875 Titan Service Manual
875 Titan Service Manual
875 Titan Service Manual
A Textron Company
Be sure that this manual remains as part of the permanent service record should the vehicle be resold.
E-Z-GO Division of Textron, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the informa-
tion contained in this manual is subject to change without notice.
E-Z-GO Division of Textron, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this
manual.
CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124
OUTSIDE USA PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local
Distributor, authorized Branch or the Warranty Department with vehicle serial number and
manufacturer code.
The use of non Original Equipment Manufacturer (OEM) parts may void the warranty.
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75° F (-60° C).
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
TITLE PAGE
Safety ........................................................................................................................... Inside Covers
Notes .................................................................................................................................................ii
Safety Information ............................................................................................................................ v
TITLE SECTION
General Information & Routine Maintenance ...................................................................................A
Safety ...............................................................................................................................................B
Body .................................................................................................................................................C
Wheels and Tires .............................................................................................................................D
Electronic Speed Control 36V ..........................................................................................................E
Electronic Speed Control 48V .......................................................................................................... F
Motor ............................................................................................................................................... G
Batteries and Charging.....................................................................................................................H
Electrical System.............................................................................................................................. J
Brakes ..............................................................................................................................................K
Rear Suspension.............................................................................................................................. L
Rear Axle......................................................................................................................................... M
Paint .................................................................................................................................................N
Steering & Front Suspension ...........................................................................................................P
Lightning Protection & Grounding ................................................................................................... Q
Troubleshooting................................................................................................................................R
General Specifications .....................................................................................................................S
Notes:
This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures
developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible
service from the product. To reduce the chance of personal injury and/or property damage, the following instructions
must be carefully observed:
GENERAL
Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. The manufacturer strongly suggests that the owner-operator read this entire manual paying
particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees
and other operators be encouraged to do the same.
If you have any questions, contact your closest representative or write to the address on the back cover of this publica-
tion, Attention: Product Service Department.
The manufacturer reserves the right to make design changes without obligation to make these changes on units previ-
ously sold and the information contained in this manual is subject to change without notice.
The manufacturer 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.
This vehicle conforms to the current applicable standard for safety and performance requirements.
These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety
Standards and are not equipped for operation on public streets. Some communities may permit these vehicles to be
operated on their streets on a limited basis and in accordance with local ordinances.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
Never use the chassis or body as a ground connection.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and
disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the
vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when
used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,
terrain and common sense.
GENERAL OPERATION
Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
Always read and observe all warnings and operation instruction labels affixed to the vehicle.
Always follow all safety rules established in the area where the vehicle is being operated.
MAINTENANCE
Always maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
Always ensure that mechanics performing repairs are trained and qualified to do so.
Always follow the manufacturer’s directions if you do any maintenance on your vehicle. Be sure to disable the vehicle
before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery
wire.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by short-
ing the battery terminals or associated wiring. Remove the batteries or cover exposed terminals with an insulating
material.
Always check the polarity of each battery terminal and be sure to rewire the batteries correctly.
Always use specified replacement parts. Never use replacement parts of lesser quality.
Always use recommended tools.
Always determine that tools and procedures not specifically recommended by the manufacturer will not compromise
the safety of personnel nor jeopardize the safe operation of the vehicle.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a
jack. Lift the vehicle in accordance with the manufacturer’s instructions.
Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that could result in severe
personal injury or death and damage to the vehicle. Use extreme caution and, if unsure 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 that is free of
both vehicular and pedestrian traffic.
VENTILATION
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 ceiling of buildings necessitating proper ventilation. Five air
exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the recepta-
cle when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable
electrical code (whichever is higher).
Notes:
TIRES...............................................................................................................................................A - 3
TRAILERING....................................................................................................................................A - 4
HARDWARE ....................................................................................................................................A - 4
LIST OF ILLUSTRATIONS
Fig. 1 Initial Service Chart ...............................................................................................................A - 1
Fig. 2 Lubrication Points..................................................................................................................A - 2
Fig. 3 Add, Check and Drain Rear Axle Lubricant...........................................................................A - 2
Fig. 4 Torque Specifications............................................................................................................A - 4
Fig. 5 Periodic Service Schedule ....................................................................................................A - 5
Notes:
SERIAL AND MANUFACTURING NUMBER stand all Notes, Cautions and Warnings in this
A
LABEL LOCATIONS manual.
Supplemental Information Label Location It is in the best interest of both vehicle owner and servic-
ing dealer to carefully follow the procedures recom-
The supplemental Information label is located on the mended in this manual. Adequate preventative
inside of the cowl (driver side). maintenance, applied at regular intervals, is the best
Serial and Manufacturing No. Label Location guarantee for keeping the vehicle both dependable and
The serial and manufacturing number label is located on economical
the inside of the cowl (driver side). To reduce the possibility
Serial and Manufacturing No. (Stamped) ! !
of causing an electrical
The serial number and manufacturing number are
arc, which could result in
stamped on the frame below the load bed.
a battery explosion, turn off all electrical loads from
the batteries before removing any heavy gauge bat-
Serial No. Sticker Location tery wires.
The serial number is located under the seat on the frame. Wear eye protection when working on or
Design changes take place on an ongoing basis. In order around vehicle. In particular, use care when
to obtain correct components for the vehicle, the manu- working around the batteries, or when
facture date code, serial number and vehicle model must using solvents or compressed air.
be provided when ordering service parts. Servicing requiring adjustments to be made to the
powertrain while the motor is running, must be made
SERVICING THE ELECTRIC VEHICLE with both drive wheels raised.
Read and understand the following text and Never operate vehicle at full throttle for more than 4-5
warnings before attempting to service vehicle. seconds while vehicle is in a “no load” condition.
In any product, components will eventually fail to perform Before a new vehicle is put into operation, it is recom-
properly as the result of normal use, age, wear or abuse. mended that the items shown in the INITIAL SERVICE
It is virtually impossible to anticipate all possible compo- CHART be performed (Ref Fig. 1 on page A-1).
nent failures or the manner in which each component
may fail.
A vehicle requiring repair indicates that the vehicle is no ITEM SERVICE OPERATION
longer functioning as designed and should be considered
potentially hazardous. Use extreme care when working Batteries Charge batteries
on any vehicle. When diagnosing, removing or replacing
Seats Remove protective plastic covering
any components that are not operating correctly, take the
time to consider the safety of yourself and others around Brakes Check operation and adjust if necessary
you if the component should move unexpectedly. Check hydraulic brake fluid level
Some components are heavy, spring loaded, highly cor- Tires Check pressure
rosive, explosive, may produce amperage or reach high
temperatures. Battery acid and hydrogen gas could
result in serious bodily injury to the technician/mechanic Fig. 1 Initial Service Chart
and bystanders, if not treated with the utmost caution. Be Vehicle batteries must be fully charged before initial use.
careful not to place hands, face, feet or body in a location
that could expose them to injury should an unforeseen
dangerous situation occur. ROUTINE MAINTENANCE
This vehicle will give years of satisfactory service provid-
Before attempting any
ing it receives regular maintenance. Refer to the Periodic
! ! type of servicing opera-
Service Schedule (Ref Fig. 5 on page A-5) for appropri-
tions, read and under-
ate service intervals. Refer to Lubrication Points (Ref Fig. REAR AXLE
2 on page A-2) for appropriate lubrication locations.
The only maintenance required for the first five years is
Do not use more than three (3) pumps the periodic inspection of the lubricant level. The rear
of grease in each grease fitting at any axle is provided with a lubricant level check/fill plug
one time. Excess grease may cause grease seals to fail or located on the bottom of the differential. Unless leakage
grease migration into areas that could damage components. is evident, the lubricant need only be replaced after five
Some maintenance items must be serviced years.
more frequently on vehicles used under severe
Checking the Lubricant Level
driving conditions.
Clean the area around the check/fill plug and remove
plug. The correct lubricant level is just below the bottom
of the threaded hole. If lubricant is low, add as required.
Brake Pedal Add lubricant slowly until lubricant starts to seep from the
hole. Install the check/fill plug. In the event that the lubri-
cant is to be replaced, the vehicle must be elevated and
the oil pan removed or the oil siphoned out through the
2 Lower check/fill hole (Ref Fig. 3 on page A-2).
Control Arms
2 King Pins
4 Wheel Bearing
"PACK"
4 Ball Joints
Check/Fill Plug
Depress the brake pedal. The pedal should have some VEHICLE CARE PRODUCTS
free travel and then become hard. A brake pedal that has
no free travel, excessive free travel or a spongy feel is To help maintain the vehicle, the manufacturer has sev-
indicating that a brake inspection is required. A brake eral products, available through a local Distributor, a
pedal that falls after it is applied indicates a leak in the Branch, or the Service Parts Department.
master or wheel cylinders. Check for adequate brake
fluid level. Adjust brakes if required and inspect system
• Touch-up paint specially formulated to match vehi-
cle colors for use on both metal and TPO (plastic)
for fluid leaks.
bodies. (P/N28140-G** and 28432-G**)
• Multi-purpose Battery Protectant formulated to
TIRES form a long-term, flexible, non-tacky, dry coating
Tire condition should be inspected on a daily basis. Infla- that will not crack, peel or flake over a wide tem-
tion pressures should be checked when the tires are perature range. (P/N 75500-G01)
cool. For additional information, refer to WHEELS AND • White Lithium Grease designed to provide lubrica-
TIRES section. tion protection in areas where staining or discolor-
ing is a problem, or in areas of extreme
CARE AND CLEANING OF THE VEHICLE temperature ranges. (P/N 75502-G01)
BOLT SIZE 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"
4 8 15 24 35 55 75 130 125 190
Grade 2
(5) (11) (20) (33) (47) (75) (102) (176) (169) (258)
Class 8.8 2 4 7 18 35 61 97
(Grade 5) 8.8 (3) (6) (10) (24) (47) (83) (131)
DAILY
BEFORE USE:
✓ Check service brake general operation
✓ Check park brake function
✓ Check warning device function in reverse
✓ Check tire condition
✓ Check overall vehicle condition
♦ Recharge batteries to full state of charge after each day’s use
✓ Inspect charger AC plug and cord for damage. Be sure ground pin is in place
WEEKLY
TIRES ✓ Examine for cuts, excessive wear and pressure
(See GENERAL SPECIFICATIONS)
WHEELS ✓ Check for bent rims, missing or loose lug nuts
MONTHLY - 20 HOURS (includes items listed in previous table & the following)
♦ Clean batteries & terminals. See BATTERY CLEANING.
BATTERIES
✓ Check charge condition and all connections
WIRING ✓ Check all wiring for loose connections and broken/missing insulation
ACCELERATOR ✓ Check for smooth movement
SERVICE BRAKE
✓ Conduct brake performance test
(HYDRAULIC BRAKES)
PARK BRAKE ✓ Check brake performance and adjust if required
DIRECTION SELECTOR (36V models) ✓ Check attachment, tighten if required
STEERING ASSEMBLY ✓ Check for abnormal play, tightness of all hardware
TIE ROD/LINKAGES ✓ Check for excessive play, bent components or loose connections
✓ Check for Controller braking force (see 48V MODEL VEHICLES in text)
48V SYSTEM
proper operation of system
REAR AXLE ✓ Check for leakage, add SAE 30 oil as required
QUARTERLY - 50 HOURS (includes items listed in previous tables & the following)
FRONT AXLE ✓ Check for damage to axle and loose or missing hardware
FRONT SHOCK ABSORBERS ✓ Check for oil leakage and loose fasteners
Fig. 5 Periodic Service Schedule
SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)
DIRECTION SELECTOR ✓ Check for wear and smooth movement (lubricate shaft with light oil if required)
KING PINS ✓ Check for excessive play and tightness of retaining nuts
STEERING ASSEMBLY ✓ Check bellows and pinion seal for damage or grease leakage
GREASE FITTINGS ♦ Lubricate, use wheel bearing grease
REAR AXLE ✓ Check for unusual noise and loose or missing mounting hardware
ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)
FRONT WHEEL BEARINGS ✓ Check and adjust as required, see Technician’s Repair and Service Manual
REAR AXLE ✓ Check lubricant, add lubricant (SAE 30 oil) as required
♦ Clean and adjust, see Technician’s Repair and Service Manual
SERVICE BRAKES ✓ Check brake shoe linings, see Technician’s Repair and Service Manual
✓ Check brake fluid
LIST OF ILLUSTRATIONS
Fig. 1 Battery Connections ..............................................................................................................B - 7
Fig. 2 Lifting the Vehicle ..................................................................................................................B - 8
Notes:
GENERAL
B
manual without the manufacturer’s prior written authori-
zation. Where authorized modifications have been made,
The following text is provided as recommended by part II the user shall ensure that capacity, operation, warning,
of ASME/ANSI B56.8-1988. The manufacturer strongly and maintenance instruction plates, tags, or decals are
endorses the contents of this specification. changed accordingly.
4.3.3 As required under paras. 4.3.1 or 4.3.2, the
PART II manufacturer shall be contacted to secure new name-
FOR THE USER plates, warnings, or instructions which shall then be
affixed in their proper place on the carrier.
4.8 Control of Noxious Gases and Fumes (a) instructional material provided by the manufac-
turer;
4.8.1 When equipment powered by internal com-
bustion engines is used in enclosed areas, the atmo- (b) emphasis on safety of passengers, material loads,
sphere shall be maintained within limits specified in the carrier operator, and other employees;
American Conference of Governmental Industrial
(c) general safety rules contained within this Standard
Hygienists publication, “Threshold Limit Values for
and the additional specific rules determined by the user
Chemical Substances and Physical Agents in the Work-
in accordance with this Standard, and why they were for-
room Environment”. This shall be accomplished by venti-
mulated;
lation provided by the user, and/or the installation, use,
and proper maintenance of emission control equipment (d) introduction of equipment, control locations and
recommended or provided by the manufacturer of the functions, and explanation of how they work when used
equipment. properly and when used improperly, and surface condi-
tions, grade, and other conditions of the environment in
4.9 Warning Device(s) which the carrier is to be operated;
4.9.1 The user shall make periodic inspections of (e) operational performance tests and evaluations dur-
the carrier to be certain that the sound-producing and/or ing, and at completion of, the program.
visual device(s) are maintained in good operating condi-
tion. 5.3 Personnel and Burden Carrier Operator
Responsibility
4.9.2 The user shall determine if operating condi-
tions require the carrier to be equipped with additional 5.3.1 Operators shall abide by the following safety
sound-producing and/or visual devices and be responsi- rules and practices in paras. 5.4, 5.5, 5.6, and 5.7.
ble for providing and maintaining such devices, in accor-
dance with the manufacturer’s recommendations. 5.4 General
5.4.1 Safeguard the pedestrians at all times. Do not
drive carrier in a manner that would endanger anyone.
