Fairplay ZX Manual Download Page 2

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TECHNICIAN'S REPAIR AND SERVICE MANUAL

FOREWORD

FAIRPLAY

Company reserves the right to make design changes without obligation to make these

changes on units previously sold and the information contained in this manual is subject to change

without notice.

Division of FAIRPLAY CO. LTD. is not liable for errors in this manual or for incidental or consequential

damages that result from the use of the material in this manual.

Fairplay Electric Cars

Address: 743 Horizon Court, Suite 333, Grand Junction,

Colorado 81506, USA

Tel: 970 257 0346

Fax: 970 257 0325

Summary of Contents for ZX

Page 1: ......

Page 2: ...nd the information contained in this manual is subject to change without notice Division of FAIRPLAY CO LTD is not liable for errors in this manual or for incidental or consequential damages that resu...

Page 3: ...on when towing the vehicle s Do not tow a single vehicle at speeds in excess of 12 mph 19 kph Do not tow more than three vehicles at a time Do not exceed 5 mph 8 kph while towing multiple vehicles Tow...

Page 4: ...ES CAUTIONS and WARNINGS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or render it...

Page 5: ...charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of ele...

Page 6: ...the FORWORD of this publication Attention Product Service Department FAIRPLAY Company reserves the right to make design changes without obligation to make these changes on units previously sold The in...

Page 7: ...s apply service brake to control speed on steep grades Always maintain adequate distance between vehicles Always reduce speed in wet areas Always use extreme caution when approaching sharp or blind tu...

Page 8: ...nsure as to the potential for injury refer the repair or maintenance to a qualified mechanic Always test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area t...

Page 9: ...CE A SAFETY B FRONT SUSPENSION AND STEERING C REAR SUSPENSION D REAR AXLE E MECHANICAL BRAKES F WHEELS AND TIRES G MOTOR H ELECTRONIC SPEED CONTROL I BATTERY CHARGER J BODY K ACCESSORY WIRINGS L PAINT...

Page 10: ...TROL SYSTEM A 8 TIRES A 8 CARE AND CLEANING OF THE VEHICLE A 8 VEHICLE CARE PRODUCTS A 9 CANOPY AND WINDSHIELD A 9 TRAILERING A 9 HARDWARE A 10 TORQUE SPECIFICATIONS A 10 PERIODIC SERVICE SCHEDULE A 1...

Page 11: ...itch of vehicles should be set to its position Tow in order to protect the motor and controller from damage The vehicle is provided with a Run Tow switch that is positioned underneath the passenger si...

Page 12: ...en towing vehicle Do not tow a single vehicle in excess of 12 mph 19 kph or multiple vehicles not more than 3 towed vehicles in excess of 5 mph 8 kph Towing vehicles at a speed over those recommended...

Page 13: ...serious bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be careful not to place the hands face feet or body in a location that could expose them to injury sh...

Page 14: ...is disconnected for any reason on the vehicle the Run Tow Maintenance switch must be left in the Tow position for at least 30 seconds after the circuit is restored Before a new vehicle is put into ope...

Page 15: ...ase in each grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Some maintenance items must be serviced more frequen...

Page 16: ...ing test All driving brake tests must be done in a safe location with regard for the safety of all personnel Determine the braking performance of the vehicle by latching the parking brake at a common...

Page 17: ...ats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use o...

Page 18: ...lvents Multi purpose Hand Cleaner is an industrial strength cleaner containing no harsh solvents yet gently lifts grease off hands May be used with or without water Battery Cleaner that promotes easy...

Page 19: ...brake and secure the vehicle to the trailer by ropes HARDWARE Periodically the vehicle should be checked for loose fasteners Fasteners should be tightened in accordance with the Torque Specifications...

Page 20: ...stem at each charge MONTHLY 20 HOURS includes items listed in previous table the following BATTERY Clean batteries terminals with 1 4 cup 60 ml baking soda to 1 1 2 gallons 6 liters water solution and...

Page 21: ...es items listed in previous tables the following DIRECTION SELECTOR 9 Check for wear and smooth movement lubricate shaft with light oil if required KING PINS 9 Check for excessive play and tightness o...

