube Thrust Washer Spindle King Pin Bushing P...

Page 54: ...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 Bearing and King...

Page 55: ...ehicle per SAFETY section Remove dust cap 1 and cotter pin 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 t...

Page 56: ...threads on each end The end with the flat area 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 l...

Page 57: ...press shock absorber to clear the mounting bracket Loosen the nut securing the top of the shock absorber to the vehicle frame and then rotate the shock absorber while holding the nut in place with a w...

Page 58: ...rmediate 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 bolt 20 securing fro...

Page 59: ...possible damage to the rack and pinion unit the driver side spring must be mounted to the axle with the hardware 20 23 installed in its orig inal location Ref Fig 6 Driver side spring installation is...

Page 60: ...ush 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 bearings about 1 2 3 4 full with grease and apply a li...

Page 61: ...eplaced To install race 5 make sure bore of hub 1 is clean and place new race over bore of hub Evenly tap with hammer and bearing driver to drive race fully in bore Repeat on other side of hub Clean s...

Page 62: ...k 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 fully to the left Remove...

Page 63: ...n and lower vehicle per SAFETY section 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...

Page 64: ...Ref Fig 15 first loosen passen ger side front wheel and lift and support front of vehicle per SAFETY section Remove passenger side front wheel and turn steering wheel fully to the left Remove rack bal...

Page 65: ...ndle 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 vehicle per SAFE...

Page 66: ...Remove rack and pinion unit from vehicle Rack and Pinion Unit Replacement on page E 15 Anchor in vice by clamping on the mounting ears of the unit Disassemble rack and pinion unit 1 by first removing...

Page 67: ...e front wheels Remove bolt 13 and washer 14 securing intermediate shaft 15 to rack and pinion unit 12 Remove cotter pin 2 and loosen castellated nut 3 until rack ball joint 1 threads are protected Usi...

Page 68: ...ize compound 1 Torque wrench 1 2 drive ft lbs 1 To maintain correct orientation when replacing steering wheel first turn wheels straight ahead To prevent damage to the steering wheel cover perform the...

Page 69: ...To remove steering shaft 4 Ref Fig 24 remove the steering wheel Steering Wheel Replacement on page E 16 Loosen front wheels Lift and support front of vehicle per SAFETY section and remove front wheels...

Page 70: ...ers and Warnings B Tighten bolt 1 securing intermediate shaft to steering shaft to 156 216 in lbs 180 250 kg cm torque Install front wheel s per WHEELS AND TIRES section and lower vehicle per SAFETY s...

Page 71: ...OF ILLUSTRATIONS Fig 1 Performance Characteristics F 1 Fig 2 Run Tow Maintenance Switch F 2 Fig 3 Access to Pedal Box F 3 Fig 4 Controller and Solenoid F 3 Fig 5 Battery Reference Voltage F 5 Fig 6 C...

Page 72: ...e F ii Repair and Service Manual Notes ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions Dangers and Warnin...

Page 73: ...beeper will not sound until either the vehicle speed is reduced to 8 mph 13 kph at which it freely coasts between 8 and 3 mph 5 kph or the accelerator pedal is applied When pedal up feature is activa...

Page 74: ...released for more than one second c the vehicle begins to roll above 2 mph 3 kph the electronic braking will limit speed to approximately 2 mph 3 kph and the warning beeper will sound When the accele...

Page 75: ...led sensor to read the impulses of a ring magnet attached to the armature shaft of the motor Magnetic pulses are converted into electri cal signals which the controller uses to determine the motor spe...

Page 76: ...before conducting any tests To prevent possible motor damage never operate vehicle at full throttle for more than 4 5 seconds while vehicle is in a no load condi tion For static tests raise the rear...

Page 77: ...ontinuity Place one probe on one contact of the switch place the second probe on the second terminal of the switch Ref Fig 6 Actuating a normally open NO switch will cause the DVOM to show 0 or give a...