5 OPERATING SAFETY RULES AND
PRACTICES 5.4.2 Riding on the carrier by persons other than the
operator is authorized only on personnel seat(s) provided
5.1 Personnel and Burden Carrier Operator by the manufacturer. All parts of the body shall remain
Qualifications within the plan view outline of the carrier.
5.1.1 Only persons who are trained in the proper 5.4.3 When a carrier is to be left unattended, stop
operation of the carrier shall be authorized to operate the carrier, apply the parking brake, stop the engine or turn
carrier. Operators shall be qualified as to visual, auditory, off power, turn off the control or ignition circuit, and
physical, and mental ability to safely operate the equip- remove the key if provided. Block the wheels if machine
ment according to Section 5 and all other applicable is on an incline.
parts of this Standard. 5.4.4 A carrier is considered unattended when the
operator is 25 ft. (7.6 m) or more from the carrier which
5.2 Personnel and Burden Carrier Operators’ remains in his view, or whenever the operator leaves the
Training carrier and it is not within his view. When the operator is
dismounted and within 25 ft. (7.6 m) of the carrier still in
5.2.1 The user shall conduct an operators’ training
his view, he still must have controls neutralized, and the
program.
parking brake(s) set to prevent movement.
5.2.2 Successful completion of the operators’ train-
5.4.5 Maintain a safe distance from the edge of
ing program shall be required by the user before opera-
ramps and platforms.
tion of the carrier. The program shall be presented in its
entirety to all new operators and not condensed for those 5.4.6 Use only approved carriers in hazardous loca-
claiming previous experience. tions, as defined in the appropriate safety standards.
5.2.3 The user should include in the operators’ train- 5.4.7 Report all accidents involving personnel,
ing program the following: building structures, and equipment.
5.4.8 Operators shall not add to, or modify, the car- 5.5.14 To negotiate turns, reduce speed to improve
rier. stability, then turn hand steering wheel or tiller in a
5.4.9 Carriers shall not be parked or left unattended smooth, sweeping motion.
such that they block or obstruct fire aisles, access to
5.6 Loading
stairways, or fire equipment.
5.6.1 Handle only stable and safely arranged loads.
5.5 Traveling When handling off-center loads which cannot be cen-
5.5.1 Observe all traffic regulations, including autho- tered, operate with extra caution.
rized speed limits. Under normal traffic conditions keep 5.6.2 Handle only loads within the capacity of the
to the right. Maintain a safe distance, based on speed of carrier as specified on the nameplate.
travel, from a carrier or vehicle ahead; and keep the car-
5.6.3 Handle loads exceeding the dimensions used
rier under control at all times.
to establish carrier capacity with extra caution. Stability
5.5.2 Yield the right of way to pedestrians, ambu- and maneuverability may be adversely affected.
lances, fire trucks, or other carriers or vehicles in emer-
gency situations. 5.7 Operator Care of Personnel and Burden
5.5.3 Do not pass another carrier or vehicle travel- Carriers
ing in the same direction at intersections, blind spots, or 5.7.1 At the beginning of each shift during which the
at other dangerous locations. carrier will be used, the operator shall check the carrier
5.5.4 Keep a clear view of the path of travel, condition and inspect the tires, warning devices, lights,
observe other traffic and personnel, and maintain a safe battery(s), speed and directional controllers, brakes, and
clearance. steering mechanism. If the carrier is found to be in need
of repair, or in any way unsafe, the matter shall be
5.5.5 Slow down or stop, as conditions dictate, and reported immediately to the designated authority and the
activate the sound-producing warning device at cross carrier shall not be operated until it has been restored to
aisles and when visibility is obstructed at other locations. safe operating condition.
5.5.6 Ascend or descend grades slowly. 5.7.2 If during operation the carrier becomes unsafe
5.5.7 Avoid turning, if possible, and use extreme in any way, the matter shall be reported immediately to
caution on grades, ramps, or inclines; normally travel the designated authority, and the carrier shall not be
straight up and down. operated until it has been restored to safe operating con-
5.5.8 Under all travel conditions the carrier shall be dition.
operated at a speed that will permit it to be brought to a 5.7.3 Do not make repairs or adjustments unless
stop in a safe manner. specifically authorized to do so.
5.5.9 Make starts, stops, turns, or direction rever- 5.7.4 The engine shall be stopped and the operator
sals in a smooth manner so as not to shift the load, shall leave the carrier while refueling.
endanger passengers, or overturn the carrier.
5.7.5 Spillage of oil or fuel shall be carefully and
5.5.10 Do not indulge in dangerous activities, such as completely absorbed or evaporated and fuel tank cap
stunt driving or horseplay. replaced before starting engine.
5.5.11 Slow down when approaching, or on, wet or 5.7.6 Do not operate a carrier with a leak in the fuel
slippery surfaces. system or battery(s).
5.5.12 Do not drive carrier onto any elevator unless 5.7.7 Do not use open flames for checking electro-
specifically authorized to do so. Approach elevators lyte level in storage battery(s) or liquid level in fuel tanks.
slowly, and then enter squarely after the elevator car is
properly leveled. Once on the elevator, neutralize the
controls, shut off power, and set parking brakes. It is 6 MAINTENANCE PRACTICES
advisable that all other personnel leave the elevator
before a carrier is allowed to enter or exit. 6.1 Introduction
5.5.13 Avoid running over loose objects, potholes, 6.1.1 Carriers may become hazardous if mainte-
and bumps. nance is neglected. Therefore, maintenance facilities,
trained personnel, and procedures shall be provided. (n) Fuel systems shall be checked for leaks and condi-
Such facilities may be on or off the premises. tion of parts. If a leak is found, action shall be taken to
prevent the use of the carrier until the leak has been
6.2 Maintenance Procedures eliminated.
6.2.1 Maintenance and inspection of all carriers (o) The carrier manufacturer’s capacity, operation, and
shall be performed in conformance with the manufac- maintenance instruction plates, tags, or decals shall be
turer’s recommendations and the following practices. maintained in legible condition.
(a) A scheduled preventive maintenance, lubrication, (p) Batteries, motors, speed and directional control-
and inspection system shall be followed. lers, limit switches, protective devices, electrical conduc-
(b) Only qualified and authorized personnel shall be tors, and connections shall be inspected and maintained
permitted to maintain, repair, adjust, and inspect carriers. in conformance with manufacturers recommended pro-
cedures.
(c) Before undertaking maintenance or repair, follow
the manufacturer’s recommendations for immobilizing (q) Carriers shall be kept in a clean condition to mini-
the carrier. mize fire hazards and facilitate detection of loose or
defective parts.
(d) Block chassis before working underneath it.
(r) Modifications and additions which affect capacity
(e) Before disconnecting any part of the engine fuel
and safe machine operation shall not be performed by
system of a gasoline or diesel powered carrier with grav-
the customer or user without manufacturer’s prior written
ity feed fuel systems, be sure shutoff valve is closed, and
authorization; where authorized modifications have been
run engine until fuel system is depleted and engine stops
made, the user shall ensure that capacity, operation,
running.
warning, and maintenance instruction plates, tags, or
(f) Before disconnecting any part of the engine fuel decals are changed accordingly.
system of LP gas powered carriers, close the LP gas cyl-
(s) Care shall be taken to ensure that all replacement
inder valve and run the engine until fuel in the system is
parts are interchangeable with the original parts and of a
depleted and the engine stops running.
quality at least equal to that provided in the original
(g) Operation to check performance of the carrier shall equipment.
be conducted in an authorized area where safe clear-
ance exists.
(h) Before commencing operation of the carrier, follow
the manufacturer’s instructions and recommended pro-
cedures. End of ASME/ANSI B56.8-1988, Part II
(i) Avoid fire hazards and have fire protection equip-
ment present in the work area. Do not use an open flame
to check level or leakage of fuel, battery electrolyte, or
coolant. Do not use open pans of fuel or flammable
cleaning fluids for cleaning parts.
(j) Properly ventilate the work area.
(k) Handle LP gas cylinders with care. Physical dam-
age, such as dents, scrapes, or gouges, may danger-
ously weaken the tank and make it unsafe for use.
(l) Brakes, steering mechanisms, speed and direc-
tional control mechanisms, warning devices, lights, gov-
ernors, guards, and safety devices shall be inspected
regularly and maintained in a safe operating condition.
(m) Special carriers or devices designed and
approved for hazardous area operation shall be
inspected to ensure that maintenance preserves the orig-
inal approved safe operating features.
LIST OF ILLUSTRATIONS
Fig. 1 Cowl Attachment .................................................................................................................. C - 1
Fig. 2 Swing Out Battery Rack ....................................................................................................... C - 1
Fig. 3 Fixed Battery Racks ............................................................................................................. C - 2
Fig. 4 Body Components................................................................................................................ C - 3
Fig. 5 Body Components (Seating) ................................................................................................ C - 4
Fig. 6 Battery Charger Support ...................................................................................................... C - 5
Fig. 7 Bumper and Hitches............................................................................................................. C - 6
Fig. 8 Cargo Decks......................................................................................................................... C - 7
Notes:
BODY
C
In the following text, there are references to SWING OUT BATTERY RACK
removing/installing bolts etc. Additional hard- 5
ware (nuts, washers etc.) that are removed must always be 4
installed in their original positions unless otherwise specified.
Non-specified torques are as shown in the table in Section A.
Front of Vehicle
General
Part of Body
To prevent possible seri-
! ! ous injury or death
resulting from a battery
explosion. Batteries 1
should always be removed before any servicing that
could generate sparks, or repairs that require welding
or cutting.
The body is a welded frame and body unit. Both the 48V
and 36V two passenger models use a common frame
and body. The 48V unit has two swing out battery racks
that pivot out from both sides of the vehicle and are held 2
in place with positive latches. The 36V two passenger
unit is not equipped with swing out battery racks but is fit- 3
ted with two battery racks with blank panels that are
mounted in the battery rack cavities. The four passenger Part of Frame
model uses a separate frame and body assembly. The
cowl which incorporates the dash panel, bolts to the front
of both frame configurations (Ref Fig. 1 on page C-1).
The seat back support/cargo deck, bulkhead bolt to the Fig. 2 Swing Out Battery Rack
body, as do the seats.
rack is not supported by the rollers (3) or are difficult to
open, first check that all grease points have been lubri-
Cowl cated and that the racks are in adjustment.
Dash Panel
The battery racks are adjusted at the factory to accom-
modate the batteries that the vehicle was shipped with. If
a heavier/lighter battery is retrofitted, the racks may have
to be shimmed to accommodate the change in weight.
Loosen the upper pivot (4) and support the outer end of
the battery rack with a floor jack, If the outer end of the
rack is to be raised, remove shims (5) as required. If
lighter batteries are used requiring the outer end of the
battery rack to be lowered, add shims as required. The
correct adjustment is when the battery rack (with batter-
ies installed) just contacts the nylon rollers (3).
Fixed Battery Racks
The battery racks in the two and four passenger 36V
Fig. 1 Cowl Attachment models are bolted to the frame members and are not
intended to be removed during normal usage of the vehi-
Swing Out Battery Racks cle (Ref Fig. 3 on page C-2).
To open the battery rack (1), lift up on the latch (2) and Access panels for the master cylinder, parking brake and
pull the rack outwards (Ref Fig. 2 on page C-1). If the parking brake support assembly are held in place with
2 PASSENGER
Front of Vehicle
4 PASSENGER
4 Passenger Shown
Front Seats common with 2 Passenger Models
Battery Charger
Part of Frame
Notes:
LIST OF ILLUSTRATIONS
Fig. 1 Wheels and Tires ................................................................................................................. D - 2
Notes:
WHEEL AND TIRE SERVICE inflation pressure should be in the higher allowable
D
range, but under no condition should inflation pressure
Tools List Qty. Required be higher than recommended on tire sidewall. All four
Lug wrench, 3/4" ......................................................... 1 tires should have the same pressure for optimum han-
Impact wrench, 1/2" drive............................................ 1 dling characteristics. Be careful not to overinflate. Due to
the low volume of these small tires, overinflation can
Impact socket, 3/4", 1/2" drive..................................... 1
occur in a matter of seconds. Be sure to install the valve
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
dust cap after checking or inflating.
To prevent injury caused Tire Repair
! !
by a broken socket, use
only sockets designed The vehicle is fitted with low pressure tubeless tires
for impact wrench use. Never use a conventional mounted on one piece rims.
socket. Generally, the most cost effective way to repair a flat tire
resulting from a puncture in the tread portion of the tire is
Tire condition should be inspected on a daily basis. Infla- to use a commercial tire plug.
tion pressures should be checked on a weekly basis
when tires are cool. When removing wheels with an Tire plug tools and plugs are available at most
impact wrench, use only impact sockets. Regular sockets automotive parts outlets and have the advan-
are not designed for impact pressures exerted by power tage of not requiring the tire be removed from the wheel.
tools. If the tire is flat, remove the wheel and inflate the tire to
the maximum recommended pressure for the tire.
A tire exp losion can Immerse the tire in water to locate the leak and mark with
! !
cause severe injury or chalk. Insert tire plug in accordance with manufacturer’s
death. Never exceed specifications.
inflation pressure rating on tire sidewall.
If tire is to be removed or mounted, the tire changing
To prevent tire explosion, pressurize tire with machine manufacturer’s recommendations must be fol-
small amount of air applied intermittently to seat lowed in order to minimize possibility of personal injury.
beads. Never exceed the tire manufacturer’s rec-
ommendation when seating a bead. Protect face To prevent injury, be
and eyes from escaping air when removing valve ! !
sure mounting/demount-
core. ing machine is anchored
Use caution when inflating tires. Due to the low to floor. Wear OSHA approved safety equipment when
volume of these small tires, overinflation can mounting/demounting tires.
occur in a matter of seconds. Overinflation could Follow all instructions and safety warnings provided by
cause the tire to separate from the wheel or cause the mounting/demounting machine manufacturer.
the tire to explode, either of which could cause
personal injury. Wheel Installation
Use caution when inflating tires. Due to the low volume of Do not tighten lug nuts to more than 85
these small tires, overinflation can occur in a matter of ft. lbs. (115 Nm) torque.
seconds. Overinflation could cause the tire to separate
from the rim or cause the tire to explode, either of which It is important to follow the ‘cross sequence’
could cause personal injury. pattern when installing lug nuts. This will
assure even seating of the wheel against the hub.