Page 22: ...NS B 2 NOTES CAUTIONS AND WARNINGS B 11 IMPORTANT SAFETY WARNING B 11 MODIFICATIONS TO VEHICLE B 12 GENERAL MAINTENANCE B 12 BEFORE SERVICING THE VEHICLE B 12 OTHER WARNINGS B 13 CARS BATTERY REMOVAL...

Page 23: ...their premises to identify areas where golf cars should not be operated and to identify possible hazards Steep Grade In areas where steep grades exist golf car operations should be restricted to the d...

Page 24: ...controlling party Preventive Maintenance A regularly scheduled inspection and preventive maintenance program in accordance with the manufacturer s recommendations should be established Such a program...

Page 25: ...c control system shut down the system and turn key to the OFF position to prevent short circuit or electric shock Avoid fire hazards and have fire protection equipment available Before performing any...

Page 26: ...dance with applicable fire and safety requirements Storage and handling of liquefied petroleum gas fuels shall be in accordance with American Gas Association recommendations and applicable fire safety...

Page 27: ...nd establish and train golf car operators to comply with additional specific safety practices Nameplates Markings Capacity and Modifications The user shall maintain in a legible condition all nameplat...

Page 28: ...uld include in the operators training program the following Instructional material provided by the manufacturer Emphasis on safety of passengers material loads golf car operator and other employees Ge...

Page 29: ...uipment Operators shall not add to or modify the golf car Golf cars shall not be parked or left unattended such that they block or obstruct fire aisles access to stairways or fire equipment Driving Go...

Page 30: ...th sweeping motion Loading Handle only stable and safely arranged loads When handling off center loads which cannot be centered operate with extra caution Handle only loads within the capacity of the...

Page 31: ...and recommended procedures Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check level or leakage of fuel battery electrolyte or coolant Do...

Page 32: ...y fail to perform properly 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 each component may fail Be awar...

Page 33: ...vehicle be sure to read and understand the following warnings Before working on vehicle remove all jewelry watches rings etc Be sure that no loose clothing or hair can become caught in the moving part...

Page 34: ...niques when moving batteries Always lift the battery with a commercially available battery lifting device Use care not to tip batteries when removing or installing them spilled electrolyte can cause b...

Page 35: ...d wrench from shorting out a battery which could result in an explosion and severe personal injury or death Turn vehicle key to OFF and remove Insure all optional electrical accessories are turned OFF...

Page 36: ...container to prevent the metal can from contacting battery terminals which could result in an explosion 2 passenger 6 passenger Fig B1 Battery Connections LIFTING THE VEHICLE Tool List Qty Required F...

Page 37: ...he frame crossmember as indicated Lower the jack and test the stability of the vehicle on all four jack stands If only the front or rear of the vehicle is to be raised place the chocks in front and be...

Page 38: ...10 WHEEL BEARING INSPECTION LUBRICATION C 11 SEAL INSTALLATION C 12 BEARING ADJUSTMENT C 13 KING PIN BUSH REPLACEMENT C 14 WHEEL ALIGNMENT C 15 LIST OF ILLUSTRATIONS Fig C1 Front Shock Absorbers Repl...

Page 39: ...ar wheels Test the stability of the vehicle on the jack stands before starting any repair procedure Never get under a vehicle while it is supported by a jack Front Shock Absorber Replacement Tool List...

Page 40: ...1 Jack stands 2 Open end wrench 18 1 Socket 19 1 Pliers 1 Socket 16 1 Socket 17 1 Plastic faced hammer 1 Open end wrench 16 1 Torque wrench 1 Lift and support front of vehicle per SAFETY section Remov...

Page 41: ...eel alignment Certainly front wheel alignment shall be fulfilled when wheel shaft replacement The replaced front axle must be aligned to the frame The distance from the center bolt at rear of left spr...

Page 42: ...nt springs as a set Lift and support front of vehicle per SAFETY section Support front axle with jack stand Remove the front wheels Remove the hardware 12 securing the front spring leaf and wheel shaf...

Page 43: ...o 65 75ft lb 90 100 N m Replace the front wheels as stated in WHEELS AND TIRES section Underside of Vehicle Tie Rod Wheel Bearing King Pin Inspection Grasp the tie rod and check for any vertical motio...

Page 44: ...od and the installation sequence is just reverse of disassembly Ref Fig C5 Tighten the slotted nut 3 to a minimum of 56 ft lb 80 N m and continue tightening the nut as required in order to insert a ne...