Page 78: ...diagrams will assist in servicing the vehi cle By utilizing the Fault Codes considerable time will be saved in determining the probable vehicle operating malfunction The vehicle power and control wiri...

Page 79: ...Throttle Fault 1 Vehicle will not run Check pedal box adjustment connections Replace ITS 1 3 Speed Sensor Fault Vehicle runs slowly Check speed sensor magnet wire sensor connector connections Replace...

Page 80: ...eplace controller 4 5 Welded auxiliary con tact Vehicle runs slowly Replace controller 5 1 EEprom failsafe Vehicle will not run Replace controller 5 2 Main coil open Vehicle will not run Check coil co...

Page 81: ...WHT RED RED RED RED RED WHT YEL YEL Solenoid Reed Switch Motor Speed Sensor OUT To Hand Held Diagnostic Unit SPARE SPARE SPARE ORN RED RED YEL YEL RED WHT RED WHT RED WHT GRY GRN WHT GRN VIO ORN WHT...

Page 82: ...onnector Pedal Box ITS MS3 GRN RED BLK BLK WHT RED RED RED RED WHT YEL YEL Solenoid Reed Switch ORN RED RED YEL YEL RED WHT RED WHT RED WHT GRY GRN WHT GRN VIO ORN WHT FWD REV N Direction Selector Swi...

Page 83: ...ng and pin 8 voltage J1 3 BRV Verify tow switch and aux power wiring J1 7 BRV Verify wire connections Possible controller failure J1 8 BRV Verify wiring Possible faulty controller J1 20 Performance op...

Page 84: ...onnected to 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 rot...

Page 85: ...BL BRF preferably 48 Volt Perform 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 prob...

Page 86: ...7V 0 5 volts at full pedal Ref Fig 17 If the reading is out of specification the ITS sensor must be replaced The ITS attaches to the plastic pedal box using two plastic studs and two speed nuts Use c...

Page 87: ...and Warnings Fig 16 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 frame o...

Page 88: ...ces Cautions Dangers and Warnings Fig 17 ITS Adjustment Sheet 2 of 2 Micro switch activated Plunger enters ITS Plunger fully activated Pedal bracket rests on rear of pedal frame opening 3 4 SOLENOID A...

Page 89: ...Tighten the controller mounting bolts to 108 132 in lbs 12 15 Nm torque and the M6 F1 and F2 bolts to 80 90 in lbs 9 10 Nm torque and M8 B M B bolts to 120 130 in lbs 14 15 Nm torque Replace controll...

Page 90: ...10 Black Wire From Power Harness 4 Wire B From Power Harness 10 White Wire From B Controller to 48V 4 Wire M From Power Harness 18 Yellow Wire From J1 Pin 5 Control Harness 18 Blue From J1 Pin 17 Con...

Page 91: ...Disassembly G 1 Bearing Replacement G 3 Field Coil Replacement G 3 Brush Replacement G 3 Motor Assembly G 4 Motor Tests G 4 Motor Installation G 4 LIST OF ILLUSTRATIONS Fig 1 Disconnect Battery Cable...

Page 92: ...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 all Notices Cautions Dangers and Warnings...

Page 93: ...motor wires could cause an explosion Tool List Qty Required Insulated wrench 9 16 1 Chalk or paint pen 1 Socket 7 16 3 8 drive 1 Ratchet 3 8 drive 1 Internal snap ring pliers 1 Using an insulated wren...

Page 94: ...rvice Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 3 Motor Components 15 17 8 11 9 14 12 3 2...

Page 95: ...uter race to avoid bearing dam age Press the new bearing into the commutator end cover using heat again to aid installation Install the snap ring If brushes are to be replaced proceed now to Brush Rep...

Page 96: ...ith second snap ring Ref Fig 3 on page G 2 Motor Tests The motor housing is not available as an individual part No testing is recommended to determine the specific area of failure When a test of the p...