Tire inflation should be determined by the condition of the
terrain. See GENERAL SPECIFICATIONS section for With the valve stem to the outside, mount the wheel onto
recommended tire inflation pressure. For outdoor appli- the hub with lug nuts. Finger tighten lug nuts as shown
cations with major use on grassy areas, the following (Ref Fig. 1 on page D-2). Then, tighten lug nuts to 50 - 85
should be considered. On hard turf, it is desirable to have ft. lbs. (70 - 115 Nm) torque in 20 ft. lbs. (30 Nm) incre-
a slightly higher inflation pressure. On very soft turf, a ments following the same pattern.
lower pressure prevents tires from cutting into the turf.
For vehicles being used on paved or hard surfaces, tire
1 3 1
3 4
4 2 2
5
CONTROLLER REPLACEMENT...................................................................................................E - 18
SOLENOID REPLACEMENT.........................................................................................................E - 18
LIST OF ILLUSTRATIONS
Fig. 1 Access to Pedal Box .............................................................................................................E - 1
Fig. 2 Controller and Solenoid.........................................................................................................E - 2
Fig. 3 Battery Reference Voltage ....................................................................................................E - 4
Fig. 4 Continuity Check of Switch....................................................................................................E - 5
Fig. 5 Continuity Check of Solenoid ................................................................................................E - 5
Fig. 6 Simplified Troubleshooting Diagram .....................................................................................E - 6
Fig. 7 Detailed Troubleshooting Diagram (Sheet 1 of 8) .................................................................E - 7
Fig. 8 Detailed Troubleshooting Diagram (Sheet 2 of 8) .................................................................E - 8
Fig. 9 Detailed Troubleshooting Diagram (Sheet 3 of 8) .................................................................E - 9
Fig. 10 Detailed Troubleshooting Diagram (Sheet 4 of 8) .............................................................E - 10
Fig. 11 Detailed Troubleshooting Diagram (Sheet 5 of 8) .............................................................E - 11
Fig. 12 Detailed Troubleshooting Diagram (Sheet 6 of 8) .............................................................E - 12
Fig. 13 Detailed Troubleshooting Diagram (Sheet 7 of 8) .............................................................E - 13
Fig. 14 Detailed Troubleshooting Diagram (Sheet 8 of 8) .............................................................E - 14
Fig. 15 ITS and Plunger ................................................................................................................E - 15
Fig. 16 ITS Adjustment..................................................................................................................E - 16
Fig. 17 ITS Adjustment..................................................................................................................E - 17
Fig. 18 Wiring Diagram..................................................................................................................E - 19
Notes:
GENERAL
E
tains the pedal position micro switch and a solid state
Inductive Throttle Sensor (ITS) that is activated by a
The Electronic Speed Control system consists of two
moving plunger attached to the accelerator pedal.
separate units, the pedal box and the controller.
Pedal Box To access the pedal box (3), remove the three screws (4)
The Pedal Box assembly is a modularized unit (Ref Fig. and remove the access cover (5) from the floor. The ITS
1 on page E-1) that contains the accelerator pedal (1), and plunger are accessed by removing the top cover
return spring (2) and an enclosed pedal box (3) that con- from the enclosed pedal box.
4
Front of Vehicle
Controller
If the diode is incorrectly oriented, the
pedal box micro switch and the direc-
tion selector micro switch may be permanently damaged.
Front of Vehicle
Power Harness To
A2 Controller
From Control
Harness To +36V
Resistor
Phillips screwdriver, small ........................................... 1 With the adequacy of the batteries confirmed, use a
DVOM connected directly to the battery terminal posts to
Shop towel .................................................................. 1 determine the open voltage of the set (Ref Fig. 3 on page
Allen wrench, .050" ..................................................... 1 E-4). In the following tests, this voltage level will be used
Continuity Check
?v Before attempting to
Battery
! !
perf orm a continuity
Reference check, turn the key
Voltage switch to ‘OFF’ and place the direction selector in
neutral.
Positive Probe
2 PASSENGER to BL+ Using an insulated wrench,
remove the B+ wire from the
Front of Vehicle Negative Probe battery to disconnect electrical
to BL-
power to vehicle.
Continuity checks must be performed with the power
off.
If the solenoid does not function, the pedal micro switch,
neutral micro switch (direction selector switch), solenoid,
key switch and four pin connector should be checked for
continuity.
Turn the key switch to ‘OFF’ and place the direction
selector in neutral before disconnecting power by remov-
ing the B+ connection to the battery. Always use insu-
lated wrenches when working on batteries. To check
for continuity, set the DVOM to the KΩ setting and select
‘Continuity’. The meter will give an audible signal when it
detects continuity. If the meter does not have a continuity
Negative Probe
to BL- setting, set it to KΩ, the meter will indicate “0” when it
4 PASSENGER detects continuity.
Testing a Switch for Continuity
Positive Probe
Front of Vehicle to BL+ Place one probe on one contact of the switch, place the
second probe on the second terminal of the switch (Ref
Fig. 4 on page E-5).
Actuating a normally open (NO) switch will cause the
DVOM to show “0” or give an audible indication when the
switch is operated. A normally closed (NC) switch will
cause the meter to show “0” or give an audible indication
when the probes are attached without activating switch.
The audible indicator will stop and the meter display will
indicate a value greater than “0” when the switch is acti-
vated.
The change in display or audible indicator demonstrates
Fig. 3 Battery Reference Voltage that the switch is functioning.
as a reference. Some loss due to resistance or wires and
connectors may be indicated by readings that could be
up to one volt less than the reference voltage. No reading
indicates an “open” condition and the battery wires
should be inspected for a broken or disconnected wire or
component.
Press to
activate
switch
No Yes
Solenoid Click? Reference
Voltage?
Yes No
Check Go to Step 23
Vehicle ITS
Operation (Steps 23 - 35)
No No Go to Step 37
Vehicle Operates? Vehicle Operates? Power Circuit
(Steps 37 - 46)
Yes
Yes
Stop No
Stop Vehicle Operates? Go To
Step 1
Yes
Stop
3
Voltage Between
Reference Voltage? Yes Battery B- &
Controller Side
of Solenoid
No
4
Correct Wiring 0.5 - 2.5 Volts Voltage Between
Problem Between Less Than Yes
Battery B- &
Battery B+ & Solenoid Reference Voltage? Controller B+
No
5
0.5 - 2.5 Volts Voltage Between
(Same Voltage as Less Than Yes
Controller B- &
Reference Voltage) Check Solenoid Reference Voltage? Controller B+
Replace if Welded
No
No
Correct Wiring
Problem Between
Battery B- / Controller B-
No No (Zero)
Key ON, DirectSelect in FORWARD Disconnect Charger Harness Red Wire
Pedal Depressed
7 From Charger Receptacle Small White Wire
Voltage Across Small 11
Voltage Between
Terminals on Solenoid Battery B- &
Charger Receptacle
Small White Wire
No (Zero)
No (Zero)
Key ON, DirectSelect in FORWARD Remove Charger Receptacle Cover
Pedal Depressed
8 12
Voltage Between Voltage Between
Battery B- & Battery B- &
Small Solenoid Terminal Charger Receptacle
With 2 Red Wires Positive Pin
No (Zero)
No (Zero)
Key ON, DirectSelect in FORWARD Correct Charger Harness
9 Large White Wire
Voltage Between Problem
Battery B- & Reassemble
DirectSelect Microswitch
Terminal w/ Blue Wire
Yes
Reference Voltage? Go To Step 13
No (Zero)
No (Zero)
Reconnect Key Switch Harness
Remove Gauge Plate From Reference Voltage? Yes Correct Problem In Red
Instrument Panel Control Harness Wire
Key On, DirectSelect in FORWARD
14 Voltage Between Battery
B- & Key Switch Terminal
With Green Key Switch No (Zero)
Harness Wire Key ON, DirectSelect in FORWARD
Return to Step 6 Pedal Depressed
17
Battery B- to Back Side
of Pedal Box Harness
4-Pin Connector
Reference Yes Correct Green Key Switch (Pin With Red Wire)
Voltage? Harness Wire Problem
No (Zero)
Yes Correct Problem In 4-Pin
DirectSelect in FORWARD Reference Voltage?
15 Voltage Between Battery Connector Assembly
B- & Key Switch Terminal
With Blue Key Switch
Harness Wire No (Zero)
Key ON, DirectSelect in FORWARD
18 Battery B- to Back Side
of Pedal Box Harness
4-Pin Connector
Yes Replace Key Switch; (Pin With Green Wire)
Reference Voltage?
Reassemble
No (Zero)
Yes
Reference Voltage? Go To Step 20
Correct Problem In Blue
Key Switch Harness Wire;
Reassemble
No (Zero)
Key ON, DirectSelect in FORWARD
19
Battery B- to Back Side
of Control Harness
4-Pin Connector
(Pin With Green Wire)
No (Zero)
No (Zero)
No (Outside Range)
Disconnect Black Wire to Pin 2
Key ON, DirectSelect in FORWARD
Pedal Depressed
24
Voltage Between
Controller B- &
Controller Pin 2
Reconnect Black Wire to Pin 2
Key ON, DirectSelect in FORWARD
Pedal Depressed Until Solenoid Clicks
25
Yes Voltage Between
13.0 - 15.5 Controller B- &
Volts? Controller Pin 3
Correct Problem in
13.0 - 15.5 Yes Control Harness White
Volts? Wire; Replace White
Wire to Pin 3
No (Outside Range)
Key ON, DirectSelect in FORWARD
Pedal Fully Depressed
29
Battery B- to Back Side
of Pedal Box Harness
4-Pin Connector
(White Wire Pin)
Correct Problem in
13.0 - 15.5 Yes 4-Pin Connector;
Volts? Replace White
Wire to Pin 3
No (Outside Range)
Key ON, DirectSelect in FORWARD
Pedal Fully Depressed
30
Battery B- to Back Side
of Pedal Box Harness
4-Pin Connector
(Black Wire Pin) Pull Up Floor Mat
Remove Pedal Box Cover
Key ON, DirectSelect in FORWARD
Pedal Fully Depressed
32
Yes Voltage Between
13.0 - 15.5 Battery B- to ITS
Volts? (Terminal with
Black Wire)
Key ON, DirectSelect in FORWARD
No (Outside Range) Pedal Fully Depressed
Key ON, DirectSelect in FORWARD 33
Voltage Between
Pedal Fully Depressed Yes Battery B- to ITS
13.0 - 15.5
31 Volts? (Terminal with
Battery B- to Back Side
of Control Harness White Wire)
4-Pin Connector
(Black Wire Pin)
No (Outside Range)
Correct Problem in Correct Problem in
13.0 - 15.5 Yes Pedal Box Harness
Pedal Box Harness
Correct Problem in Black Wire; Volts? White Wire;
13.0 - 15.5 Yes 4-Pin Connector; Reconnect White Wire Reconnect White Wire
Volts? Reconnect White
Wire to Pin 3
No (Outside Range)
Return to Step 23
No (Outside Range)
No
No (No Voltage)
.5 - 2.5 V Less Than Yes
Reference Voltage? Go to Step 48
Replace Controller
No
No (60% Reference Voltage) DIRECTION SELECTOR
Key ON, DirectSelect in FORWARD
Go to Step 48 38
Voltage Between D A
Battery B- &
Motor A1
C
Key ON, DirectSelect in FORWARD B
39
Voltage Between A - Controller M-
.5 - 2.5 V Less Than Yes Battery B- & B - Motor S2
Reference Voltage? Motor A2 C - Controller A2
D - Motor S1
No (No Voltage)
No (No Voltage)
Replace Motor
No (No Voltage)
No (No Voltage)
.5 - 2.5 Volt
Correct Problem Less Than Yes
in DirectSelect Go to
Reference Voltage Step 48
No (No Voltage)
No
50 Reinstall Orange Wire
Key ON
DirectSelect in FORWARD
Pedal Fully Depressed
Yes
Wheels Move? Lower Vehicle
& Test Drive
No
Check for
Yes Electrical Shorts
& Mechanical
Obstructions
No
Replace Motor
Yes
Vehicle Operates Lower Vehicle
Correctly? & Test Drive
No
Go to Step 1
INDUCTIVE THROTTLE SENSOR (ITS) strip the plastic studs while tightening the nuts enough to pre-
vent movement of the ‘ITS’.
TESTING AND REPLACEMENT
Carefully remove the two wires that attach to the ITS and
Tool List Qty. Required
carefully remove the nuts securing the ITS to the plastic
Phillips screwdriver ..................................................... 1 pedal box studs.
Wrench, 7/16" ............................................................. 1 Install a new ITS being careful to align the ITS and not to
Nut driver, 7/16" .......................................................... 1 overtighten the retaining nuts. Attach the wiring.
Drill bit, 17/64"............................................................. 1 With the accelerator pedal in the full up position, insert a
DVOM ......................................................................... 1 17/64" drill bit between the plunger and the face of the
Raise the rear wheels of the vehicle and support the ITS. The drill bit should be used to verify and adjust the
vehicle on jack stands (Refer to Lifting Procedure in Sec- distance between the face of the ITS and the face of the
tion ‘B’ Safety). Test the vehicle stability before proceed- plunger (Ref Fig. 16 on page E-16). If the plunger
ing. needs adjustment, loosen the lock nut and rotate the
plunger until the desired dimension is achieved. Firmly
Remove the access cover and remove the four screws
tighten the jam nut.
securing the plastic cover to the pedal box (Ref Fig. 15
on page E-15). Replace the plastic cover and press it firmly into place
before tightening the cover screws.
Replace the metal access cover.
