Cushman 625615 Technician'S Repair And Service Manual Download

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TECHNICIAN’S REPAIR AND SERVICE MANUAL

ELECTRIC POWERED UTILITY VEHICLES

625615

REVISED AUGUST 2012

ISSUED MARCH 2012

Summary of Contents for 625615

Page 1: ...TECHNICIAN S REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLES 625615 REVISED AUGUST2012 ISSUED MARCH 2012...

Page 2: ...red on a flat surface To prevent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS Limit speed b...

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

Page 4: ...s 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 electrical drain The battery charger and the controller...

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

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

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

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

Page 9: ...in the charging cycle of batteries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation...

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

Page 11: ...THE ELECTRIC VEHICLE A 1 ROUTINE MAINTENANCE A 2 REAR AXLE A 2 BRAKES A 2 TIRES A 2 LIGHT BULB REPLACEMENT A 2 VEHICLE CLEANING AND CARE A 2 VEHICLE CARE PRODUCTS A 3 SUN TOP AND WINDSHIELD A 3 HARDWA...

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

Page 13: ...ly 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 pa...

Page 14: ...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 resulti...

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

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

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

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

Page 19: ...IONS WARNINGS AND DANGERS B 1 IMPORTANT SAFETY WARNING B 1 MODIFICATIONS TO VEHICLE B 1 GENERAL MAINTENANCE B 1 BEFORE SERVICING THE VEHICLE B 1 Additional Warnings B 2 BATTERY REMOVAL INSTALLATION B...

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 Notices Cautions Warnings and Dangers...

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

Page 22: ...rks away from the batteries Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the...

Page 23: ...g 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...

Page 24: ...ifting process 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...

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

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

Page 27: ...BODY C 1 General C 1 BODY COMPONENT REPLACEMENT C 1 PAINTING C 7 Minor Scratches C 7 Larger Scratches C 7 Complete Panel Repair C 7 LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Front Bo...

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

Page 29: ...ed with a minimum of specialized tools Most body components are held in place with conventional removable hardware nuts bolts washers and screws Some components are mounted with pop rivets which requi...

Page 30: ...Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 48 Cowl Instrumental Panel Fender Flare Brush Guard Front Basket Floorpan S...

Page 31: ...ll of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ASHTRAY FLOOR MOUNT GUN HOLDER Floor Mat Seat Frame Gun Holder Rocker...

Page 32: ...BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Splash panel Battery Tray Rear Fender Rear Bumper Access P...

Page 33: ...clean 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...

Page 34: ...Page C 6 Repair and Service Manual Notes BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 35: ...S FOR SECTION D SECTION TITLE PAGE NO Page D i Repair and Service Manual WHEELS AND TIRES WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 2 LIST OF ILLUSTRATIONS Fig 1 Wheel and Tire I...

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

Page 37: ...ould cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor applications with...

Page 38: ...he cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tight...

Page 39: ...Page D 3 Repair and Service Manual B B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 40: ...Page D 4 Repair and Service Manual B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 41: ...5 Steering 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 Adjus...

Page 42: ...E ii Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 43: ...icular attention to Notices Cautions Warnings and Dangers Fig 1 Axle Mounted Steering and Front Suspension Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate...

Page 44: ...nts Do not use more than three 3 pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Wheel Be...

Page 45: ...in 2 and loosen castellated nut 3 If performing a wheel bearing adjustment as part of another procedure make sure wheel is mounted to hub hand tight with lug nuts 4 and hub is loosely retained on spin...

Page 46: ...e flat area on the threaded tube has left hand threads clock wise to loosen while the end without the flat has conventional right hand threads counter clockwise to loosen To adjust wheel alignment loo...

Page 47: ...List Qty Wrench 9 16 1 Remove the nut 1 from the bottom of the shock absorber 2 at the front axle 3 Ref Fig 6 Compress shock absorber to clear the mounting bracket Loosen the nut securing the top of t...