Page 97: ...H 2 BATTERY REPLACEMENT H 3 PROLONGED STORAGE H 4 BATTERY CHARGING H 5 AC Voltage H 5 TROUBLESHOOTING H 5 Hydrometer H 5 Using A Hydrometer H 6 LIST OF ILLUSTRATIONS Fig 1 Correct Electrolyte Level H...

Page 98: ...age H ii Repair and Service Manual Notes BATTERIES CHARGING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 99: ...ushed with water Overfilling batteries may result in electro lyte being expelled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aero...

Page 100: ...omponent damage 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 d...

Page 101: ...crete asphalt floor After hosing down the batteries a residue will be left on the batteries which is conductive and will contribute to the discharge of the batteries To prevent battery damage be sure...

Page 102: ...e that all battery terminals are installed crimp up Tighten the battery post hardware to 50 70 in lbs 6 8 Nm torque Protect the battery terminals and bat tery wire terminals with a commercially availa...

Page 103: ...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 voltage If multiple...

Page 104: ...ude a conversion scale to cor rect the float reading It is important to recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been opera...

Page 105: ...attery of the same brand type and approximate age Fig 8 Hydrometer Temperature Correction 160 71 032 030 150 66 028 026 140 60 024 022 130 54 020 018 120 49 016 014 110 43 012 010 100 38 008 006 90 32...

Page 106: ...Page H 8 Repair and Service Manual Notes BATTERIES CHARGING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 107: ...AGE NO BATTERY CHARGER Page J i Repair and Service Manual CHARGER DESCRIPTION J 1 PORTABLE CHARGER INSTALLATION J 1 Charger Maintenance J 1 LIST OF ILLUSTRATIONS Fig 1 Charger Installation J 1 Fig 2 P...

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

Page 109: ...ceptacle located on the panel underneath the driver seat Ref Fig 2 After inserting the polarized DC plug wait a few seconds and observe ammeter on charger to make sure it moves indicating that charger...

Page 110: ...Page J 2 Repair and Service Manual Notes BATTERY CHARGER Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 111: ...dal and Linkage Inspection K 8 Periodic Brake Performance Test PBPT K 10 Aggressive Stop Test K 11 Wheel Brake Inspection K 12 MAINTENANCE AND REPAIRS K 15 Parts Replacement vs Repair K 15 Adjusting B...

Page 112: ...K 13 Fig 15 Periodic Brake Performance Test K 14 Fig 16 Equally Load Vehicle K 15 Fig 17 Adjuster Mechanism K 15 Fig 18 Brake Shoe Wear K 16 Fig 19 Orientation of Brake Shoe Springs K 17 Fig 20 Free...

Page 113: ...ove 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 remov...

Page 114: ...e NOTE Unless fluid is lost or a brake line is disconnected 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 gro...

Page 115: ...andard automotive DOT 3 brake fluid Never reuse any excess fluid or return to the original container Dispose of brake fluid properly Brake fluid should never be returned to the original con tainer and...

Page 116: ...e travel of the brake cables to move the brake shoes against the brake drums The travel of the brake cables is governed by the brake pedal If the cables can not travel far enough to absorb the slack f...

Page 117: ...the adjuster arm and turning the star wheel Permanent damage to adjuster will result Adjustment takes place only when the brake is fully applied and released while the vehicle is moving Ref Fig 4 It...

Page 118: ...The spring loaded Parking Brake pedal returns to its original position releasing the brake Compensator Assembly The compensator assembly contains a spring which is compressed until the stop tube withi...

Page 119: ...ight 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 120: ...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 121: ...ed 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 Starting 20...

Page 122: ...or 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 Chec...

Page 123: ...er brake operation depends on periodic main tenance Brake Pedal and Linkage Inspection 1 Inspect brake pedal return bumper Be sure that the brake pedal is contacting the pedal return bumper when relea...