Micro Switch
Adjusting Cam
Micro Switch
Lock Nut
Plunger 'ITS'
Connector
2
1
PEDAL UP PEDAL PRE-TRAVEL
Lock Nut
To adjust plunger:
- Loosen lock nut
- Rotate plunger until
desired dimension Is
achieved
- Tighten Lock Nut
4
3 PEDAL ALL THE WAY DOWN
1.5 - 1.7 volts
SOLENOID ACTIVATED
0.4 - 0.6 volts
Cam
Micro switch
activated
Plunger enters
'ITS'
Plunger fully
activated
SOLENOID REPLACEMENT
Tool List Qty. Required
Socket, 3/8", 3/8" drive ................................................ 1
Socket, 7/16", 3/8" drive .............................................. 1
Socket, 1/2", 3/8" drive ................................................ 1
Ratchet, 3/8" drive ....................................................... 1
Extension, 6", 3/8" drive .............................................. 1
Insulated wrench, 9/16" ............................................... 1
Shop towel................................................................... 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
- BLK - - -
- - - B-
Charger BLU
Receptacle + + +
BLK Key Switch
BLU
GRN
ITS MS3
Pedal
Box
WHT
Direction WHT BLK GRN RED
BLK Selector
Switch RED
GRN
WHT BLK
C
RED/WHT
BLK
BLU B D
MS2 RED
ORN
MS4 RED BLK A BLK BLU Solenoid YEL
RED
BLK
BLK BLK
BLK
RED
Motor BLK
RED WHT RED BLK
A2
S2
+ - ORN
1
2 B- B+
3 BLK
A1 S1
M- A2
On-Board
Charger BLK
BLK
Notes:
OPERATION ....................................................................................................................................F - 2
Pedal Box ..............................................................................................................................F - 3
Controller ...............................................................................................................................F - 3
CONTROLLER REPLACEMENT...................................................................................................F - 20
SOLENOID REPLACEMENT.........................................................................................................F - 20
LIST OF ILLUSTRATIONS
Fig. 1 Run-Tow/Maintenance Switch...............................................................................................F - 2
Fig. 2 Access to Pedal Box .............................................................................................................F - 4
Fig. 3 Controller and Solenoid.........................................................................................................F - 5
Fig. 4 Controller...............................................................................................................................F - 6
Fig. 5 Battery Reference Voltage ....................................................................................................F - 7
Fig. 6 Continuity Check of Switch....................................................................................................F - 8
Fig. 7 Continuity Check of Solenoid ................................................................................................F - 9
Fig. 8 48 Volt Fault Codes.............................................................................................................F - 10
Fig. 9 Controller Connectors and Connections .............................................................................F - 11
Fig. 10 48 Volt Wiring Diagram ....................................................................................................F - 12
Fig. 11 J-1 Pin Connector Diagnostics ..........................................................................................F - 13
Fig. 12 J-1 Pin Connector Diagnostics (Continued) ......................................................................F - 14
Fig. 13 J-2 Pin Connector Diagnostics ..........................................................................................F - 15
Fig. 14 Secondary Wiring Diagnostics ..........................................................................................F - 16
Fig. 15 ITS and Plunger ................................................................................................................F - 17
Fig. 16 ITS Adjustment (Sheet 1 of 2) ...........................................................................................F - 18
Fig. 17 ITS Adjustment (Sheet 2 of 2) ...........................................................................................F - 19
Fig. 18 Controller Wiring................................................................................................................F - 21
Notes:
48 VOLT SYSTEM VEHICLES GENERAL Performance options of the Precision Drive System
F
include:
48 Volt vehicles may be equipped with one of four modes
or “performance options”. The factory installed Perfor- • Anti-Roll back to limit backward motion of the
mance Option is the ‘No Plug’, however it is possible that vehicle down an incline to less than 2 mph (3 kph)
the technician may encounter a vehicle equipped with an
aftermarket option. The option of the vehicle is deter- • Walk-Away to limit vehicle movement without
mined by which performance plug is installed in the Elec- driver input, slowing the vehicle to 2 mph (3 kph)
tronic Speed Control Assembly. The options are defined and sounding an audible alarm (reverse beeper)
as follows:
• Anti-Stall protection to prevent commutator dam-
1. The ‘No Plug’ performance option: The motor’s speed age from stalling the vehicle against an object or
is sensed and regulated to 13.5 mph (22 kph) directly on a hill
by the controller, the vehicle’s flat ground speed will
not change with different ground surfaces. The speed • High pedal disable to prevent undesired accelera-
sensor also allows for precise control of the downhill tion if the direction selector lever is changed, or
vehicle speed during compression braking. Compres- the key is turned on while the accelerator is
sion braking occurs when the throttle is released depressed
while the vehicle is moving. The motor will electrically
retard the motion of the vehicle until the throttle is • Diagnostic light indicator to ease troubleshooting
depressed again or the vehicle stops. This is the
strongest of the two compression braking options. As
the vehicle crests a hill and begins to descend, the PERFORMANCE OPTIONS & DIAGNOSTICS
speed will be smoothly regulated to 13.5 mph (22
kph). This option is enabled when there is a blank Performance Top Speed Compression Anti-Stall
plug installed. Option Braking Protection
Strength
2. The ‘Blue Plug’ performance option: This option
includes all of the driving features of the ‘No Plug’ No Plug 13.5 mph Heavy Yes
(22 kph)
option except that the compression braking feel is
milder. Blue Plug 13.5 mph Mild Yes
(22 kph)
3. The ‘Yellow Plug’ performance option: This option
Yellow Plug 15 mph Heavy Yes
includes all of the driving features of the ‘No Plug’
(24 kph)
option, except the flat ground compression braking
speeds are 15 mph (24 kph) instead of 13.5 mph (22 Red Plug 15 mph Mild Yes
(24 kph)
kph).
4. The ‘Red Plug’ performance option: This option
includes all of the driving features of the ‘Blue Plug’ Changing Performance Options
option except that the flat ground and downhill com-
pression braking speeds are 15 mph (24 kph) instead The performance option may be changed if the existing
of 13.5 mph (22 kph). option is not compatible with the terrain that the vehicle
will be operated.
ENANC
E
‘TOW/M
Select
Always
RUN
CE n. ents
ENAN al compon
MAINT battery explosio
and s or electric
.
The 48 volt system also incorporates an anti-stall protec- The pedal box and controller are connected by a four pin
tion feature that prevents commutator damage from stall- connector that is located at the front of the vehicle.
ing the vehicle against an obstacle or ascending a hill. The controller is wired to the batteries and develops a
The electrical power to the motor will be interrupted inter- regulated power supply for the ITS. The plunger position
mittently allowing the vehicle to roll a short distance, relative to the ITS varies the voltage which is fed back to
thereby allowing the internal components of the motor to the controller which interprets the change in voltage and
move before damage can be done. supplies the appropriate power to the motor.
The No Plug option (See chart on page 1) features a dif- The ITS unit and the controller are both solid state units
ferent degree of compression braking that takes place that contain no user serviceable parts. The testing pro-
any time that accelerator pedal is released. The No Plug cedures are designed to test the basic functionality
option will rapidly slow the vehicle to a stop unless the of the power and control wiring systems. Once the
accelerator pedal is depressed. The three other options functionality of the wiring has been confirmed, the
will slow the vehicle to a stop at different rates unless the remaining tests are used to identify which of the compo-
accelerator pedal is depressed. nents (controller or ITS) must be replaced.
The 48 volt system is a low power consumption unit but it
will drain the vehicle batteries over a period of time. If the
vehicle is to be stored for a prolonged period of time, the
48 volt system should be disconnected from the batteries
by selecting the ‘TOW/MAINTENANCE’ position on the
Run-Tow/Maintenance switch located under the passen-
ger seat.
The Electronic Speed Control system consists of three
separate units, a pedal box, speed sensor and controller.
Pedal Box
The Pedal Box assembly is a modularized unit that con-
tains the accelerator pedal (1), return spring (2) and an
enclosed pedal box (3) that contains lthe pedal position
micro switch and a solid state Inductive Throttle Sensor
(ITS) that is activated by a moving plunger attached to
the accelerator pedal.
To access the pedal box (3), remove the three screws (4)
and remove the access cover (5) from the floor (Ref Fig.
2 on page F-4). The ITS and plunger are accessed by
removing the top cover from the enclosed pedal box.
4
Front of Vehicle
Front of Vehicle
BLK From
24-Pin Connector Charger
From Control Harness
To J1 Controller
WHT From Power
Harness to F1Controller
3-Pin Connector
From Speed Sensor
To J2 Controller
From B+ Power
Harness To Controller
From Solenoid
To B+ Controller
From M- Power
Harness To Controller
BLK From F2 Power 4-Pin Connector
Harness To F2 Controller
From Control Harness
From B- Controller To Tow Switch Connector
To 48V
WHT From
Control Harness
From Solenoid
To +48V
Resistor
GENERAL TROUBLESHOOTING
Tool List Qty. Required
Floor jack..................................................................... 1
Jack stands ................................................................. 2
Wheel chocks .............................................................. 4
Jumper wire (with alligator clips) ................................. 1
DVOM.......................................................................... 1
Socket, 3/8", 3/8" drive ................................................ 1
Ratchet, 3/8" drive ....................................................... 1
Torque wrench, in. lbs., 3/8" drive ............................... 1
Torque wrench, ft. lbs., 3/8" drive ................................ 1 before
towing.
ING
TOW ANCE’ position TOW E
AINTEN ENANC
‘TOW/M MAINT
connectors may be indicated by readings that could be setting, set it to KΩ, the meter will indicate “0” when it
up to one volt less than the reference voltage. No reading detects continuity.
indicates an “open” condition and the battery wires
should be inspected for a broken or disconnected wire or Testing a Switch for Continuity
component.
Continuity Check
To prevent possible inju-
! !
ry or death resulting
from a battery explo-
sion, use an insulated wrench and remove the BL-
wire from the battery to disconnect electrical power to
vehicle.
Before attempting to perform a continuity check, turn
the key switch to ‘OFF’ and place the direction selec-
tor in neutral.
Before any electrical service is per-
formed on 48 volt model vehicles, the
Run-Tow/Maintenance switch must be placed in the ‘Tow/Mainte-
nance’ position.
If a power wire (battery, motor or controller) is disconnected for Press to
any reason on the 48 volt model vehicle, the Run-Tow/Mainte- activate
nance switch must be left in the ‘Tow/Maintenance’ position for switch
at least 30 seconds after the circuit is restored.
Fig. 6 Continuity Check of Switch
Turn the key switch to ‘OFF’ and place the direction
Place one probe on one contact of the switch, place the
selector in neutral before disconnecting power by remov-
second probe on the second terminal of the switch (Ref
ing the BL- connection to the battery. Always use insu-
Fig. 6 on page F-8).
lated wrenches when working on batteries. To check
for continuity, set the DVOM to the KΩ setting and select Actuating a normally open (NO) switch will cause the
‘Continuity’. The meter will give an audible signal when it DVOM to show “0” or give an audible indication when the
detects continuity. If the meter does not have a continuity switch is operated. A normally closed (NC) switch will
cause the meter to show “0” or give an audible indication
when the probes are attached without activating switch.
The audible indicator will stop and the meter display will
indicate a value greater than “0” when the switch is acti-
vated.
The change in display or audible indicator demonstrates
that the switch is functioning.
Testing a Solenoid for Continuity
Place one probe on one of the large terminals and the
other probe on the second large terminal (Ref Fig. 7 on
page F-9). If the meter shows “0” or gives an audible indi-
TROUBLESHOOTING DIAGRAMS
The following diagrams will assist in servicing the vehi-
cle. By utilizing the Fault Codes, considerable time will
be saved in determining the probable vehicle operating
malfunction. The vehicle power and control wiring dia-
gram is included for your convenience in tracing the elec-
trical wiring (Ref Fig. 10 on page F-12). The following 6
flow charts will assist in diagnosing and correcting prob-
lems not diagnosed through the Fault Codes.
--- Direction Selector Fault Vehicle Operates in • At Direction Selector check wiring
One Direction Only Bad - Replace/repair wiring; Good - Replace selector switch
0-0 No Fault Codes Vehicle Inoperative • Open Pedal Box, verify micro switch wiring is connected & is not dam-
with Key ON aged; Repair/replace as necessary;
• Direction Selector Forward micro switch OPEN, verify switch is opera-
tional and wiring is connected & not damaged; Repair/replace as neces-
sary;
• Verify Key Switch is operational; Repair/replace as necessary
The following codes require the rear wheels be raised before performing tests:
1-1 Hardware Failsafe Vehicle will not run • Check motor wiring; Replace controller
1-2 Throttle Fault 1 Vehicle will not run • Check pedal box adjustment, connections; Replace ITS
1-3 Speed Sensor Fault Vehicle runs slowly • Check speed sensor magnet, wire, sensor & connector connections;
Replace speed sensor if necessary
1-4 High pedal disable Vehicle will not run • Release and reapply pedal; Check pedal box, linkage, switch, key
switch
2-1 Low Battery Voltage Vehicle performance • Perform discharge test; Charge batteries/replace bad batteries
reduced
2-2 High Battery Voltage Vehicle performance • Verify that battery system is less than 48 volts
reduced
2-3 Thermal Cutback Vehicle performance • Allow controller to cool and verify heat sink bolt tightness
reduced
2-4 Main driver on Vehicle runs slowly • Solenoid driver defective; Replace controller
2-5 Volts direct current fault Vehicle will not run • Replace controller
3-3 Precharge fault Vehicle will not run • Check for additional electronics attached to B+; Replace controller
3-4 Field missing Solenoid closes, Vehi- • Check wiring; Replace power harness and motor if required
cle will not run
3-5 Field overcurrent Vehicle will not run • Field windings or power harness shorted; Verify; Replace motor if nec-
essary
4-1 Current sense fault Vehicle will not run • Replace controller
4-3 M- fault Vehicle will not run • Check M- wiring and repair; Replace controller
4-4 Auxiliary contact did not Vehicle will not run • Replace controller
close
5-2 Main coil open Vehicle will not run • Check coil connections/wiring; Replace solenoid if necessary
5-3 Main contact did not Vehicle will not run • Check all solenoid wiring; Replace solenoid if necessary
close
5-5 Missing contactor Vehicle stops • Check all solenoid wiring; Replace solenoid if necessary
Frame
F1
B-
J1
M- J2
B+
F2
BLK
48 Volt Battery Pack
Pedal Box
ITS MS3
Charging
Connector RED GRN
WHT BLK
F2
YEL
Reed
J3
Switch Solenoid To Hand B+
Held Motor
Motor Diagnostic
A1 F2
Speed Unit
Sensor
J2
- BLK
WHT
4 1 SPARE
OUT 5 2 SPARE
+ RED 6 3 SPARE A2 F1
M-
J1 Key
BLK WHT / YEL Switch
13 1
2 ORN / RED
SPARE 14
WHT / BLK RED / YEL
15 3
4 RED
SPARE 16
BLU 17 5 YEL
Performance
Plug 18 6 RED / WHT
SPARE
GRN / BLK GRY
19 7
BRN GRN / WHT
2 20 8
VIO
SPARE 21 9 FWD Direction
GRN N Selector
SPARE 22 10
BLU / WHT ORN Switch
3 23 11 REV
BLK / WHT WHT
5 24 12
1 B-
WHT
F1
Reverse Aux
RED Buzzer RED RED YEL
Pedal Box
ITS MS3
Charging
Connector +
1264 Controller
F2
YEL
Reed
J3
Switch Solenoid B+
J2
4 1
5 2
6 3
M-
J1 Key
BLK WHT / YEL Switch
13 1
2 ORN / RED
SPARE 14
WHT / BLK RED / YEL
15 3
4 RED
SPARE 16
BLU 17 5 YEL
Performance
Plug 18 6 RED / WHT
SPARE
GRN / BLK GRY
19 7
BRN GRN / WHT
2 20 8
VIO
SPARE 21 9 FWD Direction
GRN N Selector
SPARE 22 10
BLU / WHT ORN Switch
3 23 11 REV
BLK / WHT WHT
5 24 12
1 B-
WHT
F1
Reverse Aux
RED Buzzer RED RED YEL
All tests are to be performed with the negative lead of the DVOM connected to the negative side
of battery pack voltage.