Page 48: ...t pulling apart intermediate shaft Remove the three 1 3 4 long bolts 18 two 1 1 2 long bolts 28 spring plate 24 and five lock nuts 19 secur ing axle to springs and discard lock nuts At the 3 1 2 long...

Page 49: ...e 25 27 securing rear of spring 17 to vehicle frame and discard lock nuts 27 To prevent stress and possible damage to the rack and pinion unit the driver side spring must be mounted to the axle with t...

Page 50: ...the bore Tap gently into place until seal is flush with end of hub Lubri cate lips of seal and spindle with grease Ref Fig 10 Place new hub onto spindle and fill the area between the two wheel bearin...

Page 51: ...e of hub 1 is clean and place new race over bore of hub Evenly tap with hammer and bearing driver to drive race fully in bore Repeat on other side of hub Clean spindle 2 and pack new bearings with gre...

Page 52: ...t 11 16 1 To remove rack ball joint 1 loosen passenger side front wheel and lift and support front of vehicle per SAFETY section Ref Fig 12 Remove passenger side front wheel and turn steering wheel fu...

Page 53: ...ion Check front wheel alignment and adjust if necessary Wheel Alignment on page E 3 Tie Rod Inspection Replacement Tool List Qty Tape Measure 1 Wrench 3 4 1 Wrench 9 16 1 Needle Nose Pliers 1 Wrench 1...

Page 54: ...e per SAFETY section Remove passenger side front wheel and turn steering wheel fully to the left Remove rack ball joint 2 and jam nut 3 from rack extension 4 Rack Ball Joint Replacement on page 10 Cut...

Page 55: ...l List Qty Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hammer 1 Wrench 3 4 1 Socket 3 4 1 Socket 11 16 1 Torque Wrench ft lbs 1 The spindle bearings are designed to be use...

Page 56: ...hey are found to be damaged or excessively worn a new rack and pinion unit must be installed Secure rack and pinion unit in vice by the mounting ears only The rack and pinion unit is made of aluminum...

Page 57: ...6 1 Torque Wrench in lbs 1 To remove rack and pinion unit 12 Ref Fig 12 loosen front wheels and lift and support front of vehicle per SAFETY section Remove front wheels Remove bolt 13 and washer 14 se...

Page 58: ...te the 1 8 gap Tighten jam nut 5 to 35 45 ft lbs 47 61 Nm torque Secure bellows to rack and pinion unit with new wire tie 14 Steering Wheel Replacement Tool List Qty Socket 15 16 1 Ratchet 1 2 drive 1...

Page 59: ...pres ent replace clipboard Install by carefully pressing first the top two then the bottom two retaining tabs into the matching slots in steering wheel Steering Shaft and Column Replacement Tool List...

Page 60: ...of seal in bushing 12 at top of column and press steering shaft and bearing assem bly into column base Secure with large retaining ring making sure it is fully seated in groove of column Place steerin...

Page 61: ...19 Repair and Service Manual B B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 62: ...E 20 Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 63: ...TING DIAGRAMS F 6 INDUCTIVE THROTTLE SENSOR ITS TESTING AND REPLACEMENT F 10 CONTROLLER REPLACEMENT F 13 SOLENOID REPLACEMENT F 13 LIST OF ILLUSTRATIONS Fig 1 Run Tow Maintenance Switch F 2 Fig 2 Acce...

Page 64: ...F ii Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRONIC SPEED CONTROL...

Page 65: ...tion is enabled by the handheld diagnotic tool 4 The Freedom performance option This option includes all of the driving features of the Golf Coastal option except that the flat ground and downhill com...

Page 66: ...ectronic braking will limit speed to approximately 2 mph 3 kph and the warning beeper will sound When the accelerator pedal is depressed the electronic braking and warning beeper will be overridden an...

Page 67: ...TS and plunger are accessed by removing the two screws and top cover from the enclosed pedal box Fig 2 Access to Pedal Box Speed Sensor The speed sensor uses a sealed sensor to read the impulses of a...