Page 124: ...pins Check clevis pins attaching the brake cables to the brake lever They must be loose when the brake pedal has been released Ref Fig 21 If the clevis pins are not loose but brake pedal free travel...

Page 125: ...be done in a safe location with regard for the safety of all personnel The Periodic Brake Performance Test PBPT should be performed regularly see Periodic Service Schedule in the GENERAL INFORMATION...

Page 126: ...n page J 17 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 failure Aggressive Stop Test To preven...

Page 127: ...aving 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 the wheel brake as...

Page 128: ...and trailing edges Ref Fig 18 If the brake shoe thickness is approaching 06 1 5 mm it is recommended that the shoes be replaced It is rec ommended that the brake shoe springs and brake adjusters be r...

Page 129: ...ake system is serviced or when parts are replaced Brake pedal free travel is the distance the pedal travels from rest to the point at which the brake cables start to move the brake levers This should...

Page 130: ...ing brake pedal free travel To check parking brake latching force place a bathroom scale on the service and parking brake pedals Using both feet press the scale down against the parking brake pedal un...

Page 131: ...are and tighten the nut to 80 90 ft lbs 108 122 Nm torque Continue to tighten until a new cotter pin can be installed through the castel lated nut and the hole in the axle Maximum torque is 140 ft lbs...

Page 132: ...y or backing plate to the axle tube flange Install new hardware locknut should only be used once and tighten to 23 28 ft lbs 31 38 Nm torque Brake Shoe and Adjuster Replacement It is recommended that...

Page 133: ...is installed with both spring hooks installed down through the brake shoes Check to see that the brake is functioning properly Install the brake drum Brake Drum Removal and Installa tion on page J 18...

Page 134: ...in blade screwdriver between the small hook and the bracket Move the hook back and to the side to release the torsion spring Ref Fig 29 Remove the lock nut 5 the shoulder bolt 6 and remove the brake p...

Page 135: ...assembly 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 J 23 Pedal Bumper Adjustment Loosen the bumper lo...

Page 136: ...re must be no gap between the top of the cam and the latch arm To adjust the kick off cam 6 engage the parking brake and loosen the two cam setscrews 5 and rotate the cam until it contacts the latch a...

Page 137: ...G L 1 POWER SUPPLY L 3 ACCESSORY WIRING L 3 LIGHT BULB REPLACEMENT L 3 FUSE REPLACEMENT L 3 LIST OF ILLUSTRATIONS Fig 1 DVOM L 1 Fig 2 Wiring Diagram L 2 Fig 3 Headlight Turn Signal Marker Light Bulb...

Page 138: ...ge L ii Repair and Service Manual Notes ELECTRICAL COMPONENTS WIRING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warning...

Page 139: ...ighting circuit Example 2 If a problem occurs in the lighting circuit that results in only one of the headlights not working there is no reason to check battery wiring or the fuse since it is obvious...

Page 140: ...15 AMP 15 AMP BLU WHT BLU WHT Light 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 Tu...

Page 141: ...be to each wire terminal on the fuse block A reading of battery voltage indicates that the fuse is in good condition No reading indicates a faulty fuse replace with a good 15 amp fuse ACCESSORY WIRING...

Page 142: ...Notices Cautions and Warnings are available from a local Distributor an authorized Branch or the Service Parts Department Fig 3 Headlight Turn Signal Marker Light Bulb Replacement Fig 4 Tail and Brake...

Page 143: ...n B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings Fig 5 Ignition Switch Fuse Block GRN RED ORN WHT BLU WHT Battery BL Light Switch Horn...

Page 144: ...f Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings Fig 6 Horn Fig 7 Turn Signal Headlight Tail Light Front of Vehicle BLK YEL HO...

Page 145: ...N Page M i Repair and Service Manual 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 2 LIST OF ILLUSTRATIO...

Page 146: ...Page M ii Repair and Service Manual Notes REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 147: ...ket and the lower mounting plate Shock Absorber Installation Install the shock absorber washer 2 with the cupped surface facing upward and rubber shock absorber bushing 3 on the top stud of the shock...