The positive lead of the DVOM is used to probe the controller/battery connections. Leave connections
plugged in the controller.
Verify the Battery Reference Voltage at the main battery pack leads. (should be around 48 volts in
.
8 battery applications) All pin connector checks are performed with the key 'ON' and the 'Tow/Maintenance'
switch in the RUN position.
J1-1 BRV Verify key switch, wiring connections, and pin 12 voltage.
J1-2 BRV Verify reed switch, tow switch, and wiring connections
J1-13 1-3.5 volts ITS output. Verify wiring and ITS field. Measured with pedal up to
wide open throttle.
J1-15 16 - 17 volts ITS input voltage. If low voltage is observed, unplug from field. If
voltage comes up, replace the ITS field. If voltage remains low,
replace the controller
J1-17 BRV BRV will be observed until solenoid engages. BRV will diminish to
around 0 volts to engage solenoid. If not, verify wiring. Possible
faulty controller or shorted solenoid.
J1-19 BRV BRV will be observed until vehicle is placed in the reverse
direction. BRV will diminish to 0 - 4 volts. Operates reverse alarm.
If not, verify wiring. Possible faulty controller.
1264 Controller
F2
J3
Motor B+
Speed
Sensor
J2
BLK
- WHT
4 1 SPARE
OUT 5 2 SPARE
+ RED
6 3 SPARE
M-
J1
13 1
14 2
15 3
16 4
17 5
18 6
19 7
20 8
21 9
22 10
23 11
24 12
B-
F1
All tests are to be performed with the negative lead of the DVOM connected to the negative side
of battery pack voltage.
The positive lead of the DVOM is used to probe the controller connections. Leave connections
plugged in the controller
Armature will need to be rotated for this test. Jack vehicle up on the passenger side and rotate
the rear wheel by hand
J2-1 Spare
J2-2 Spare
J2-3 Spare
J2-4 0 volts Verify sensor harness and connection.
This connection serves as the sensor ground
J2-5 0 - 6.5 volts Verify the speed sensor and harness . This
connection provides the flash voltage from
the sensor while the armature rotates.
BLK
48 Volt Battery Pack
Charging
Connector
BLK
1264 Controller
F2
J3 Motor
Solenoid B+
A1
J2 F2
4 1
5 2
6 3 A2
M- F1
J1
13 1
14 2
15 3
16 4
17 5
18 6
19 7
20 8
21 9
22 10
23 11
24 12
B-
WHT
F1
This test will verify secondary circuit voltage. Please refer the chart for probe connections.
Positive prove on BL+ and BRF preferably 48 Volt Perform battery discharge test.
negative probe on BL- Verify the chrager/process
Negative probe on BL- and BRF Verify wire/connection quality
positive probe on battery
side of solenoid
Negative probe on BL- and BRF with solenoid engaged Verify primary voltage at Pin 5 & 17.
positive probe on solenoid B+ If BRF is found on the primary
terminals, replace solenoid.
Positive probe on B+ and 1-48 Volt depending on To verify: engage solenoid at high
negative probe on M- performance plug pedal. Voltage should start around
1-2 volt. As the pedal is slowly
depressed to the floor, voltage should
rise to around 48 volt. If extremely low
voltage is observed, replace the
controller. If immediate high voltage is
observed, replace the motor.
Micro Switch
Adjusting Cam
Micro Switch
Lock Nut
Plunger 'ITS'
Connector
2
1
PEDAL UP PEDAL PRE-TRAVEL
Lock Nut
To adjust plunger:
- Loosen lock nut
- Rotate plunger until
desired dimension Is
achieved
- Tighten Lock Nut
4
3 PEDAL ALL THE WAY DOWN
2.7 +
_ 0.5 volts
SOLENOID ACTIVATED
1.0 +
_ 0.3 volts
Cam
Micro switch
activated
Plunger enters
'ITS'
Plunger fully
activated
CONTROLLER REPLACEMENT 80 - 90 in. lbs. (9 - 10 Nm) torque and M8 (B+, M-, B-)
bolts to 120 - 130 in. lbs. (14 - 15 Nm) torque.
Tool List Qty. Required
Reconnect the BL- battery cable and replace the cargo
Socket, 10mm, 3/8" drive ............................................ 1 bed.
Socket, 7/16", 3/8" drive .............................................. 1
Socket, 13mm, 3/8" drive ............................................ 1
SOLENOID REPLACEMENT
Ratchet, 3/8" drive ....................................................... 1
Extension, 6", 3/8" drive .............................................. 1 Tool List Qty. Required
Insulated wrench, 9/16" ............................................... 1 Socket, 3/8", 3/8" drive ................................................1
Shop towel................................................................... 1 Socket, 7/16", 3/8" drive ..............................................1
Torque wrench, 3/8" drive, in. lbs. ............................... 1 Socket, 1/2", 3/8" drive ................................................1
Torque wrench, 3/8" drive, ft. lbs. ................................ 1 Ratchet, 3/8" drive .......................................................1
Extension, 6", 3/8" drive ..............................................1
Remove the cargo bed to access electrical box. Remove Insulated wrench, 9/16" ...............................................1
electrical box cover. Shop towel...................................................................1
Torque wrench, 3/8" drive, in. lbs.................................1
Before any electrical service is per-
formed on 48 volt model vehicles, the
Run-Tow/Maintenance switch must be placed in the ‘Tow/Mainte- Remove the cargo bed to access electrical box. Remove
nance’ position. electrical box cover.
If a power wire (battery, motor or controller) is disconnected for Before any electrical service is per-
any reason on the 48 volt model vehicle, the Run-Tow/Mainte- formed on 48 volt model vehicles, the
nance switch must be left in the ‘Tow/Maintenance’ position for Run-Tow/Maintenance switch must be placed in the ‘Tow/Mainte-
at least 30 seconds after the circuit is restored. nance’ position.
To prevent electrical If a power wire (battery, motor or controller) is disconnected for
! !
shock, the BL- wire must any reason on the 48 volt model vehicle, the Run-Tow/Mainte-
be removed before dis- nance switch must be left in the ‘Tow/Maintenance’ position for
charging the controller by shorting the B+ and B- ter- at least 30 seconds after the circuit is restored.
minals of the controller with a large screwdriver. Be
sure to hold screwdriver by the insulated portion. To prevent electrical
! !
shock, the BL- wire must
Using an insulated wrench, remove the BL- wire from the be removed before dis-
battery. charging the controller by shorting the B+ and B- ter-
minals of the controller with a large screwdriver. Be
Note the location of the wiring on the controller sure to hold screwdriver by the insulated portion.
before removing wiring from controller. (Ref
Fig. 18 on page F-21) Using an insulated wrench, remove the BL- wire from the
Remove the controller mounting hardware and remove battery.
the controller.
Note the location of the wiring on the solenoid
Mount new controller to electrical box and reconnect wir- before removing wiring from solenoid (Ref Fig.
ing. Tighten the controller mounting bolts to 108 - 132 in. 18 on page F-21)
lbs. (12 - 15 Nm) torque and the M6 (F1 and F2) bolts to
When connecting wires to solenoid, be sure to use a wrench to
hold the inner nut while tightening the outer one.
Remove the solenoid mounting bolts and remove the
solenoid.
Mount new solenoid and reconnect wiring. Tighten the
solenoid mounting nuts to 67 - 82 in. lbs. (8 - 9 Nm)
torque, the #10 terminal nuts to 13 - 17 in. lbs. (1 - 2 Nm)
From M- Power
Harness To
B+ Controller
BLK From F2 Power Control Harness
Harness To F2 Controller
3-Pin Connector
From Solenoid 4-Pin Connector
From B- Controller From Speed Sensor
To B+ Controller From Control Harness
To 48V To J2 Controller
To Tow Switch Connector
24-Pin Connector
From Control Harness
To J1 Controller
Notes:
LIST OF ILLUSTRATIONS
Fig. 1 Disconnect Battery Cable..................................................................................................... G - 1
Fig. 2 Mark Axle and Motor ............................................................................................................ G - 2
Fig. 3 Motor Components............................................................................................................... G - 2
Fig. 4 Brush Wear .......................................................................................................................... G - 3
Fig. 5 Securing Brushes ................................................................................................................. G - 4
Fig. 6 Motor Wiring 36V.................................................................................................................. G - 4
Fig. 7 Motor Wiring 48V.................................................................................................................. G - 4
Notes:
GENERAL
G
Do not hold a 36V vehicle on a hill or 36V (2 PASSENGER)
ramp using accelerator and motor. Front of Vehicle
Leaving the motor in a stalled condition for more than 3-4 sec-
onds will raise the commutator bars resulting in unacceptable
noise and accelerated brush wear and cause permanent damage
to motor.
Disassembly of the motor is not recommended except to
replace a worn or noisy bearing. If the motor is disassem-
bled, it should be cleaned of any dirt buildup and the
brush length checked. Replace brushes if required. Remove Battery Cable
The motor housing and field coils are not available as From (-) Battery Terminal
individual components, therefore in the unlikely event of
a failure in these components, the entire housing and Remove Battery Cable
field coil assembly must be replaced. From (-) Battery Terminal
36V (4 PASSENGER)
Motor Removal Front of Vehicle
Disconnect the negative
! !
(BL-) battery cable with
an insulated wrench
before attempting to remove wires from the motor
(see safety procedures in SAFETY section of this
manual). The shorting of motor wires could cause an
explosion.
Tool List Qty. Required
Insulated wrench, 9/16"............................................... 1
Chalk or paint pen ....................................................... 1
48V (2 PASSENGER)
Socket, 7/16", 3/8" drive.............................................. 1
Front of Vehicle
Ratchet, 3/8" drive....................................................... 1
Internal snap ring pliers............................................... 1
Using an insulated wrench, disconnect the negative (-)
battery cable from the battery (Ref Fig. 1 on page G-1).
Remove all wires from motor.
Mark both the axle and motor housings to permit realign-
ment during reassembly of motor to rear axle (Ref Fig. 2
Remove Battery Cable
on page G-2). From (-) Battery Terminal
12
2
3
14
9 15
8 10
11
1
6
2
A1 A
2
7
F1 F
17 18
13 19
18
5 4
21
20
48V PDS ONLY
Motor Installation
Brush Tool List Qty. Required
Brush
Spring Socket, 7/16", 3/8" drive .............................................. 1
BATTERY........................................................................................................................................ H - 1
BATTERY MAINTENANCE............................................................................................................. H - 1
At Each Charging Cycle ....................................................................................................... H - 1
Monthly ................................................................................................................................. H - 2
Electrolyte Level and Water.................................................................................................. H - 2
Cleaning Batteries ................................................................................................................ H - 2
Battery Replacement ............................................................................................................ H - 3
Prolonged Storage................................................................................................................ H - 5
Battery Charging................................................................................................................... H - 5
TROUBLESHOOTING .................................................................................................................... H - 6
Hydrometer........................................................................................................................... H - 6
Using A Hydrometer ............................................................................................................. H - 6
BATTERY CHARGER..................................................................................................................... H - 7
Description............................................................................................................................ H - 7
On-Board Charger Use......................................................................................................... H - 7
Charger Maintenance ........................................................................................................... H - 8
LIST OF ILLUSTRATIONS
Fig. 1 Correct Electrolyte Level ...................................................................................................... H - 2
Fig. 2 Water Purity Table................................................................................................................ H - 2
Fig. 3 Automatic Watering Gun ...................................................................................................... H - 3
Fig. 4 Preparing Acid Neutralizing Solution.................................................................................... H - 3
Fig. 5 Battery Connections ............................................................................................................. H - 4
Fig. 6 Freezing Point of Electrolyte ................................................................................................ H - 5
Fig. 7 Hydrometer........................................................................................................................... H - 6
Fig. 8 Hydrometer Temperature Correction ................................................................................... H - 7
Fig. 9 AC Charger Plug Requirements........................................................................................... H - 7
Notes:
SAFETY explosion.
H
Always observe the following warnings when working on Wrap wrenches with vinyl
or near batteries: tape to prevent the possibili-
ty of a dropped wrench from
To prevent battery explo- ‘shorting out’ a battery,
! !
sion that could result in which could result in an explosion and severe
severe personal injury or personal injury or death.
death, keep all smoking materials, open flame or
sparks away from the batteries.
BATTERY
Hydrogen gas is formed when charging batteries.
Do not charge batteries without adequate ventila- A battery is defined as two dissimilar metals immersed in
tion. A 4% concentration of hydrogen gas is an acid. If the acid is absent or if the metals are not dis-
explosive. similar, a battery has not been created. The batteries
most commonly used in these vehicles are lead acid.
Be sure that the key switch is off and all electrical
accessories are turned off before starting work on A battery does not store electricity, but is able to produce
vehicle. electricity as the result of a chemical reaction which
releases stored chemical energy in the form of electrical
Never disconnect a circuit under load at a battery energy. The chemical reaction takes place faster in warm
terminal. conditions and slower in cold conditions. Temperature is
Batteries are heavy. Use proper lift- important when conducting tests on a battery and test
ing techniques when moving them. results must be corrected to compensate for temperature
Always lift the battery with a com- differences.
mercially available battery lifting As a battery ages, it still performs adequately except that
device. Use care not to tip batteries its capacity is diminished. Capacity describes the time
when removing or installing them; that a battery can continue to provide its design amperes
spilled electrolyte can cause burns from a full charge.
and damage.
