PDF Service Manual E-Z-GO Electric Personnel Carrier & Golf Car - 1 MB
This repair and service manual covers a range of E-Z-GO Textron electric-powered personnel carriers and golf cars.
It is an essential resource for technicians and fleet managers responsible for maintaining these vehicles.
The manual includes detailed information on battery care, electrical system troubleshooting, motor service, and chassis repair.
Keep your fleet running reliably and efficiently with this comprehensive guide.
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--- Page 1 ---
600938
A Textron Company
TECHNICIAN’S
REPAIR AND SERVICE MANUAL
ELECTRIC POWERED
PERSONNEL CARRIERS
AND GOLF CAR
ISSUED SEPTEMBER 2004 REVISED NOVEMBER 2010
--- Page 3 ---
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Rubber parts should be cleaned with non-abrasive • Battery Maintenance Kit for complete battery
household cleaner. cleaning and watering, with battery maintenance
Occasional cleaning and waxing with non-abrasive prod- instructions (P/N 25587-G01).
ucts designed for ‘clear coat’ automotive finishes will • Biodegradable Cleaner that cleans the toughest
enhance the appearance and durability of the painted dirt and heavy soils by breaking down grease to
surfaces. be easily wiped or rinsed away (P/N 75507-G01).
Corrosive materials used as fertilizers or for dust control
• Multi-purpose Value Pack sampler package
including 4 ounce (118 ml) aerosol cans of Battery
can collect on the underbody of the vehicle. These mate-
Protector, Penetrant/Lubricant, White Lithium
rials will accelerate corrosion of underbody parts. It is
Grease, and Carburetor and Choke Cleaner (P/N
recommended that the underbody be flushed occasion-
75508-G01).
ally with plain water. Thoroughly clean any areas where
mud or other debris can collect. Sediment packed in
• Plexus plastic cleaner and polish removes minor
scratches from windshield (P/N 28433-G**).
closed areas should be loosened to ease its removal,
taking care not to chip or otherwise damage paint.
TOP AND WINDSHIELD
VEHICLE CARE PRODUCTS The top does not
To help maintain the vehicle, there are several products ! ! provide protection
available through local Distributors, authorized from roll over or fall-
Branches, or the Service Parts Department. ing objects.
• Touch-up paint specially formulated to match vehi- The windshield does not provide protec-
cle colors for use on TPE (plastic) bodies (P/N tion from tree limbs or flying objects.
28140-G** and 28432-G**). The top and windshield are designed for weather protec-
• Multi-purpose Battery Protectant formulated to tion only.
form a long-term, flexible, non-tacky, dry coating
Clean with lots of water and a clean cloth. Minor
that will not crack, peel or flake over a wide tem-
scratches may be removed using a commercial plastic
perature range (P/N 75500-G01).
polish or Plexus plastic cleaner available from Service
• White Lithium Grease designed to provide lubrica-
Parts Department.
tion protection in areas where staining or discolor-
ing is a problem, or in areas of extreme
temperature ranges (P/N 75502-G01).
• Penetrant/Lubricant, a 4-in-1 product that pene-
trates the most stubborn of frozen parts, lubricates
leaving a light lubricating film, prevents corrosion
by adhering to wet or dry surfaces and displaces
moisture, sealing against future moisture return
(P/N 75503-G01).
• Multi-purpose Cleaner and Degreaser that con-
tains natural, environmentally safe solvents (P/N
75504-G01).
• Multi-purpose Hand Cleaner is an industrial
strength cleaner containing no harsh solvents, yet
gently lifts grease off hands. May be used with or
without water (P/N 75505-G01).
• Battery Cleaner that promotes easy, non-violent
neutralization of battery acids and battery acid
crystals. The resulting sodium salts are water sol-
uble and easily washed away (P/N 75506-G01).
Repair and Service Manual Page A-3
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SAFETY
Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
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.