Page 68: ...open volt age test If there is any doubt as to the adequacy of the battery set charge the batteries and perform a load test using a discharge machine following manufacturer s instructions If batterie...

Page 69: ...ate 0 when it detects continuity Testing a Switch for Continuity Place one probe on one contact of the switch place the second probe on the second terminal of the switch Ref Fig 5 on Page F 5 Actuatin...

Page 70: ...ed to be closed 3 9 Throttle reapplied 1 Contactor opened 2 Contactor coil or wiring opened MAIN DRIVER OFF Main Driver FET detected as not turning ON Throttle applied to cause Contactor to close 3 8...

Page 71: ...owers up with Key Direction and Throttle applied OR Throttle applied before Key and Direction switch applied KSI ON Forward or Reverse ON 8 Throttle 25 1 Incorrect sequence of Vehicle input controls 2...

Page 72: ...ting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 8 Controller Connectors and Connections RU N TO W C From Motor 4AWG A1 From Motor 4AWG CB To Solenoid 4AWG CB T...

Page 73: ...ions Warnings and Dangers Fig 9 Controller Wiring Diagram KSI WHT WHT WHT YEL BLU MAIN COIL BLU RED RED RED RED RUN TOW ORG RED ORG GRN GREY WHT YEL WHT RED RED GRN BLK BLK BLK BLK BLK A1 A A2 F2 S2 S...

Page 74: ...V when the solenoid clicks and 2 7V 0 5 volts at full pedal If the reading is out of specification the ITS sensor must be replaced The ITS attaches to the plastic pedal box using two plas tic studs an...

Page 75: ...ngs and Dangers Fig 11 ITS Adjustment Sheet 1 of 2 Use 7 32 drill to measure gap between plunger and ITS Micro switch disengaged Micro switch disengaged Pedal bracket rest against front of pedal frame...

Page 76: ...ices Cautions Warnings and Dangers Fig 12 ITS Adjustment Sheet 2 of 2 Micro switch activated Plunger enters ITS Plunger fully activated Pedal bracket rests on rear of pedal frame opening 3 4 SOLENOID...

Page 77: ...d the terminal bolts to 120 144 in lbs 13 5 16 3 Nm torque Replace the environmental cover and tighten the mount ing bolts to 35 44 in lbs 4 5 Nm torque Reconnect the BL battery cable and replace the...

Page 78: ...g any procedure Pay particular attention to Notices Cautions Warnings and Dangers Reconnect the BL battery cable and replace the seat Fig 13 Solenoid Wiring SOL Red Wire Ring Terminal From Main Wire H...

Page 79: ...F 15 Repair and Service Manual Notes ELECTRONIC SPEED CONTROL TCT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dang...

Page 80: ...F 16 Repair and Service Manual Notes ELECTRONIC SPEED CONTROL TCT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dang...

Page 81: ...al G 1 Motor Disassembly G 1 Bearing 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 G 1 Fig 2 Mark...

Page 82: ...Page G ii Repair and Service Manual Notes MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 83: ...ason on the TCT model vehicle the Run Tow Maintenance switch must be left in the Tow Maintenance position for at least 30 seconds after the circuit is restored Disconnect the negative BL battery cable...

Page 84: ...Service Manual B MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 Motor Components Speed Sensor 13 5...

Page 85: ...against the side of the brush This keeps the brushes out of the way during bearing replacement Ref Fig 5 on Page G 4 Remove internal snap ring 8 and heat the commutator end cover again Press bearing 9...

Page 86: ...g Ref Fig 3 on Page G 2 Motor Tests The armature and motor housing are not available as individual parts No testing is recommended to deter mine the specific area of failure When a test of the power w...

Page 87: ...Page G 5 Repair and Service Manual Notes MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 88: ...Page G 6 Repair and Service Manual Notes MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 89: ...s H 3 Battery Replacement H 3 Prolonged Storage H 5 Battery Charging H 5 AC Voltage H 6 TROUBLESHOOTING H 6 Hydrometer H 6 Using A Hydrometer H 7 LIST OF ILLUSTRATIONS Fig 1 Correct Electrolyte Level...