Page 45: ...eering wheel nut and strike the plastic faced hammer sharply with a ball peen hammer Ref Fig C7 Do not strike a nut or end of steering shaft directly with ball peen hammer When steering wheel is loose...

Page 46: ...ear case 14 Ref Fig C8 then draw the soldering cup back to the spline housing and use white chalk to draw a straight marking line at the middle junction of the universal joint Replace the universal jo...

Page 47: ...g column 9 Ref Fig C8 Remove the steering column from vehicle body Use inner snap ring pliers to remove the inner snap ring 18 use outer snap ring pliers to remove the outer snap ring 24 press down th...

Page 48: ...and the frame and then take the steering gear case out of the vehicle underneath Ref Fig C8 Replace the steering gear case in reverse sequence Tighten the mounting bolt 30 to 35 50 ft lb 50 70 N m Tig...

Page 49: ...g Replacement The front wheel bearings are tapered roller type and must be packed with grease at installation or any time the bearing is removed for inspection It is recommended that a bearing packer...

Page 50: ...ing Rotate the wheel 2 3 turns or more to displace excess grease If required tighten the castellated nut again till slight resistance may be felt If the cotter pin hole in the spindle 2 aligns with a...

Page 51: ...ent Remove the spindle assembly remove the inner distance sleeve 24 clean king pin bush 22 with solvent Ref Fig C12 If the wear of inner diameter of the bush is 0 880 inch 22 35 millimetres or more th...

Page 52: ...the tires should be 1 8 1 5 inch 3 5 millimetres less than the rear Manufacturing tolerance may cause difference in data however general measurement of front wheel should be 33 1 2 85 centimetres To...

Page 53: ...F CONTENTS SHOCK ABSORBER REMOVAL D 2 SHOCK ABSORBER INSTALLATION D 3 REAR LEAF SPRING REMOVAL D 3 REAR LEAF SPRING INSTALLATION D 3 REAR AXLE ASSEMBLY REMOVAL D 3 REAR AXLE INSTALLATION D 5 LIST OF I...

Page 54: ...ts of the rear axle and attachments that secure it to the springs and shock absorbers Ref Fig D3 Rear axle shaft removal is covered in REAR AXLE section Shock Absorber Removal To reduce the possibilit...

Page 55: ...e the rear spring shackle assembly 9 and the front spring mounting nuts 10 Remove the spring 11 Rear leaf Spring Installation Spring installation is in the reverse order of disassembly The shock absor...

Page 56: ...e electrical system is thus powered off Fig D1 Disconnect Battery Cable Remove the wires to the motor being careful to prevent the axle assembly 6 from rotating remove the bottom shock mounting hardwa...

Page 57: ...in the reverse order of disassembly Tighten the motor terminal fastening pieces to 66 inch pound 7 N m Ref Fig D2 Ref Fig D3 Install a new cotter pin Motor Wiring Motor Terminal Wire Marker Wiring Po...

Page 58: ...TABLE OF CONTENTS REAR AXLE DISASSEMBLY E 2 AXLE SHAFT REMOVAL AND DISASSEMBLY E 2 REAL AXLE SHAFT SEAL REMOVEMENT AND REPLACEMENT E 2 REAR AXLE SHAFT REPLACEMENT E 3 LIST OF ILLUSTRATIONS Fig E1 Remo...

Page 59: ...rsonal injury follow the lifting procedure in section SAFETY of this manual Place wheel chocks in front and behind the front wheels and check the stability of the vehicle on the jack stands before sta...

Page 60: ...nce it is disassembled and this may result in instable installation of the shaft and the vehicle may fail to run normally we recommend that the rear axle shaft assembly shall be replaced by a new one...

Page 61: ...RAKE PEDAL FREE TRAVEL F 24 BRAKE DRUM REMOVAL AND INSTALLATION F 25 WHEEL BRAKE SERVICE F 27 BACKING PLATE ENTIRE WHEEL BRAKE ASSEMBLY REMOVAL AND INSTALLATION F 29 BRAKE SHOE AND ADJUSTER REPLACEMEN...