A battery has a maximum life, therefore good mainte-
The electrolyte in a storage battery is an acid nance is designed to maximize the available life and
solution which can cause severe burns to the skin reduce the factors that can reduce the life of the battery.
and eyes. Treat all electrolyte spills to the body
and eyes with extended flushing with clear water.
Contact a physician immediately. BATTERY MAINTENANCE
Always wear a safety shield or approved Tool List Qty. Required
safety goggles when adding water or Insulated wrench, 1/2" .................................................1
charging batteries. Battery carrier ..............................................................1
Hydrometer ..................................................................1
Any electrolyte spills should be neutralized with a Battery maintenance kit P/N 25587-G01 .....................1
solution of 1/4 cup (60 ml) sodium bicarbonate At Each Charging Cycle
(baking soda) dissolved in 1 1/2 gallons (6 liters)
of water and flushed with water. To reduce the possibility
Overfilling batteries may result in electrolyte ! !
of fire, never plug in an
being expelled from the battery during the charge on-board battery charg-
cycle. Expelled electrolyte may cause damage to er that is to be unattended beyond the normal charg-
the vehicle and storage facility. ing cycle. Overcharging could cause damage to the
vehicle batteries and result in extreme overheating.
Aerosol containers of battery terminal protectant The charger should be checked after 24 hours and
must be used with extreme care. Insulate metal unplugged after the charge cycle is complete.
container to prevent the metal can from contact-
ing battery terminals which could result in an
Color ................................................................................Clear
Expansion Vent Cap
Suspended ..................................................................... Trace
Space
Gas Vent Total Solids....................................................................... 100
1/4" to 3/8"
(6 to 10 mm) Vent Calcium & Magnesium Oxides .......................................... 40
Iron ..................................................................................... 5
Ammonia ............................................................................ 8
1/2" (13 mm) Organic & Volatile Matter................................................... 50
Electrolyte level should be Nitrites ................................................................................ 5
at least 1/2" (13 mm) above
the plates and 1/4" to 3/8" Nitrates .............................................................................. 10
Plates (6 to 10 mm) below vent Chloride .............................................................................. 5
Plastic
Spray
Electrolyte Bottle
Level
Pure Water Single Battery Cell Fig. 4 Preparing Acid Neutralizing Solution
Fig. 3 Automatic Watering Gun in order to remove any residue that could cause the self
discharge of the battery. Rinse the entire area with low
To prevent battery damage, be sure that pressure clear water. All of the items required for com-
all battery caps are tightly installed. plete battery cleaning and watering are contained in the
Cleaning should take place per Periodic Service Sched- Battery Maintenance Kit (P/N 25587-G01).
ule (Ref. GENERAL INFORMATION & ROUTINE MAIN-
Battery Replacement
TENANCE).
When cleaning the outside of the batteries and terminals, Before any electrical service is per-
do not use a water hose without first spraying with a solu- formed on 48 volt model vehicles, the
Run-Tow/Maintenance switch must be placed in the ‘Tow/Mainte-
tion of sodium bicarbonate (baking soda) and water to
nance’ position.
neutralize any acid deposits.
Use of a water hose without first neutralizing any acid, If a power wire (battery, motor or controller) is disconnected for
will move acid from the top of the batteries to another any reason on the 48 volt model vehicle, the Run-Tow/Mainte-
area of the vehicle or storage facility where it will attack nance switch must be left in the ‘Tow/Maintenance’ position for
the metal structure or the concrete/asphalt floor. After at least 30 seconds after the circuit is restored.
hosing down the batteries, a residue will be left on the Remove battery hold downs and cables. Lift out batteries
batteries which is conductive and will contribute to the with a commercially available lifting device.
discharge of the batteries.
If the batteries have been cleaned and any acid in the
The correct cleaning technique is to spray the top and battery rack area neutralized as recommended, no corro-
sides of the batteries with a solution of sodium bicarbon- sion to the battery racks or surrounding area should be
ate (baking soda) and water. This solution is best applied present. Any corrosion found should be immediately
with a quart sized hand sprayer. The solution should con- removed with a putty knife and a wire brush. The area
sist of 2 teaspoons (10 ml) of sodium bicarbonate (bak- should be washed with a solution of sodium bicarbonate
ing soda) mixed with 1 quart (1 liter) of clear water (Ref (baking soda) and water and thoroughly dried before
Fig. 4 on page H-3). In addition to the batteries, special priming and painting with a corrosion resistant paint.
attention should be paid to metallic components adjacent
The batteries should be placed into the battery racks and
to the batteries which should also be sprayed with the
the battery hold downs tightened to 45 - 55 in. lbs. (5 - 6
sodium bicarbonate (baking soda) solution.
Nm) torque, to prevent movement but not tight enough to
Allow the solution to sit for at least three minutes; use a cause distortion of the battery cases.
soft bristle brush or cloth to wipe the tops of the batteries
From Solenoid
Main Contactor
From
B - Controller
From
B - Controller
BLK Wire From
Control Harness
Front of Vehicle
From Solenoid
Main Contactor
From
B - Controller
Inspect all wires and terminals. Clean any corrosion from from the batteries. The batteries must be cleaned and all
the battery terminals or the wire terminals with a solution deposits neutralized and removed from the battery case
of sodium bicarbonate (baking soda) and brush clean if to prevent self discharge. The batteries should be tested
required. or recharged at thirty day minimum intervals.
incomplete charge in a normally adequate time period, which is accomplished by measuring the specific gravity
low AC voltage could be the cause and the power com- of the electrolyte. The greater the concentration of sulfu-
pany should be consulted. ric acid, the more dense the electrolyte becomes. The
higher the density, the higher the state of charge.
TROUBLESHOOTING
In general, troubleshooting will be done for two distinct Bulb Float
1100
reasons. First, a battery that performs poorly and is out- 32 1125
28
side of the manufacturers specification should be identi- Add to Float 24 1150
fied in order to replace it under the terms of the Reading 20 1175
16
manufacturer’s warranty. Different manufacturers have 12 1200
different requirements. Consult the battery manufacturer 8 1225
4
or the manufacturer’s representative for specific require- 0
Cylinder 1250
ments. 4 1275
8
The second reason is to determine why a particular vehi- 1300
1100
12
1125
1150
1200
16
1225
Subtract 20 1300
may result in a vehicle that runs slowly or in a vehicle that from Float 24
is unable to operate for the time required. 28
Reading 32
A new battery must mature before it will develop its max- 36
imum capacity. Maturing may take up to 100 charge/dis- 32
28
24
20
16
12
8
4
TROUBLESHOOTING ..................................................................................................................... J - 1
POWER SUPPLY............................................................................................................................. J - 6
LIST OF ILLUSTRATIONS
Fig. 1 DVOM.................................................................................................................................... J - 1
Fig. 2 36 Volt Wiring Diagram ......................................................................................................... J - 2
Fig. 3 48 Volt Wiring Diagram ......................................................................................................... J - 3
Fig. 4 36V Accessory Wiring Harness............................................................................................. J - 4
Fig. 5 48V Accessory Wiring Harness............................................................................................. J - 5
Fig. 6 Ignition Switch, Direction Selector, State of Charge Meter, Hour Meter, Horn Button .......... J - 7
Fig. 7 Horn, Fuse Block................................................................................................................... J - 8
Fig. 8 Turn Signal, Headlight, Tail Light .......................................................................................... J - 9
Notes:
BRAKE LINKAGE.............................................................................................................................K - 2
BLEEDING BRAKES........................................................................................................................K - 8
LIST OF ILLUSTRATIONS
Fig. 1 Hydraulic Brake System ........................................................................................................K - 1
Fig. 2 Brake Linkage Adjustment ....................................................................................................K - 2
Fig. 3 Front Brake Shoe Adjustment ...............................................................................................K - 3
Fig. 4 Centering Brake Shoes .........................................................................................................K - 3
Fig. 5 Accessing Front Brake ..........................................................................................................K - 4
Fig. 6 Bearing Adjustment ...............................................................................................................K - 5
Fig. 7 Rear Brake Shoe Adjustment................................................................................................K - 7
Fig. 8 Brake Shoe Replacement .....................................................................................................K - 7
Fig. 9 Bleeding Brakes ....................................................................................................................K - 8
Fig. 10 Bleeder Valve ......................................................................................................................K - 9
Fig. 11 Parking Brake System.......................................................................................................K - 10
Fig. 12 Parking Brake....................................................................................................................K - 11
Fig. 13 Parking Brake Adjustment.................................................................................................K - 11
Notes:
Front of Vehicle
Part of
Frame
Master Front Brake
Cylinder Line
Part of
Frame
Part of
Body
Rear Brake
Line
Part of
Frame
HOW THE BRAKE SYSTEM WORKS Master Cylinder Removal and Replacement
A hydraulic system is used to actuate the brakes. The During this process, it is likely that
system transmits the power required to activate the fric- brake fluid will leak from the master cyl-
tion surfaces (shoes or pads) of the braking system from inder. Avoid allowing brake fluid to contact the painted body
the pedal to the individual brake units at each wheel. components of the vehicle. Wipe off immediately.
The hydraulic system operates as follows: Clean the area around the master cylinder to prevent dirt
and grease from contaminating the cylinder or hydraulic
When at rest, the entire system is full of brake fluid. Upon
lines.
application of the brake pedal, fluid trapped in front of the
master cylinder piston is forced through the lines to the Disconnect the brake light terminal and the brake lines at
wheel cylinders. Here, it forces the pistons outwards the branch tee.
against the brake shoes or pads which in turn contact the Remove the hardware that secures the master cylinder
brake drum or disc. Upon release of the brake pedal, a to the vehicle and remove the master cylinder from the
spring located inside the master cylinder immediately vehicle(Ref Fig. 1 on page K-1).
returns the piston to the normal position. The brake shoe
Remove the reservoir cover and drain the brake fluid
return springs retract the brake shoes and wheel cylin-
from the reservoir.
ders which returns the brake fluid to its original position
within the master cylinder. Refer to ‘Front Hydraulic Disc Master Cylinder Installation
Brakes’ for additional information. Reinstall hardware securing master cylinder to frame.
Reinstall brake lines and brake light terminal to branch
BRAKE MASTER CYLINDER FLUID tee to 70 - 80 in. lbs. (8 - 9 Nm).
Hydraulic brake systems must be totally Replace brake fluid into reservoir and bleed system per
flushed if the fluid becomes contaminated with ‘Bleeding Brakes’.
water, dirt or other corrosive chemicals. To flush, bleed the
entire system until all brake fluid has been replaced with fresh
DOT 3 standard automotive brake fluid. BRAKE LINKAGE
It is important to maintain proper fluid levels in the brake Tool List Qty. Required
master cylinder. The fill cap for the cylinder is located Wrench, 9/16" ..............................................................1
under the seat. To prevent contamination when checking
the fluid, wipe off any dirt from the fill cap before remov- The master cylinder has built in free travel.
ing it. Fluid level should be maintained at 1/8" (3 mm)
below the top of the housing. Use DOT 3 standard auto-
motive brake fluid.
2
MASTER CYLINDER SERVICING
The usual reason for a master cylinder failure is the cylin- Front of Vehicle
der seals (cups) deteriorate. Fluid leaks past the cups
and shows as an external leak. A common symptom is a
3
‘spongy’ brake pedal that goes all the way to the floor 6
when all the other brake components are in good condi- 4
tion. The rubber parts wear with usage or deteriorate with 1
age or fluid contamination. Corrosion or deposits formed Shorten
in the cylinder bore due to moisture or dirt in the hydrau- Lengthen
lic system may result in wear of the cylinder bore or
related parts. The manufacturer of you vehicle does not
recommend disassembly or rebuilding of the master cyl-
5
inder. Replace a failed master cylinder with a new one.
Fig. 2 Brake Linkage Adjustment
The brake pedal linkage is set at the factory. However, if The vehicle may be equipped with an optional automo-
the master cylinder should have to be removed for any tive type brake drum and shoe system on the front
reason, the pedal will require readjustment. wheels. Should the braking be inadequate, adjustment
The master cylinder (1) is located under the floor access should be made at the wheel brake (Ref Fig. 3 on page
panel and is connected to the brake pedal (2) by an K-3).
adjustable linkage (Ref Fig. 2 on page K-2). The Raise the vehicle enough so that the wheel turns freely.
threaded operating rod (3) should be snug against the (See SAFETY Section for procedure and safety informa-
master cylinder piston (4) (inside cylinder, under rubber tion). The adjusters are eccentric cams (1) which push
boot (5)) with no pressure on the piston. the brake shoes (2) outwards. Loosen the lock nuts (3)
To adjust, loosen jam nut (6) on the rod and turn the rod on the rear of the backing plate (4) and attach a wrench
in the desired direction until it becomes snug against the to each of the adjusters. Raise both wrenches until the
piston. Tighten jam nut firmly. shoes contact the drum (5) and then back off slightly to
prevent the shoes from dragging. Tighten the lock nuts
firmly while holding each adjuster in place.
FRONT BRAKE SHOE ADJUSTMENT Rotate the wheel by hand and check that the brake
Tool List Qty. Required shoes are not contacting the brake drum.
Lug wrench, 3/4" ......................................................... 1
Jack............................................................................. 1 FRONT BRAKE SHOE CENTERING
Jack stands ................................................................. 4 Tool List Qty. Required
Open end wrench, 1/4" ............................................... 2
Lug wrench, 3/4" ......................................................... 1
Open end wrench, 9/16" ............................................. 1
Jack ............................................................................. 1
The front brakes are adjusted in a different way Jack stands ................................................................. 4
from the rear. Open end wrench, 1"................................................... 2
Eccentric
Adjuster 3
1
1
2
4
5
2
Fig. 3 Front Brake Shoe Adjustment
Fig. 4 Centering Brake Shoes
Brake shoes (1) are centered at the factory, however, in FRONT BRAKE DISASSEMBLY
the event that the heel pin (2) should come loose or the
brake has a ’spongy’ feel that bleeding the brakes does Tool List Qty. Required
not rectify, the brake shoes should be centered (Ref Fig. Lug wrench, 3/4"..........................................................1
4 on page K-3). Jack .............................................................................1
Loosen the heel pin nut (3) on the rear of the backing Jack stands..................................................................4
plate (4) and apply the brakes (brake drum in place). Straight blade screwdriver ...........................................1
With the brakes applied, tighten the heel pin lock nut.