Page 90: ...age H ii Repair and Service Manual Notes BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 91: ...ter Overfilling batteries may result in electro lyte being expelled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aerosol container...

Page 92: ...attery being charged will gas with the majority of the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be car...

Page 93: ...Fig 4 Preparing Acid Neutralizing Solution Allow the solution to sit for at least three minutes use a soft bristle brush or cloth to wipe the tops of the batteries in order to remove any residue that...

Page 94: ...aking soda and brush clean if required To prevent battery explosion that could result in severe personal injury or death extreme care must be used with aerosol containers of battery terminal protectan...

Page 95: ...charge the battery For portable chargers disconnect the charging plug from the vehicle recepta cle For on board chargers disconnect the charging har ness from the batteries The batteries must be clean...

Page 96: ...y must mature before it will develop its maximum capacity Maturing may take up to 100 charge discharge cycles After the maturing phase the older a battery gets the lower the capacity The only way to d...

Page 97: ...rolyte temperature is above or below 80 F 27 C Adjust the reading to conform with the electrolyte temperature e g if the reading indicates a specific gravity of 1 250 and the electrolyte temperature i...

Page 98: ...Page H 8 Repair and Service Manual Notes BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 99: ...TEM DIGITAL VOLT OHM METER J 1 TROUBLESHOOTING J 1 POWER SUPPLY J 4 MAIN ACCESSORY WIRING J 4 LIST OF ILLUSTRATIONS Fig 1 DVOM J 1 Fig 2 Accessory Wiring Diagram J 2 Fig 3 Main Harness Wiring Diagram...

Page 100: ...Page J ii Repair and Service Manual Notes ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 101: ...ot the lighting circuit Example 2 If a problem occurs in the lighting circuit that results in only one of the headlights not working there is no reason to check battery wiring or the fuse since it is...

Page 102: ...s butt connection within wiring harness Brake Switch RED BRN WHT BLK BLK NO C Driver Side Passenger Side Driver Side Passenger Side State of Charge Meter Solenoid Hour Meter Turn Turn Marker Marker He...

Page 103: ...1 12 13 14 15 16 S 1 1 1 1 S 1 1 PURPLE GREEN WHITE 1 2 3 4 GRAY 1 3 4 2 A5 1 1 1 2 2 4 4 3 3 W17 W8 W7 W14 W13 W11 W10 W12 W6 W18 W16 1 W21 W19 W20 W9 W5 W4 W3 W2 W1 W15 W23 W22 W25 W24 RUN TOW SWITC...

Page 104: ...ess voltage readings may be somewhat lower than battery volt age A reading of 1 volt below battery voltage is acceptable 3 Check Converter Supply Firmly attach the black probe to the most negative bat...

Page 105: ...ection before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRICAL SYSTEM Fig 5 Electrical Accessories RED GRN BLK REVERSE BUZZER DASH MOUNTED DIRECTIO...

Page 106: ...ing any procedure Pay particular attention to Notices Cautions Warnings and Dangers ELECTRICAL SYSTEM Fig 6 Electrical Accessories ON OFF GRN HOR N Floorboard 58 89 Steering column cover Key Switch an...

Page 107: ...tion to Notices Cautions Warnings and Dangers ELECTRICAL SYSTEM Fig 7 Electrical Accessories TURN SIGNAL HEAD LIGHT Rear Fender WHT to BLK from Harness Both Sides BLK to BLU WHT from Harness Both Side...

Page 108: ...Page J 8 Repair and Service Manual Notes ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 109: ...e Entire Wheel Brake Assembly Removal and Installation K 17 Brake Shoe and Adjuster Replacement K 17 Brake Cable and Equalizer Assembly Removal and Installation K 18 Compensator Assembly Removal and I...

