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Page T-1

Repair and Service Manual

GENERAL SPECIFICATIONS

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

MODEL: SHUTTLE 4X

TYPE: ELECTRIC POWERED PERSONNEL CARRIER

MODEL YEAR: 2012

Part No:. 619212

TruCourse Technology:

Programmable to multiple vehcle terrains, with expanded regenerative braking function, and vehicle charger lockout

Solid State continuously variable seperately excited speed controller

Six, 8 Volt Deep Cycle Batteries

Dash mounted direction selector switch (Forward-Neutral-Reverse)

Full torque, reduced speed reverse

Anti-roll back, walkaway braking and alarm

Inductive throttle sensor

Programmable regenerative braking, acceleration and speed

Handheld vehicle diagnostics and rounds tracking

Battery Charger:

PowerWise 48QE high frequency, fully line compensating. 10ft (3m) DC Cord. Underwriters Lab. (U.L.) Listed, (C.S.A. Certified)

Input: 120 Volts AC, 50/60Hz, 8 amps

Output: 48 Volts DC at 13 amps

Motor:

48 Volt DC shunt wound, brazed armature, solid copper windings

Drive Train:

Direct motor shaft connected to transaxle pinion shaft

Electrical System:

48 Volt DC, six, 8 volt deep cycle batteries (117 minute minimum, 170 amp-hour @ 20 hr. discharge rate)

Transaxle:

Differential with helical gears

Brakes:

Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with self-compensating system

Capacity:

Seating for 4 persons. Rear Seat converts to Cargo Bed

Dimensions

Performance

Overall Length

108.5 in (276 cm)

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

Overall Height (With Canopy) 82.0 in (208 cm) (Top of Sun Canopy)

Vehicle load capacity

800 lb (363 kg)

Wheel Base

65.5 in (166 cm)

Outside Clearance Circle

19 ft (5.8 m)

Front Wheel Track

38.0 in (97 cm)

Intersecting Aisle Clearance

N/A

Rear Wheel Track

38.5 in (98 cm)

Speed (Level Ground)

17.5 mph ± 0.5 mph (28.2 kph ± 0.8 kph)

Gnd Clearance @ Differential 5.5 in (14 cm)

Towing Capacity

N/A

Load Bed Width

40.0 in (102 cm)

Steering & Suspension

Load Bed Length

32.0 in (81 cm)

Steering

Self-compensating rack and pinion

Vehicle Power

Front Suspension

Leaf springs with hydraulic shock absorbers

Power Source

48 Volts DC

Rear Suspension

Leaf springs with hydraulic shock absorbers

Motor Type

Shunt Wound

Service Brake

Rear wheel mechanical self-adjusting drum

Horsepower (kW)

3.0 HP (2.2kW) Continuous

Parking Brake

Self-compensating, single point engagement

Electrical System

48 Volt

Front Tires

Trail Wolf 20 x 11 - 10 Uni-directional

Batteries (Qty, Type)

Six, 8 Volt Deep Cycle

Rear Tires

Trail Wolf 20 x 11 - 10 Uni-directional

Key or Pedal Start

Pedal Start

Body & Chassis

Battery Charger

48 VDC PowerWise™ QE, 120 VAC, UL/CSA Frame

Welded steel with DuraShield™ powder coat

Speed Controller

250 Amp Solid State Controller

Front Body & Finish

Injection Molded TPO

Drive Train

Motor Shaft Direct Drive

Rear Body & Finish

Injection molded TPO

Transaxle

Differential with helical gears

Standard Color

Patriot Blue

Gear Selection

Dash Mounted Forward-Neutral-Reverse

Rear Axle Ratio

14.76:1

Some items shown may be optional equipment

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

PRODUCT OVERVIEW

Содержание 625615

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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