Page 62: ...Fig F16 Adjuster Mechanism F 21 Fig F17 Inspect the brake shoe springs F 22 Fig F18 Orientation of Brake Shoe Springs F 22 Fig F19 Free Travel Adjustment F 24 Fig F20 Check Clevis Pins F 25 Fig F21 Ch...

Page 63: ...mage to the brake components Unlike automotive hydraulic brakes mechanical brakes depend on the travel of the brake cables to move the brake shoes against the brake drums The travel of the brake cable...

Page 64: ...ction of drum rotation This movement results in the typical brake shoe wear patterns Equalizer Link The equalizer link balances braking between the driver and passenger sides of the vehicle Variations...

Page 65: ...the brake shoe lining wears When the brake pedal is released the adjuster spring retracts the brake adjuster arm which contacts the star wheel Note that adjustment only takes place when the brake ped...

Page 66: ...e pedal to return to its original position disengaging the latch arm from the catch bracket This is the preferred method which minimizes wear on components 2 Pressing the accelerator pedal rotates the...

Page 67: ...pedal is held in the applied down position by the catch bracket The latch arm is held in position by the tension in the brake linkage The Parking Brake can be released by two methods 1 Depressing the...

Page 68: ...justment and correction Pedal free travel correct Adjust free travel Conduct periodic brake performance test PBPT Test result Aggressive stop test 10 times 3 periodic brake performance tests Test resu...

Page 69: ...l the pedal free returning stabilizes within the specified range Disassemble clean and lube bosses Damaged worn 06 or less glazed Install brake drum and tighten it Install inner brake drum washers and...

Page 70: ...azed surface Sand the shoes with emery cloth Brake shoes must have 06 1 5 mm min material remaining System not adjusted properly Check and adjust per manual Brake cable s loose from anchor brackets Ch...

Page 71: ...rake will not stay latched Excessive wear Check for worn latch mechanism and replace if needed this part can be flipped for extended use Fig F7 Troubleshooting Table Continued New Vehicle Troubleshoot...

Page 72: ...pedal is contacting the pedal return bumper when released that the bumper is in good condition and that a 1 4 3 8 6 9 5 mm gap exists between the brake pedal arm and the setscrew heads of the kick of...

Page 73: ...ke pedal is depressed enough to remove slack from the compensator and cables Too much pedal free travel may indicate wheel brakes not adjusting wear in the cables and linkages or initial break in of c...

Page 74: ...aching the brake cables to the brake lever They must be loose when the brake pedal has been released Ref Fig F19 If the clevis pins are not loose but brake pedal free travel is correctly adjusted and...

Page 75: ...epair of golf car F 15 Fig F11 Equalizer and Compensator 9 Check the condition and operation of the parking brake latching mechanism The parking brake should latch firmly and release as soon as the ac...

Page 76: ...ig F12 It is very important that the correct setscrews are used to hold the kick off cam to the pivot rod Use of longer screws prevents correct adjustment of pedal bumper pedal travel and may prevent...

Page 77: ...ted by latching the parking brake to eliminate different pedal pressures and to include the affects of link age mis adjustment and significant changes or differences in braking performance will be evi...

Page 78: ...below then repeat the Periodic Brake Performance Test three more times second set of three If the vehicle passes two of three Periodic Brake Performance Tests check that the clevis pins at the brake...

Page 79: ...gard for the safety of all personnel To perform an Aggressive Stop Test equally load both sides of the vehicle Ref Fig F13 and apply maximum force and travel to the service brake pedal while moving Do...

Page 80: ...Check for excessive wear indicated by the friction surface being significantly worn and leaving a ledge of unworn drum Inspect the splines for galling wear and corrosion If any of these problems are f...

Page 81: ...oated washers Ref Fig F23 7 Check the condition and operation of the moving anchor assembly Ref Fig F23 Operate the brake lever to check for free motion The adjuster assembly and brake lever should mo...

Page 82: ...ers be replaced when installing new brake shoes Fig F17 Inspect the brake shoe springs 10 Inspect the brake shoe springs Be sure that they are not broken or damaged and are correctly installed The hoo...

Page 83: ...wdriver 1 Air impact wrench 1 Socket 19 1 Socket 17 1 Socket 10 1 Torque wrench 10 100 N m 1 Open end wrench 13 1 Open end wrench 17 1 Open end wrench 19 1 10 Open end wrench 1 5 Hexagon ring spanner...