Page 110: ...ng Brake Latching Pressure K 15 Fig 20 Brake Assembly K 16 Fig 21 Wheel Brake Lubrication Points K 17 Fig 22 Backing Plate Removal and Installation K 17 Fig 23 Brake Shoes and Springs K 18 Fig 24 Sett...

Page 111: ...the system and still apply the shoes to the drums the braking effort at the wheel brake will not be adequate The self adjusting mechanism in the wheel brakes requires enough cable travel at the wheel...

Page 112: ...to adjuster will result Adjustment takes place only when the brake is fully applied and released while the vehicle is moving Ref Fig 2 It is very important that the brake cables permit the brake lever...

Page 113: ...rom the catch bracket This is the preferred method which minimizes wear on components 2 Pressing the accelerator pedal rotates the kick off cam which forces the pedal latch arm to move away from the c...

Page 114: ...is 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 Sea...

Page 115: ...ng 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 br...

Page 116: ...eck 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 In Excess of 2 1 4 5 4 cm fre...

Page 117: ...uires complete adjustment Adjust entire system Brake pedal not returning Check for binding of brake pedal Check brake pedal free travel Grabbing brakes oversensitive Moisture has caused surface rust o...

Page 118: ...need for routine brake testing and inspection as shown on the Periodic Service Schedule in Section A Contin ued proper brake operation depends on periodic main tenance Brake Pedal and Linkage Inspecti...

Page 119: ...e conditions are found replace both cables and equalizer as a set 5 Check the clevis pins Check clevis pin attaching the brake cables to the brake levers They must be loose when the brake pedal has be...

Page 120: ...esulting 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 saf...

Page 121: ...he Periodic Brake Performance Test three more times second set of three If the vehicle passes two of three Periodic Brake Perfor mance Tests check that the clevis pins at the brake levers are loose If...

Page 122: ...ms Remove excess dust and dirt from the drum with a brush The drum must not be turned to true a worn friction surface Turning will make the drum too thin causing drum failure and a loss of brakes whic...

Page 123: ...shoes and by the moving anchor assembly Replace both backing plates if any gouges or galling is found 9 Measure the brake shoe thickness Measure at the most worn area Brake shoe thickness must never b...

Page 124: ...e condition of worn components is critical to the operation of the brake system In some cases component replacement may be more cost effective than the removal cleaning inspec tion and reassembly of t...

Page 125: ...The parking brake latching force can be checked as verifi cation after setting brake pedal free travel To check park ing brake latching force place a bathroom scale on the service and parking brake p...

Page 126: ...l cotter pin Install the remaining hardware 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...

Page 127: ...be Ref Fig 22 Fig 22 Backing Plate Removal and Installation Remove the clevis pin securing the brake cable to the brake lever Installation is the reverse of removal Connect the brake cable to the whee...

Page 128: ...hown Ref Fig 23 The opposite end of the adjuster spring is hooked to the adjuster with the hook end facing out The brake shoe springs must be installed with the light spring closest to the adjuster me...

Page 129: ...ke pedal free travel Adjusting Brake Pedal Free Travel on Page M 14 Brake Pedal Removal and Installation Disconnect the compensator assembly 1 from the brake pedal by removing the cotter pin 2 and the...

Page 130: ...ing brake arm latch is a hardened part Do not grind or file it as doing so will cause the part to lose its hardness char acteristics A new part must be used Installation is in the reverse order of dis...

Page 131: ...and Kick Off Cam Removal and Installation Installation is in the reverse order of disassembly With the parking brake engaged and fully latched there mus be no gap between the top of the cam and the la...

Page 132: ...Page K 22 Repair and Service Manual B MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 133: ...Service Manual BATTERY CHARGER CHARGER DESCRIPTION L 1 PORTABLE CHARGER INSTALLATION L 1 UNDERSTANDING THE CHARGER L 2 LED DISPLAY INFORMATION L 2 LED Operation Codes L 2 LED Fault Codes L 2 MAINTENA...