Page 148: ...2 at the rear of the frame Remove the flanged urethane bushings 11 and spacers 10 as well Remove the hex head bolt 3 and nut 5 from the for ward leaf spring mounting bracket The leaf spring 1 can now...

Page 149: ...Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Front of the Vehicle 13 1 2 22 5 23 23 24 10 11 11...

Page 150: ...Page M 4 Repair and Service Manual Notes REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 151: ...N 4 Roller Bearing N 4 Oil Seals N 4 Axle Shaft Seal Surface N 4 AXLE SHAFT ASSEMBLY N 4 Bearing Installation N 4 Axle Shaft Installation N 4 LIST OF ILLUSTRATIONS Fig 1 Disconnecting Parking Brake Ca...

Page 152: ...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 all Notices Cautions Dangers and Warnings...

Page 153: ...n should hold the motor and axle in position while the springs are removed Both persons should lift the axle from jack stands and remove assem bly from under vehicle Wrap wrenches with vinyl tape to p...

Page 154: ...R section Tighten motor terminal hardware to 66 in lbs 8 Nm torque Reattach T to axle secure with lock nut and reconnect brake lines to T Torque nuts to values shown in Figure 2 Bleed the hydraulic br...

Page 155: ...e axle housing with an internal puller Do not damage bore of axle housing when removing oil seal Remove oil seal from axle housing using puller Discard seal and replace with new one at time of assembl...

Page 156: ...langed end of shaft on the axle shaft Support the bearing assembly in a suitable press Press axle shaft assembly until bearing is firmly seated against axle shaft shoulder Slide new retainer ring on t...

Page 157: ...ELD P 1 Transporting P 1 SUN TOP P 2 Rear Support Installation P 2 Front Support Installation P 2 Sun Top Installation P 2 FOLD DOWN WINDSHIELD P 4 FULL FRONT WINDSHIELD P 5 REAR WINDSHIELD P 6 LIST O...

Page 158: ...age 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 all Notices Cautions Dangers and Warnings...

Page 159: ...uce the possibility of severe injury or death while transporting vehicle Secure the vehicle and contents Never ride on vehicle being transported Always remove windshield before trans porting Maximum s...

Page 160: ...allation Remove and discard four bolts from the front cowl See Detail B Place front support item 8 on the ground in front of vehicle On driver side place lock washer item 10 onto bolt item 9 and inser...

Page 161: ...section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 1 Sun Top 6 1 4 3 Driver Side Shown Front Of Vehicle 7 5 4 8 10 9 12 11 13 14 17 16 Fr...

Page 162: ...rubber grommets 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 item 8 as show...

Page 163: ...Using a plastic faced mallet gently tap sash to ensure windshield seats properly See Detail A Insert screw item 4 through washer item 5 rubber grommet item 6 and existing hole in front strut Secure w...

Page 164: ...a plastic faced mallet gently tap sash to ensure rear windshield seats properly See Detail A Insert screw item 4 through washer item 5 rubber grommet item 6 and existing hole in rear strut Secure wit...

Page 165: ...NOSTIC UNIT R 1 MENUS R 1 Diagnostics Report R 1 Battery and Warranty R 3 Error Messages R 4 Warning Messages R 4 Setting Top Speed and Performance Profiles R 4 Course Energy Consumption R 4 ERROR AND...

Page 166: ...ii Repair and Service Manual Notes TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and W...

Page 167: ...1 or 5 are pressed The length of the bar also changes depending on how many items are in a menu When the bar is positioned at the top arrow the beginning of the menu has been reached if the bar has r...

Page 168: ...plays the speed in RPMs revolutions per minute that is being requested of the motor by the pedal position 9 MOTOR ACTUAL SPEED displayed as ACTSPEED the next line displays the actual motor speed in RP...