Page 84: ...capability Too little pedal free travel may cause the brakes to drag not fully released Either condition can prevent the brakes from adjusting properly This procedure is intended to adjust the brakes...

Page 85: ...ng force can be checked as verification after setting 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...

Page 86: ...e adjuster and require that both wheel brake assemblies be replaced If the drum does not slide from the brake assembly the brake shoes must be retracted Rotate the hub so that the hole in the drum is...

Page 87: ...mple of vehicles within the service fleet to establish the most efficient and effective service interval Remove the brake drum as described in Brake Drum Removal and Installation Wear eye protection a...

Page 88: ...surfaces lightly with emery cloth to remove any foreign material The adjusting screw must be screwed into the star wheel nut until only 1 2 threads are exposed Ref Fig F26 If the brake shoes are repl...

Page 89: ...to the axle tube flange Brake Shoe and Adjuster Replacement It is recommended that when brake shoes are replaced the adjusters and springs also be replaced It is good practice to do one side at a tim...

Page 90: ...s shown Ref Fig F23 Always replace both brake shoes on both wheels as a set Install the shoes as indicated and install the shoe clamp 5 over the shoe clamp pin 4 and rotate 90 to lock them in place Re...

Page 91: ...zer assembly and discard Fig F26 Brake Cable Equalizer and Compensator Slide the equalizer link of the new assembly over the compensator rod Loosely install the spherical nut and new locking jam nut I...

Page 92: ...new ones if corrosion or wear is found Brake pedal installation is in the reverse order of disassembly Tighten the nut 5 to 25 29 ft Ibs 34 39 N m torque and use a new cotter pin when installing the...

Page 93: ...te the location and orientation of the two torsion springs 8 Remove the push nut 9 and pin 10 Ref Fig F27 and remove the parking brake pedal The latch of the parking brake pedal arm is hardened Do not...

Page 94: ...dimension from the top of the pedal arm to the setscrew heads in the kick off cam should be approximately 1 4 3 8 6 9 5 mm Tighten the lock nut to 12 14 ft Ibs 16 19 N m Fig F29 Pedal Bumper Adjustmen...

Page 95: ...remove the cam pivot 7 cam and spacer 8 Ref Fig F30 Inspect the bushings 9 10 and spacer If they are worn replace them with new ones Assembly is in the reverse order of disassembly With the parking b...

Page 96: ...ES Read section A and B completely prior to operation or repair of golf car G 1 TABLE OF CONTENTS WHEEL AND TIRE SERVICE G 2 TIRE REPAIR G 2 WHEEL INSTALLATION G 3 LIST OF ILLUSTRATIONS Fig G1 Wheels...

Page 97: ...y higher inflation pressure On very soft turf a lower pressure prevents tires from cutting into the turf For vehicles being used on paved or hard surfaces tire inflation pressure should be in the high...

Page 98: ...unting demounting tires Follow all instructions and safety warnings provided by the mounting demounting machine manufacturer Wheel Installation With the valve stem to the outside mount the wheel onto...

Page 99: ...WHEELS AND TIRES Read section A and B completely prior to operation or repair of golf car G 4 Fig G1 Wheels and Tires...

Page 100: ...OR H 4 REPLACING BEARING H 5 REPLACING EXCITING COIL H 6 REPLACING BRUSH H 6 BRUSH WEAR H 7 ASSEMBLING MOTOR H 8 MOTOR TEST H 8 INSTALLING MOTOR H 8 LIST OF ILLUSTRATIONS Fig H1 Disconnect Battery Wir...

Page 101: ...controller is disconnected for any reason on the vehicle the Run Maintenance switch must be left in the Run position after the circuit is restored Before removing the motor wiring use insulated wrenc...

Page 102: ...f car H 3 Fig H1 Disconnect Battery Wires Fig H2 Wheel Shaft and Motor When installing the motor onto the rear bushing be careful not to damage the splines Screw off the 6 bolts securing the motor ont...

Page 103: ...ASSEMBLING MOTOR Tool List Qty Required Flat blade screwdriver 1 Ratchet 1 Socket 10 1 Plastic faced hammer 1 Insulated wrench 13 1 Insulated wrench 14 1 Screw off the fixing screw with care and then...