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

Page 135: ...any way refer all repair work to qualified personnel Not for use by children Portable chargers are shipped with the vehicle Prior to vehicle or charger operation chargers must be removed and mounted...

Page 136: ...harged RED FLASH fault code LED Fault Code RED FLASH Light turns on briefly but does not flash after that check for valid AC voltage ONE RED FLASH One flash a pause and then again one flash and a paus...

Page 137: ...Page L 3 Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BATTERY CHARGER...

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

Page 139: ...ENTS FOR SECTION M SECTION TITLE PAGE NO REAR SUSPENSION REAR SUSPENSION M 1 GENERAL M 1 Shock Absorber Removal M 1 Shock Absorber Installation M 1 Rear Spring Removal M 1 Rear Spring Installation M 1...

Page 140: ...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 Notices Cautions Warnings and Dangers...

Page 141: ...SAFETY of this manual and support the rear of the vehicle on the outer ends of the rear bumper Remove the bottom shock absorber vinyl cap 1 nut 2 Ref Fig 1 on Page M 2 Compress the shock absorber 3 a...

Page 142: ...REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Rear Suspension 8 7 11 3 6 9 10 13 5 4 7...

Page 143: ...Page M 3 Repair and Service Manual Notes REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 144: ...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 Notices Cautions Warnings and Dangers...

Page 145: ...1 Axle Shaft Seal Removal and Replacement N 2 Axle Shaft Replacement N 3 LIST OF ILLUSTRATIONS Fig 1 Add Check and Drain Rear Axle Lubricant N 1 Fig 2 Removing Installing Outer Snap Ring N 1 Fig 3 Rem...

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

Page 147: ...le is a precision assembly and therefore any repair or replacement of parts must be done with extreme care in a clean environment Before attempting to perform any service on the axle read and understa...

Page 148: ...ment Tools List Qty Internal snap ring pliers 1 Seal puller 1 Seal installer P N 18739 G1 1 Ball peen hammer 1 Use care to prevent damage to the inner surface of the axle tube at the sealing area Remo...

Page 149: ...ter snap ring Coat the outboard spline of the axle with a commercially available anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 8 on Page N 3 Fig 7 Ins...

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

Page 151: ...ervice Manual WEATHER PROTECTION TOP AND WINDSHIELD P 1 Trailering P 1 SUN TOP P 1 Rear Support Installation P 1 Front Strut P 1 Sun Top P 1 SPLIT WINDSHIELD P 3 FULL WINDSHIELD P 4 LIST OF ILLUSTRATI...

Page 152: ...Page P ii Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 153: ...adequately secured before traile ring the vehicle SUN TOP Rear Support Installation 1 Place washer 3 onto bolt 4 and insert bolt just through the top hole in the seat back support 3 4 threads 2 Insert...

Page 154: ...ON Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Sun Top Front of Vehicle 12 10 9 7 9 9 8 8 4 5 7 2 6 3...

Page 155: ...s and press the sash starting at the bottom onto the front strut so that it snaps into place Details B and C Repeat for opposite side of windshield Position top grips 8 as shown See Detail D at top ho...

Page 156: ...3 on each side of the windshield Using a rubber mallet gently tap sash to ensure windshield seats properly Insert screw 4 through washer 5 rubber grommet 6 and existing hole in front strut Secure wit...

Page 157: ...Page P 5 Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 158: ...Page P 6 Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 159: ...TION Q SECTION TITLE PAGE NO Page Q i Repair and Service Manual HANDHELD DIAGNOSTICS HOW TO USE THE HANDHELD PROGRAMMER Q 1 Primary Connection Q 1 Alternate Connection Q 1 Navigation Q 1 Changing Data...

Page 160: ...age Q ii Repair and Service Manual B HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 161: ...ow position and also when the battery charger is con nected to the vehicle The main menu appears after the data is uploaded from the unit controller charger etc the main menu will not be displayed if...