Open end wrench 1 1/16" ............................................1
Needle nose pliers .......................................................1
Rubber faced hammer .................................................1
Non ferrous punch .......................................................1
Ball peen hammer .......................................................1
Front of Vehicle
6
7
5 4
To prevent damage to the hub bore, use Clean all bearings, grease seal, hub and dust cap in sol-
a non ferrous punch to tap out the bear- vent and dry thoroughly. Inspect for signs of damage. Pit-
ing race. Tap opposite sides of the race while moving the punch ting or a blue coloration of the rollers will require
around the circumference of the race. replacement of the bearing. If the roller portion of the
bearing is to be replaced, the race must also be
If the brake drum cannot be removed, the
brake shoes may need to be retracted by rotat-
replaced.
ing the adjusters in the opposite direction to that shown (Ref The front wheel bearings are tapered roller type and
Fig. 7 on page K-7). If after retracting the shoes, the brake drum must be packed with grease at installation or any time
still remains in place, tap brake drum with a plastic faced ham- the bearing is removed for inspection. It is recommended
mer to release it from the brake shoes. that a bearing packer attached to a grease gun be used;
If the outer roller bearing (6) is to be reused, protect it from con- however, manual packing is acceptable if done correctly.
taminants until ready for reuse. To pack a bearing manually requires that a dab of grease
be placed in the palm of the hand and the bearing be
To access the front brake assembly components (Ref
dipped in the grease. Force the grease up through and
Fig. 5 on page K-4):
around all of the rollers until the entire bearing is satu-
1. Remove the wheel and tire. rated in grease.
2. Remove the dust cap (1). Assemble hub and install on spindle. (Ref Fig. 6 on page
3. Remove the cotter pin (2) from the castle nut (3) and K-5)
discard.
4. Remove the castle nut (3), and pull the brake drum WHEEL BEARING ADJUSTMENT
(4) away from axle.
Tool List Qty. Required
If the roller bearings (5) are to be replaced, remove the
grease seal (6) and the inner roller bearing (7). Socket, 1 1/2", 1/2" drive ............................................. 1
Ratchet, 1/2" drive ....................................................... 1
When replacing roller bearings, the races (5, 7) should
be replaced. Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Adapter, 3/8" drive to 1/2"............................................ 1
Assembly is in the reverse order of disassembly. Always
use a new cotter pin. Torque wrench, 3/8" drive, in. lbs. ............................... 1
If performing a wheel bearing adjustment only, lift and Thoroughly clean the backing plate of all brake dust
support front of vehicle per SAFETY section. Remove using a commercial brake cleaner following the cautions
dust cap (1) and cotter pin (2) and loosen castellated nut and warnings provided with the product. Look for signs of
(3). corrosion and remove using emory cloth. Loosen the
If performing a wheel bearing adjustment as part of brake adjusters and rotate them to the lowest position.
another procedure, make sure wheel is mounted to hub Inspect the wheel cylinder for signs of wear or fluid leak-
hand tight with lug nuts (4) and hub is loosely retained on age and replace if any is found (Brake bleeding is man-
spindle (5) with castellated nut (Ref Fig. 6 on page K-5). datory any time the hydraulic system is opened). Apply a
commercial brake lubricant following the cautions and
Seat bearings by rotating wheel while tightening castel- warnings provided with the product to the heel pin and
lated nut until slight resistance is felt. the contact surface of the brake shoe where it contacts
Rotate the wheel 2 - 3 more turns to displace excess the wheel cylinder. Install the lower brake shoe and apply
grease. If required, tighten castellated nut (3) again until a light coat of lubricant to the area around the heel pin
slight resistance is felt. If the cotter pin hole in the spindle before installing the outer brake shoe. Install the heel pin
(5) aligns with a slot in the castellated nut, insert a new retaining ring and install the brake shoe return spring.
cotter pin (2). If the hole does not align, the castellated Inspect to see that there is no lubricant on the friction
nut must be loosened to align with the closest available surface.
slot in the nut. Inspect the brake drum for excessive wear, gouges or
Check for smooth and free rotation of the wheel and an signs of overheating. If evidence is found, replace the
absence of play when the wheel is grasped by the out- drum and do not attempt to true it. Reassemble brake
side of the tire. Bend the cotter pin (2) against the flats of drum and hub and adjust bearings. See ‘WHEEL BEAR-
the castellated nut (3). ING PACKING’ on page L-5.
Replace the dust cap (1) and lower vehicle per SAFETY Adjust brakes See ‘FRONT BRAKE SHOE ADJUST-
section. MENT’ on page L-3.
If completing a wheel bearing adjustment as part of
another procedure, tighten front wheels per WHEELS REAR BRAKE SHOE ADJUSTMENT
AND TIRES section.
Tool List Qty. Required
Lug wrench, 3/4"..........................................................1
FRONT BRAKE SHOE REPLACEMENT Jack .............................................................................1
Remove the hub and drum See ‘FRONT BRAKE DISAS- Jack stands..................................................................4
SEMBLY’ on page L-4. Brake adjusting tool .....................................................1
Remove the return spring from both brake shoes. Rubber faced hammer .................................................1
Remove the retaining ring from the heel pin.
Never work on a vehicle
Pivot both shoes out from the wheel cylinder and pull ! !
supported by a jack
brake shoes from the heel pin. alone. To prevent possi-
Inspect the brake shoes. If any portion of the shoe is ble personal injury, the vehicle must be supported on
worn below 0.060" (1.5 mm) both brake shoes on both jack stands during this procedure.
front wheels must be replaced. The vehicle is equipped with an automotive type brake
If the top of one shoe and the bottom of the other show drum and shoe system on the rear wheels. Should the
excessive wear, center the brake shoes See ‘FRONT braking be inadequate, adjustment should be made at
BRAKE SHOE CENTERING’ on page L-3. the wheel brake. Use the following adjustment proce-
dure:
Tool List Qty. Required
1. At the brake to be adjusted, loosen the lug nuts 1/2
Needle nose pliers....................................................... 1 turn.
Snap ring pliers ........................................................... 1 2. Raise the vehicle enough so that the wheel turns
Commercial brake cleaner ....................................... AR freely. (See SAFETY Section for procedure and
Commercial brake lubricant...................................... AR safety information.) Remove the lug nuts and wheel.
3. Remove the brake drum and inspect the brake shoes ble personal injury, the vehicle must be supported on
to determine that at least 0.060" (1.52 mm) brake jack stands during this procedure.
shoe material remains.
The factory recommends changing all brake
If the brake drum cannot be removed, the shoes at the same time because proper adjust-
brake shoes may need to be retracted by rotat- ment will result in even wear of all brake shoes.
ing the star wheel in the opposite direction to that shown (Ref
Fig. 7 on page K-7). The star wheel is accessed through the Prior to making the repairs included in this section, check the
slot in the brake drum and adjusted with a brake adjusting tool pedal adjustment, the cylinder fluid level and the brake shoe
or a flat blade screwdriver. If after retracting the shoes, the adjustment.
brake drum still remains in place, tap brake drum with a plastic
faced hammer to release it from wheel bolts.
Adjuster
Brake Shoe
Rotate to
expand shoes
Brake
Shoe
Grn
Red
Torsion
Spring
Fig. 7 Rear Brake Shoe Adjustment Extension Adjuster Retainer
Spring
a) If shoe replacement is not required, the shoes
must be adjusted. Replace brake drum. Note that
Fig. 8 Brake Shoe Replacement
the slot in drum must be aligned with adjuster.
b) Rotate the star wheel adjuster one full turn at a The shoes should be replaced whenever any portion of
time through opening in drum until the brake the shoe material is less than 0.060" (1.52 mm), the
shoes contact the brake drum (Ref Fig. 7 on page braking effect has diminished or the brakes start squeak-
K-7). ing and proper adjustment does not remedy the problem.
c) Loosen star wheel 3 ‘clicks’. Rotate the brake Always replace both shoes at both wheels. Use the fol-
drum, if any drag is encountered, the star wheel lowing procedure for shoe replacement:
may be loosened one additional ‘click’. If the drum 1. At the rear wheels, loosen the lug nuts 1/2 turn.
still binds, repeat the adjustment procedure. If the
2. Raise the vehicle and support with jack stands. (See
drum continues to bind, the drum should be
SAFETY Section for procedure and safety informa-
checked for a warped or out of round condition.
tion.)
3. Remove wheel and brake drum as described in previ-
REAR BRAKE SHOE REPLACEMENT ous section.
Tool List Qty. Required 4. To remove the shoes, remove the extension spring
Wrench, 11/16"............................................................ 1 from the hole in each brake shoe. Remove the torsion
springs and retainers. Remove the adjuster. With
Needle nose pliers ...................................................... 1
these springs removed, the brake shoes can be
Brake cleaner .......................................................... A/R removed (Ref Fig. 8 on page K-7).
Brake lubricant ........................................................ A/R
5. Separate, clean and lubricate the adjuster with com-
Never work on a vehicle mercially available products. Screw the adjuster
! ! supported by a jack together to achieve its shortest length.
alone. To prevent possi- 6. Reassemble the brake in the reverse order of assem-
bly. Note that the slot in the drum must be in line with BLEEDING BRAKES
adjuster.
7. After assembly, the brakes should be adjusted as pre-
viously detailed.
Bleeder
Valve
PARKING BRAKE
The parking brake is operated by a lever located
between the front seats through cables to the rear wheel
brake mechanical actuators (Ref Fig. 12 on page K-11)
Bracket
Linkage Rod
Bell Crank
Front of Vehicle
Equalizer
Part of Frame
Spherical Nut
Jam Nut
Part of
Suspension Brake Cable
Front of Vehicle
Front of Vehicle
Part of
Frame
Notes:
GENERAL ........................................................................................................................................ L - 1
Shock Absorber Removal...................................................................................................... L - 1
Shock Absorber Installation................................................................................................... L - 1
Rear Spring Removal ............................................................................................................ L - 1
Rear Spring Installation ......................................................................................................... L - 2
LIST OF ILLUSTRATIONS
Fig. 1 Shock Absorber Replacement............................................................................................... L - 1
Fig. 2 Spring Replacement.............................................................................................................. L - 2
Notes:
7
8
3
2
4 9
5 12
10
11
LIST OF ILLUSTRATIONS
Fig. 1 Run - Tow/Maintenance switch ............................................................................................ M - 1
Fig. 2 Disconnecting Parking Brake Cables ................................................................................... M - 1
Fig. 3 Disconnecting Brake Lines................................................................................................... M - 2
Fig. 4 Rear Axle Removal .............................................................................................................. M - 2
Fig. 5 Motor Wiring ......................................................................................................................... M - 3
Fig. 6 Removing Brake Drum ......................................................................................................... M - 3
Fig. 7 Removing Backing Plate Nuts.............................................................................................. M - 4
Fig. 8 Removing Oil Seal with Puller .............................................................................................. M - 4
Fig. 9 Wheel Bearing Removal....................................................................................................... M - 4
Fig. 10 Components Orientation .................................................................................................... M - 4
Notes:
ility of con
Possib removing/ W/MAIN
and
EN AN
TENA
NCE'
s
is mandatory.
ce swi second
Before tch to 'TO system pla e. of 30
turn swi cal wir imu m
ctri tery
able ele ove bat w a min
To dis n and rem es, allo
Brake
Fig. 5 Motor Wiring Drum
Front of Vehicle
Backing Plate
Front of Vehicle
Wheel Bearing
Nuts
Retainer
Ring
Brake Drum
Wiper Seal Brake Shoe
Backing Plate
Backing
Plate
Fig. 8 Removing Oil Seal with Puller Nuts Bearing Retainer
Oil Seals
Inspect oil seals for signs of leaking. Look for cuts or
cracks. Be sure the spring on the inside of the seal lip is
in place.
Notes:
Notes:
PAINTING III.
N
Apply spray touch up paint in light even overlapping
strokes. Multiple coats may be applied to provide
All pa inti ng m ust be adequate coverage and finish. Always remember to
! ! done in an area with ade- shake the can for a minimum of one minute to mix
quate ventilation to safe- the paint and achieve the best color match.
ly disperse harmful vapors.
IV. After painting, allow to dry overnight. Smooth the
Wear eye protection and respirator, following manu-
mask lines using 400 grit “wet” sand paper to blend
facturers instructions to protect from overspray and
touch up area level with the rest of the part being
air borne mist.
repaired. Use a polishing compound (3M Finesse or
Provide protection from overspray to automotive grade) to renew gloss and to further
vehicle and surrounding area. blend and transition newly painted surface.
Follow the paint manufacturer’s recommendations for
specific painting procedures and information. V. Clean with alcohol and dry.
Larger Scratches
For larger scratches, the manufacturer suggests the fol-
lowing steps be taken to repair the Durashield™ body:
Notes:
STEERING .......................................................................................................................................P - 1
LIST OF ILLUSTRATIONS
Fig. 1 Steering System ....................................................................................................................P - 1
Fig. 2 Front Suspension ..................................................................................................................P - 2
Fig. 3 Front Shock Absorbers..........................................................................................................P - 3
Fig. 4 Steering Wheel Removal.......................................................................................................P - 3
Fig. 5 Steering Box..........................................................................................................................P - 4
Fig. 6 Bushings................................................................................................................................P - 4
Fig. 7 Lubrication.............................................................................................................................P - 5
Fig. 8 Wheel Bearing Replacement.................................................................................................P - 6
Fig. 9 Seal Installation .....................................................................................................................P - 6
Fig. 10 Front Spindle and Bearing...................................................................................................P - 6
Fig. 11 Front Wheel Alignment........................................................................................................P - 7
Fig. 12 Camber Adjustment.............................................................................................................P - 8
Notes:
Front of Vehicle
3
6 8
7
Part of Frame
5
9
FRONT SUSPENSION end of the transverse spring. The lower end of the king
pin and spindle assembly is attached to a lower control
The front suspension consists of a transverse leaf spring
(1) clamped to a spring perch (2) bolted to the vehicle arm (4) that is mounted to support brackets (5 & 6) that
frame (Ref Fig. 2 on page P-2). The upper end of the are bolted to the vehicle frame. Eccentric bolts (7) pass
king pin and spindle assembly (3) is attached to the outer through the brackets and the lower control arm.