Page 104: ...n end cap breakage For easy removal heat the commutator end cap before removing the armature After heating place the commutator end cap armature component onto the press support the end cap as much as...

Page 105: ...ITING COIL Tool List Qty Required Wrench 13 1 Ratchet 1 Socket specification 10 1 To replace the exciting coil 8 remove the exciting coil terminal components 9 in positions S1 and S2 Ref Fig H3 Remove...

Page 106: ...till all brush spring 15 lean on one side of the brush Ref Fig H5 Remove the brush use brush replacement tool kit to replace new brush Position the spring on side of each spring Fig H5 Fixed Brush Ter...

Page 107: ...iring system test indicates that the system runs normally while the vehicle still fails to drive or runs poorly motor may be the only component that malfunctions therefore it must be replaced INSTALLI...

Page 108: ...CONTROLLER FAULT CODE RETRIEVAL AND SOLUTIONS I 12 ACCELERATOR TESTING AND REPLACEMENT 1 13 CONTROLLER REPLACEMENT I 15 SOLENOID REPLACEMENT I 17 LIST OF ILLUSTRATIONS Fig I1 Access to Pedal Box I 2 F...

Page 109: ...pe of solid state device solenoid controls its activation and it is located underneath the passenger side seat The pedal box is connected to the controller via a 4 pin connector underneath the seat an...

Page 110: ...t 13 1 Phillips screwdriver 1 Hexagon ring spanner 5 1 Open end wrench 13 1 Ratchet 1 Rag 1 SYMPTOMS Vehicle fails to run runs poorly or runs intermittently Raise the rear wheels of the vehicle and su...

Page 111: ...the solenoid to make an audible click TESTING BATTERY VOLTAGE It is important to determine the condition of the battery set before proceeding with any electrical troubleshooting An open voltage test i...

Page 112: ...ity of the pedal microswitch FWD REV towing switch solenoid key switch and 4 pin connector of the accelerator continuity Prior to disconnecting B from battery for powering off turn the key switch to i...

Page 113: ...robed touches the switch but is still not activated The audible indicator will stop and the meter display will indicate a value greater than 0 when the switch is activated The change in display or aud...

Page 114: ...le operation resulting in possible injury or fatality Please read carefully before attempting any changes Refer to Screenshots following this description 1 All setup values have a default setting pre...

Page 115: ...ablished and then Please Select Mode See Screenshot 2 Under the main title you will now see that Not Connected has been replaced with the Controller Number and Firmware Version 9 Click on Setup The sc...

Page 116: ...troller code version are now displayed The user can now select the mode Screenshot 1 Activate KC_Host First and communication begins Now power up the controller and look for screenshot 2 Screenshot 3...

Page 117: ...speed 5 1 7 Rev Speed Limit Setting of the reverse top speed A higher number allows a higher top speed 2 1 2 Fwd Accel Rate Setting of the forward acceleration rate A higher number allows a faster 3 1...

Page 118: ...Table I 1 controller procedure Test to controller fault When golf car works abnormally or suddenly stops working on the road we can firstly find out the cause according to the fault code Steps are fol...

Page 119: ...ctor error Use multimeter to detect the pickup of contactor coil and measure the pickup current of contactor if the pickup current is 3A replace the contactor verify that it s OK and then restore the...

Page 120: ...circuit voltage verify that it s OK and then restore the towing switch 4B 4 long 11 short Excessively high voltage drop of diode Check the exterior circuit voltage verify that it s OK and then restor...

Page 121: ...connected to the potentiometer with care and screw off the nuts securing the potentiometer and pedal box Install new potentiometer be careful to align the potentiometer properly and do not tighten the...

Page 122: ...ation or repair of golf car I 15 Fig I 9 Potentiometer Adjustment CONTROLLER REPLACEMENT Tool List Qty Required Socket 10 1 Socket 13 1 Socket 14 1 Ratchet 1 Extension bar 1 Insulated wrench 13 1 Rag...

Page 123: ...ns of the wires on the controller Ref Fig I2 Remove the controller mounting bolts and remove the controller Mount new controller and reconnect wiring Tighten the controller mounting bolts to torque of...

Page 124: ...d section A and B completely prior to operation or repair of golf car I 17 Replace the environmental cover and tighten the mounting bolts to torque of 12 15 N m Reconnect the BL battery cable and repl...