Page 162: ...the value of the parame ter BOOKMARK To set a position in the Menu hold a Book mark Key down for four seconds until the Bookmark set screen is displayed To jump to a selected Bookmark position press...

Page 163: ...mph Accel Selection 1 3 2 Braking Selection 1 3 3 5 Freedom Speed 14 5 19 5 18 5 mph Accel Selection 1 2 1 Braking Selection 1 2 1 Monitor Battery Amp Hours 0 100000 AmpHr Battery Voltage 0 100 V Elas...

Page 164: ...Speed Sensor Fault 0 100000 Hrs Main Driver On 0 100000 Hrs Main Coil Open 0 100000 Hrs Main Dropout 1 0 100000 Hrs Motor Stall 0 100000 Hrs Main Driver Off 0 100000 Hrs Main Dropout 2 0 100000 Hrs C...

Page 165: ...r Fault History YES NO Information OEM Info Display OEM information Reconfigured Display reconfigure status Model Number Display handheld model number Serial Number Display handheld serial number Manu...

Page 166: ...Page Q 6 Repair and Service Manual Notes HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 167: ...Page R i Repair and Service Manual TABLE OF CONTENTS FOR SECTION R SECTION TITLE PAGE NO TROUBLESHOOTING 1206HB 5201 Controller Faults and Troubleshooting R 1...

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

Page 169: ...to cause Contactor to close 3 8 Condition clears 1 Controller defective MOTOR STALL High Armature Current when no Speed Pulses detected Contactor closed 6 Speed Pulses appear 1 Motor is stalled 2 Defe...

Page 170: ...d Throttle applied OR Throttle applied before Key and Direction switch applied KSI ON Forward or Reverse ON 8 Throttle 25 1 Incorrect sequence of Vehicle input controls 2 Defective Throttle device THE...

Page 171: ...Page R 3 Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 172: ...Page R 4 Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 173: ...NG GROUNDING REQUIREMENTS S 1 GROUND SYSTEMS S 1 LIGHTINIG PROTECTION REQUIREMENTS S 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM S 1 GROUND NETWORK REQUIREMENTS S 1 EXTERNAL GROUNDING REQUIREMENTS S...

Page 174: ...ii Repair and Service Manual Notes LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and D...

Page 175: ...ohms cannot be obtained due to high soil resistivity rock formations or other abnormal conditions alternate methods for reducing the resistance to earth must be considered Chemical Treatments No salt...

Page 176: ...below grade and be at least 24 away from the struc ture All bends in the conductor shall have a minimum radius of 8 and be no less than 90 degrees Ground Mats In areas where electrodes cannot be driv...

Page 177: ...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 178: ...4 Repair and Service Manual Notes LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and D...

Page 179: ...NTS FOR SECTION T SECTION TITLE PAGE NO GENERAL SPECIFICATIONS SHUTTLE 4X T 1 LIST OF ILLUSTRATIONS Fig 1 Vehicle Dimensions T 2 Fig 2 Vehicle Dimensions Incline Specifications and Turning Clearance D...

Page 180: ...age T ii Repair and Service Manual Notes GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 181: ...Seating Capacity 4 Person Overall Width 48 5 in 123 cm Dry Weight 685 lb 311kg Without Batteries Overall Height No Canopy 52 5 in 133 cm Top of steering wheel Curb Weight 1050 lb 477kg Trojan T 875 Ov...

Page 182: ...d this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Vehicle Dimensions Rear 38 0 in 97 0 cm Front 38 5 in 98 0 cm 74 5 in 189 0 cm 52...

Page 183: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 2 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter RECOMMENDED MAX SIDE TILT 25...

Page 184: ...ction B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 Battery Charger Dimensions 6 3 16 cm 1 8 4 5 cm 1 4 3 5cm 7 8 19 8 cm 1...

Page 185: ...Page T 5 Repair and Service Manual Notes GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 186: ...Page T 6 Repair and Service Manual Notes GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 187: ...properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle...

Page 188: ...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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