5
7
Shock Absorbers F
5
A shock absorber perch (1) is bolted to the top of the
spring perch (2) and a ‘U’ bolt (3) secures the lower
1
shock mount (4) to the king pin and spindle assembly (5) 4
(Ref Fig. 3 on page P-3). The shock absorber (6) is
mounted between upper and lower shock mounting
studs.
3
F
1 2
6
3
Fig. 4 Steering Wheel Removal
4
Steering Box Removal
5
Roll up the rubber boot (1) at the bottom of the steering
shaft (2) to expose the set screw (3) in the ‘U’ joint (4)
(Ref Fig. 5 on page P-4). Loosen the set screw (3).
Fig. 3 Front Shock Absorbers Loosen the bolt (5) and remove the nuts, washers, spac-
Steering Wheel Removal. ers and clamp (6, 7, 8 & 9) that secure the steering col-
umn (10) to the vehicle dash. Remove the steering
The steering wheel (1) is secured to the steering shaft (2)
column (10) and shaft (2) from the steering box (11).
with a roll pin (3) and a nut (4). The nut is covered by a
Raise the vehicle per SAFETY Section B and support on
decorative blank cover (5) (Ref Fig. 4 on page P-3). To
Jack stands. Remove the cotter pin (12) and castellated
remove the steering wheel, remove the decorative cover
nut (13) from the drag link (14) where it joins to the pit-
to expose the nut. Remove the nut and drive out the roll
man arm (15). Use a ball joint separator (pickle fork) to
pin. The steering wheel can now be removed.
separate the ball joint (16) from the pitman arm (15).
Installation is in the reverse order of disassembly. Remove the three bolts (17) and washers (18) securing
Tighten the nut to 91 ft. lbs. (123 Nm) torque. A new roll the steering box (11) to the vehicle frame and remove the
pin is recommended. steering box (11).
Tighten the castellated nut to 46 ft.lbs. (62 Nm) torque using a ball joint separator (pickle fork). Always use a
and be sure to use a new cotter pin. new cotter pin when installing the castellated nut.
F Front Suspension Disassembly
If the vehicle is equipped with front
brakes, the brake assemblies must be
secured with tie wraps or wire, to prevent strain being applied to
the brake hoses.
Service of the front suspension requires that the vehicle
be raised and supported on jack stands as per lifting
2 instructions in Section B SAFETY.
For unspecified torques refer to standard torque table.
6 10
F
7
9
5
8
Part of 7
Cowl 8 1
9
1 10
11
4 6
3
4
15
11
16 3
14 5
13
12
2
Part of Frame
18
17
Fig. 6 Bushings
Fig. 5 Steering Box The front suspension of the vehicle is very robust, and
with regular lubrication should require little or no mainte-
Tighten the set screw to 16 ft. lbs. (22 Nm) torque. Worn
nance (Ref Fig. 6 on page P-4). Primary wear items are
tie rod ends can be replaced in the conventional way
bushings which are located in the upper (1) and lower (2)
spring to king pin assemblies and the bushings in the
lock washer (9) securing the large clevis (10) to the king
pin. Remove the nut (8) and separate the components of
the king pin and spindle assembly, being careful to note
the location of components. Be sure to reinstall the shims
(11) in their original location to maintain correct clear-
ances of .001 to .011 between the spindle casting and
the king pin assembly. The bushings may be replaced
2 King Pins
and the assembly reassembled. Tighten the king pin nut
(8) to 100 - 130 ft. lbs. (135 - 175 Nm) torque. 4 Wheel Bearings
“PACK”
Lubrication
Tool List Qty. Required
Grease gun ................................................................. 1 4 Ball Joints
Bearing Adjustment
Assemble hub with bearings (1) on spindle (2). Reinstall
wheel on hub. Rotate the wheel while tightening the cas-
tellated nut (3). (Ref Fig. 10 on page P-6) Tighten the
castellated nut (3) until slight resistance to rotation is
10 7
noticed.
2 5
9 8
3 4 6
1
2
Before attempting a wheel alignment, thoroughly inspect adjustment of the drag link, remembering to tighten the
for worn/loose bushings or bearings and replace/adjust castellated nuts and install a new cotter pin.
as required. A wheel alignment cannot be done unless
the entire front suspension is without excess play. Wheel Alignment (Camber)
Turn the steering wheel from lock to lock and then center Tool List Qty. Required
the steering wheel in the center of travel. Check to see
that the front wheels are pointing straight ahead. If not, Floor jack..................................................................... 1
adjust the drag link between the Pitman arm and the front
spindle arm until the wheels are straight ahead with the Jack stands ................................................................. 2
steering box at the center of travel. Tighten the castel- Wheel chocks .............................................................. 4
lated nut and install a new cotter pin.
Box end wrench, 1 1/4" ............................................... 1
Rotate each wheel and scribe or chalk a line around the
circumference of the tire at the center of the tread pat- Tape measure.............................................................. 1
tern. Lower the vehicle and roll it forward approximately
five feet in order to allow the tires to take their normal Framing square ........................................................... 1
running position.
Before attempting a wheel alignment, thoroughly inspect
Measure the distance between the chalk lines at both the for worn/loose bushings or bearings and replace/adjust
front and rear of the tires. (Ref Fig. 11 on page P-7) The as required. A wheel alignment cannot be done unless
measurement taken at the front of the tire should be 1/4" the entire front suspension is without excess play.
+0 -1/8" (6.35 mm +0 -3 mm) less than the rear. This
adjustment provides a toe in of 1/2° to 1°. ALL measurements must be made with the vehicle
unloaded and on a level surface with the tires correctly
inflated (Ref Fig. 12 on page P-8).
Rear Lift the front of the vehicle and support on jack stands as
per Section ‘B’.
Fig. 11 Front Wheel Alignment Loosen the nuts securing the eccentric bolts and rotate
slightly. This will have the effect of lengthening or short-
ening the lower control arms. Tighten the nuts and lower
the vehicle.
To adjust the wheel alignment, loosen the tie rod jam
nuts and adjust the tie rods until the correct dimension is Recheck the camber and repeat the adjustment proce-
achieved. Lock the tie rod jam nuts 25 - 30 ft. lbs. (34 - 41 dure until the desired adjustment is achieved.
Nm) torque.Test drive the vehicle and confirm that the
steering wheel is correctly centered. If not, repeat the
Front of Vehicle
90o
Wheels
Straight
Ahead
X
X + 1/4"
Framing
(0.64 cm)
Square
FLAT SURFACE
90o
90o
Notes:
GS-726-006
REVISION:
A TITLE:
Q
EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding
10/19/92 Rev -, ECN 027194
1. Grounding Requirements
For the purpose of this specification, building ground systems should serve two primary functions: personal safety and
equipment protection. In order to be effective, all elements and functions of building ground system must receive equal
consideration in design and installation. Once installed, it is up to the owner to adequately maintain the system by imple-
menting periodic inspections and ground tests in order to determine its effectiveness.
2. Ground Systems
All electronic equipment is inherently related to earth by capacitive coupling, accidental or incidental contact and inten-
tional connection. The earth forms a natural readily available form of common potential reference for all electrical cir-
cuits. For maximum effectiveness, grounding must be looked at from a total system viewpoint, with various sub-systems
comprising the total facility ground system. The interconnection of the various sub-systems into a building ground sys-
tem will provide a direct path, of known low impedance, between earth and the various electrical and other equipment.
This effectively extends an approximation of ground reference throughout the building. The total building ground system
is composed of an earth electrode system, a lightning protection system and an equipment fault protective system.
Resistance To Earth: The resistance to earth of the ground system should not exceed 10 ohms. Where the resistance of
10 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, coke or other chemicals may be used to treat the soil in order to obtain the required
ground resistance readings. Approved methods of enhancement are bentonite clay or the GEM product for ground
enhancement as manufactured by Erico Products of Solon, Ohio.
Ground Tests: The resistance to earth of the ground system shall be measured by the “Fall of Potential Method”. Accept-
able resistance meters/testers are those manufactured by Biddle or AEMC.
REVISION:
GS-726-006 A TITLE:
7. Materials
Ground Rod Electrodes: Ground rod electrodes shall have a minimum diameter of 5/8" and be no less than 10'-0" in
length. Rods may be copper, copper-clad steel or stainless steel. Galvanized steel rods are not permitted unless it is
determined that the galvanized rod will have a longer life expectancy due to soil conditions.
Ground Rod Spacing: Ground rods shall not be spaced at intervals exceeding 60'-0" around the perimeter of the struc-
ture.
Ground Loop Conductor: In no case shall the ground loop conductor be smaller than a 2/0 AWG bare, stranded, soft
drawn copper wire. The ground loop must be installed at least 24" below grade and be at least 24" away from the struc-
ture. All bends in the conductor shall have a minimum radius of 8" and be no less than 90 degrees.
Ground Mats: In areas where electrodes cannot be driven, a ground mat consisting of a #6 solid copper or a copper-cop-
per clad steel mesh, utilizing a 12" x 12" cross pattern may be used. All inter-connections in the mesh shall be brazed or
silver soldered.
Ground Plates: Ground plates if utilized shall be 24" x 24" x .032" thick solid copper. Ground plates should only be used
if a ground rod cannot be driven.
Ground Connections: Unless otherwise specified or approved by the owner, all connections below grade shall be by exo-
thermic weld (Cadweld). Where exothermic welds may not be practical, UL approved grounding clamps that utilize two
bolts for pressure may be used. NOTE: Prior approval must be obtained in order to use a mechanical connection below
grade.
An electrode may be a metallic water pipe that has no isolation joints, a system of buried, driven rods interconnected
with a bare wire that normally forms a ring around the building or a ground plane of horizontal buried wires. Depending
upon soil conditions, building design and the existing water pipe networks, an electrode may be a combination of any of
the above mentioned systems.
REVISION:
GS-726-006 A TITLE:
Install the green wire ground (#6 stranded) with the AC power distribution conductors. There shall be no green wires
spliced within the conduit. All splices shall be performed at the appropriate junction boxes.
Bond the ground conductor to 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 insulated from other conduit sections, an external ground conductor may be installed to main-
tain continuity. All mounting hardware and connectors shall be UL approved.
All DC chargers are to be grounded to the green wire ground using UL approved connectors. At no point should the
chargers be isolated from the grounding system.
All interior grounding should return to a single ground point. From this location it is then connected to the exterior ground
system. Optional Interior Ground Halo: If an interior ground halo is to be installed around the inside perimeter of the
structure, this conductor (#2/0 green insulated minimum) shall be securely fastened to the structure.
Transient Voltage Surge Suppression: TVSS shall be provided at the main electrical service entrance panel. Protection
at this point shall be as follows:
UL 1449 Listed device
25,000 ampere surge capacity with maximum 495 volt clamping voltage
Protection should be Line to Ground, Neutral to Ground and Line to Neutral
Internally fused for safety
Failure mode indicator lights
Suppression may be as the 14000 series of Harger Lightning Protection, Inc., 1066 Campus Drive, Mundelein, IL (800-
842-7437), or MBP 120EFI series from EFI Electronics Corporation, 2415 South 2300 West, Salt Lake City, UT (801-
977-9009).
REVISION:
GS-726-006 A TITLE:
Notes:
Notes:
ELECTRICAL SYSTEM
R
Condition Possible Cause Correction
VEHICLE WILL NOT MOVE Key ‘OFF’ or no direction selected Turn key ‘ON’ and select direction
(36 VOLT VEHICLES)
Batteries discharged Charge batteries
Refer to (Electronic Speed
Control Section (48Volt) for 48 Volt ve- Batteries unable to be charged Load test and replace batteries that
hicles cannot be charged
Corroded or loose battery Clean and tighten battery connections
connections Apply a coat of commercial terminal
protectant to all terminals
Corroded or loose battery connections Repair or replace faulty wiring
to ESC controller, direction switch or
motor
Solenoid has failed Replace solenoid
Key switch has failed Replace key switch
Micro switch at direction selector Replace micro switch
switch has failed
Connector loose or separated Install connector correctly
Faulty motor Repair or replace motor
Faulty ESC system Test and replace components as
indicated by test procedure
Ignition interlock switch has failed Replace relay (on-board charger)
VEHICLE SPEED ERRATIC Faulty ESC system Test and replace components as
indicated by test procedure
NO REDUCED SPEED IN REVERSE Faulty ESC system Test and replace components as
indicated by test procedure
MOTOR NOISY Damaged bearing Replace bearing
Raised commutator bar(s) Replace motor
Loose motor mounting hardware Tighten
BATTERIES WILL NOT CHARGE Charger not functioning correctly Repair or replace charger
Vehicle charging wiring faulty Repair or replace wiring
Vehicle/charger connector damaged Replace connector
Battery case damaged Replace battery
Low electrolyte level Maintain correct electrolyte level
Battery capacity deficient Hydrometer/load test
Replace battery, if required
Damaged battery Replace battery
PLAY IN STEERING Steering wheel loose Check roll pin. Replace steering wheel,
if required
Tighten steering wheel nut
Steering components worn Replace
Loose wheel bearings Adjust or replace
VIBRATION Steering components worn Replace
Damaged wheel bearings Replace
Out of round tires, wheels or brake Inspect and replace, if out of round
drums
Loose lug nuts Tighten to 50 - 85 ft. lbs. (68 - 115 Nm)
STEERING PULLS TO ONE SIDE Incorrect tire pressure Inflate to recommended pressure
Dragging wheel brake Service brake system
Suspension component failure Repair
Improper alignment Align
Notes:
LIST OF ILLUSTRATIONS
Fig. 1 Vehicle Dimensions...............................................................................................................S - 4
Fig. 2 Vehicle Dimensions and Incline Specifications .....................................................................S - 5
Fig. 3 Vehicle Turning Clearance Diameter ....................................................................................S - 6
Notes:
46 in
(117cm)
29 in
(74 cm)
46 in
(117cm)
29 in
(74 cm)
44.5 in
(113 cm)
RECOMMENDED
36.75 in (93 cm) Front
MAX SIDE TILT
25% or 14o MAX 38.25 in (98 cm) Rear
RECOMMENDED
MAX RAMP GRADE
25% or 14o MAX
22 ft. (6.7 m)
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This manual may not be reproduced in whole or
in part without the express permission of
E-Z-GO Division of Textron Inc.
Technical Communications Department