Page 125: ...Electronic Speed Control Non PDS Read section A and B completely prior to operation or repair of golf car I 18 Fig I 11 Wiring Diagram...

Page 126: ...LESHOOTING J 12 CONTINUITY CHECK J 13 DIODE TEST PROCEDURE J 13 COMPONENT REPLACEMENT J 13 DESCRIPTION OF CHARGER INDICATOR IMPLICATION J 15 LIST OF ILLUSTRATIONS Fig J1 Standard Electrolyte Level J 3...

Page 127: ...te is overfilled it may overflow in the charge cycle and damage the vehicle and storage equipment Aerosol containers of battery terminal protectant must be used with extreme care Insulate the metal co...

Page 128: ...be charged after it works for several days Once Every Month y Check the wires for wear binding post for looseness and insulating materials for corrosion or aging y Check for the correct electrolyte le...

Page 129: ...of acid in electrolyte and reduce the service life of battery Battery may consume a large amount of water before its life span expires It is important to guarantee the purity of the applied water and...

Page 130: ...to discharge To prevent the battery from being damaged ensure that all top caps of battery are buckled securely As per the correct cleaning method use solution of sodium acid carbonate baking soda an...

Page 131: ...orrosion is found it should be immediately removed with a putty knife and a wire brush The corroded location shall be cleaned with mixed liquor of sodium acid carbonate baking soda and water when it g...

Page 132: ...educed to 1 240 within 20 days and it should be recharged over again If battery is not charged for a long time sulphate may appear on and inside its plates This is a type of damage beyond repair and w...

Page 133: ...cause the electrolyte to overflow out of the battery which may result in damage of relevant components y Electrolyte level in all units should be the recommended level and exceeds the plate surface y...

Page 134: ...f running in some cases New battery may reach its maximum capacity only after it reach its period of saturation Before it reaches its period of saturation it has to experience charge discharge circula...

Page 135: ...le senses no change it determines that the batteries are fully charged and shuts the charger off Conditions to be Noticed Prior to Charger Charging Electric Shock Hazard Vehicle chargers are shipped w...

Page 136: ...cle during the charge cycle it will shut off immediately y If the AC power is interrupted the charge cycle will continue normally for the remainder of the cycle when the power is restored y If the bat...

Page 137: ...contact When cleaning the auxiliary contact Ref Fig J11 wrap up the plug by abrasive paper and wipe it back and forth for approximately 10 20 times and ensure that the pressure is applied onto the con...

Page 138: ...tinuity setting set the meter then to KQ the meter will indicate 0 when continuity is detected Ref Fig J12 Fig J 12 Continuity Check DIODE TEST PROCEDURE Tool List Qty Required DVOM 1 To test the diod...

Page 139: ...RT Relay closing sound Activate START charger OFF Plug DC cable into vehicle Insert the AC wire into receptacle Charge indicator ON Finish battery check Transformer sounds Unplug AV wire and DV wire R...

Page 140: ...green Time output error Red Self check error Red flickering Battery connection error Connect the battery over again and verify the correctness of battery polarity Red yellow Charge finished battery h...

Page 141: ...2 BODY COMPONENT REPLACEMENT K 2 LIST OF ILLUSTRATIONS Fig K1 Drill Out Metal Rivet K 2 Fig K2 Body Components Front K 3 Fig K3 Bottom Plate and Rocker Panel K 4 Fig K4 Seat Frame and Battery Rack K...

Page 142: ...pop rivets which require that 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 with a sharp drill bit that is slightly...

Page 143: ...d B completely prior to operation or repair of golf car K 3 If the instrument panel is to be replaced the serial number plate must be removed and reinstalled on the instrument panel Ref Fig K2 Fig K2...

Page 144: ...BODY Read section A and B completely prior to operation or repair of golf car K 4 Fig K3 Bottom Plate and Rocker Panel...

Page 145: ...BODY Read section A and B completely prior to operation or repair of golf car K 5 Fig K4 Seat Frame and Battery Rack...

Page 146: ...BODY Read section A and B completely prior to operation or repair of golf car K 6 Fig K5 Rear Body Components...

Page 147: ...BODY Read section A and B completely prior to operation or repair of golf car K 7 Fig K6 6P Body Components Middle Fig K7 6P Rear Body Components...