Page 169: ...of charge the battery pack state of charge shown below is 85 2 TOTAL AMP HOURS displayed as TOTAL AH this is the total Amp Hours used for the life of the car 3 TOTAL MINUTES displayed as TOTAL this i...

Page 170: ...play the new speed setting on the hand held unit COURSE ENERGY CONSUMPTION read only 1 Start and Stop the Record Function display as START STOP or CLEAR 2 Scroll down to START and press the enter key...

Page 171: ...h this controller the con troller is suspect See ACTION 2 1 Replace Motor 2 Replace Controller 12576 DC Bus Timeout 1 DC Bus voltage has not reached 24 volts within 10 sec onds after key switch start...

Page 172: ...t less than 24 VDC pro ceed to step 3 if it does not fall in this range follow ACTION 3 4 Verify power resistor ohm reading is between 0 2 and 0 5 ohms 5 Remove resistor control module connec tion to...

Page 173: ...nd replace shorted component 2 Replace controller 25104 Direction Error 1 Occurs only when the reverse and forward signals are simultaneously selected normally a short condition in either the key swit...

Page 174: ...place the controller 25108 Brake Sensor Error Brake position sensor input is out of range there are three conditions which can cause this error 1 Low sensor voltage less than 0 35 volts 2 High sensor...

Page 175: ...ller B terminal If error status changes follow ACTION 1 1 Tighten or replace loose or high resistance power wire connections 2 Replace power resistor 3 Replace solenoid 4 Replace resistor control modu...

Page 176: ...and indicates that max torque current reduction is in affect 1 Refer to trouble shooting steps for the motor and controller temperature warning conditions Warning Cur Meas Cal 1 The controller s AC c...

Page 177: ...1 Current in brake circuit is greater than 100 mAmps with brake energized Controller limits drive torque current to zero in this condition 1 Normally occurs with a panic stop Release brake pedal 2 Che...

Page 178: ...the connectors and the headlight If power is not present but the other headlight functions a wiring problem is indicated between the two head lights In some cases where battery voltage is expected the...

Page 179: ...th one of the same gauge and color and wired between the correct compo nents and wire tied to the harness bundle The faulty wire should be cut back close to the harness and the ends pro tected with vi...

Page 180: ...14 Repair and Service Manual Notes TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and W...

Page 181: ...al 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 182: ...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 all Notices Cautions Dangers and...

Page 183: ...hms 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 c...

Page 184: ...24 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 dr...

Page 185: ...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 186: ...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 all Notices Cautions Dangers and...

Page 187: ...ATIONS Page T i Repair and Service Manual ST SHUTTLE 4 6 T 1 LIST OF ILLUSTRATIONS Fig 1 ST Shuttle 4 6 Vehicle Dimensions T 2 Fig 2 ST Shuttle 4 6 Vehicle Dimensions T 3 Fig 3 Vehicle Incline Specifi...

Page 188: ...Page T ii Repair and Service Manual Notes SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 189: ...duction rack and pinion STEERING WHEEL SEATING Formed fabric backed vinyl covers over cushion foam Seating for two occu pants per front two occupants at rear seat and two for option SEATING CAPAPCITY...

Page 190: ...ice Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 1 ST SHUTTLE 4 6 Vehicle Dimensions 138 in 3...

Page 191: ...ore attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 2 ST SHUTTLE 4 6 Vehicle Dimensions RECOMMENDED MAX RAMP GRADE 25 or 14 MAX RECOMMENDED MAX SIDE...

Page 192: ...this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 3 Vehicle Incline Specifications and Turning Diameter TURNING CLEARANCE DIAMETER...

Page 193: ...nd Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings Fig 4 Delta Q 48V Charger 4 9 12 45cm 4 3...

Page 194: ...Page T 6 Repair and Service Manual Notes SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Dangers and Warnings...

Page 195: ...m 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 vehicl...

Page 196: ...l may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road...

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