Page 148: ...of golf car L 1 TABLE OF CONTENTS DVOM L 2 TROUBLESHOOTING L 2 POWER SUPPLY L 4 CHECK FOR LOOSE OR BARE WIRES L 4 CHECK FOR BATTERY CONDITION L 4 CHECK POWER WIRE L 4 CHECK FUSE L 4 ACCESSORY WIRINGS...

Page 149: ...d instructions for the use and care of the meter In order to effectively troubleshoot the circuits that include the horn lighting brake turn signals and gauges the technician must be able to use the w...

Page 150: ...eadlights In some cases where battery voltage is expected the easiest way to test the circuit is to set the DVOM to DC volts and place the negative probe of the DVOM to the negative battery terminal M...

Page 151: ...re attached Place the black probe on the battery post with the black wire attached A reading of 11 VDC or greater indicates adequate battery condition No reading indicates a a poor connection between...

Page 152: ...ring from terminal to terminal operating condition of switch etc Use the wiring diagram Ref Fig L2 to check correct wiring and wire routing If there is power at the fuse end of the wire there must als...

Page 153: ...PAINT Read section A and B completely prior to operation or repair of golf car M 1 TABLE OF CONTENTS PAINTING M 2 MINOR SCRATCHES M 2 LARGER SCRATCHES M 2 COMPLETE PANEL REPAIR M 3...

Page 154: ...ing to 45 60 minutes in higher humidity using brush on touch up paint until coating layer is visible slightly above the surface of the part III After painted for 2 hours use 400 grit wet sand paper to...

Page 155: ...but recommended Follow this process with clear coat to renew and protect depth of finish 8 Wax or polish with Carnauba base product available at any automotive parts distributor COMPLETE PANEL REPAIR...

Page 156: ...n A and B completely prior to operation or repair of golf car N1 TABLE OF CONTENTS ELECTRICAL SYSTEM N 2 ELECTRICAL SYSTEM BASIC TROUBLESHOOTING N 2 ACCESSORY BASIC ELECTRIC TROUBLESHOOTING N 2 FRONT...

Page 157: ...witch Vehicle fails to run Poor contact at the joints and plug in parts Check for poor contact of the joints and plug in parts plug them over again and reset the towing switch Faulty ESC system Test a...

Page 158: ...lubricant in king pins tie rod end idler bushing or steering box Pump grease to each lubrication accessory and move the steering between the left right latched positions Do not over grease If steering...

Page 159: ...f car O 1 TABLE OF CONTENTS VEHICLE PARAMETERS O 2 PRECAUTIONS O 9 LIST OF ILLUSTRATIONS Fig O1 Vehicle Dimensions 2P O 4 Fig O2 Incline Specifications and Turning Clearance Diameter 2P O 5 Fig O3 Veh...

Page 160: ...tch forwarding reversing selector switch reversing buzzer and roll deduct alarm LIGHTING PACKAGE Headlights rear lights brake lights and turn signal lights CONVENIENCE State of charge meter STEERING W...

Page 161: ...ficiency differential with helical gears 12 49 1 ratio SPEED 13 15 miles hour 21 24km h equipped with motor 17 19 mile hour 27 31 km h CHARGER 2P Automatic ADC charger Refer to specifications of charg...

Page 162: ...operation or repair of golf car O 4 Specifications are subject to change without further notice Fig O1 Vehicle Dimensions 2P 74 02 inches 1880mm 47 24 inches 1200mm 33 86 inches 860mm 38 58 inches 98...

Page 163: ...GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car O 5 Fig O2 Incline Specifications and Turning Clearance Diameter 2P DIAMETER 21ft 6 4m...

Page 164: ...GENERAL SPECIFICATIONS Read section A and B completely prior to operation or repair of golf car O 6 Fig O3 Vehicle Dimensions 6P...

Page 165: ...ONS Read section A and B completely prior to operation or repair of golf car O 7 2 Vehicle Dimensions Incline Specifications and TuPning CleaPance DiameteP Fig O4 Incline Specifications and Turning Cl...

Page 166: ...a loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc All travel s...

Page 167: ...ng loaded highly corrosive explosive or may produce high amperage or reach high temperatures Battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystande...

Page 168: ......

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