Repair and Service Manual Page B-5
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BODY
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes,
BODY
C
that the rivet head be removed in order to push out the
shank of the rivet. The rivet head is easily removed by
In the following text, there are references to
drilling into the head with a sharp drill bit that is slightly
removing/installing bolts etc. Additional hard-
ware (nuts, washers etc.) that are removed must always be larger than the shank of the rivet (Ref Fig. 1 on page C-
installed in their original positions unless otherwise specified. 1). Care must be exercised when drilling to prevent the
Non-specified torques are as shown in the table in Section A. drill from being forced through and damaging compo-
General nents where it could damage components located imme-
To prevent possible diately behind the rivet. The best way to prevent this from
! ! injury or death from occurring is to use a sharp drill bit that requires very little
battery explosion. pressure to cut successfully and to place a piece of pro-
Batteries should always be removed tective sheet metal between the surface being drilled and
before any servicing that will generate components directly behind it.
sparks.
It is important to use a sharp drill bit Pop Rivet Drill out rivet
when removing the rivets on the side of head only
the vehicle. Extreme care must be used
when drilling out the rivets located in the
front of the body and the bottom side of
the body. Excessive pressure could
result in the drill bit being forced through
the body panel and penetrating a compo- Fig. 1 Drill Out Metal Rivet
nent. As extra protection, it is recom-
mended that a protective piece of sheet
metal be placed between the battery and BODY COMPONENT REPLACEMENT
the rivet. Use of a drill depth stop will
provide additional protection.
The body components can be replaced by removing the
In general, body component replacement can be accom-
securing hardware, replacing the component and secur-
plished with a minimum of specialized tools. Most body
components are held in place with conventional remov- ing with hardware in the same orientation as removed.
able hardware (nuts, bolts, washers and screws). Some The illustrations on the following pages indicate the
components are mounted with ‘pop’ rivets which require assembly methods for the various components.
Repair and Service Manual Page C-1
--- Page 6 ---
BODY
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Rocker Panel Removal Rear Fender Removal
Tool List Qty. Required Tool List Qty. Required
Ratchet, 3/8" drive ....................................................... 1
Phillips screwdriver bit, 3/8" drive ............................... 1
Socket, 7/16", 3/8 drive ............................................... 1
Phillips screwdriver ..................................................... 1
Lug wrench.................................................................. 1
Wrench, 1/4" ............................................................... 1
Wrench, 7/16".............................................................. 1
Wrench, 7/16" ............................................................. 1 3/8" drill ....................................................................... 1
Remove the following hardware. 3/16" drill bit................................................................. 1
Rivet gun ..................................................................... 1
The rocker panel (item 1) is held in place with two hori-
zontal screws, lock nuts and washers (items 2, 3 & 4). Small pry bar ............................................................... 1
the front attachment uses a rocker panel to fender flair Phillips screwdriver...................................................... 1
spacer (item 5) between the rocker panel and the side of Pliers ........................................................................... 1
the frame. The rear attachment uses a spacer (item 6)
Floor jack, 1 1/2 ton..................................................... 1
between the rocker panel and the side panel. Two addi-
tional truss head screws, spacers, washers and lock nuts Jack stands ................................................................. 2
(items 7, 8, 9 & 10), fasten the rocker panel to the floor- Wheel chocks .............................................................. 4
board and frame (Ref Fig. 9 on page C-11).
9
3
Front of Vehicle
4 3 7
5
4
2
8
8
5
7 6
9 1
2
10
1 3
4
6
2
Fig. 9 Rocker Panel Removal
Reassembly is the reverse of disassembly. It is recom-
mended that new lock nuts be used. Fig. 10 Rear Fender Removal
Repair and Service Manual Page C-11
--- Page 7 ---
FRONT SUSPENSION AND STEERING
TABLE OF CONTENTS FOR SECTION ‘E’
SECTION TITLE
EPAGE NO.
MAINTENANCE ...............................................................................................................................E - 2
Lubrication .............................................................................................................................E - 2
Wheel Bearing and King Pin Bushing Inspection ..................................................................E - 2
Wheel Bearing Packing .........................................................................................................E - 2
Wheel Bearing Adjustment ....................................................................................................E - 3
Wheel Alignment ...................................................................................................................E - 3
FRONT SUSPENSION ....................................................................................................................E - 5
Front Shock Absorber Replacement .....................................................................................E - 5
Front Axle Replacement ........................................................................................................E - 6
Axle Linkage Rod Replacement ............................................................................................E - 6
Front Spring Replacement.....................................................................................................E - 6
Hub Replacement..................................................................................................................E - 8
Wheel Bearing and Race Replacement ................................................................................E - 8
STEERING .....................................................................................................................................E - 10
Rack Ball Joint Replacement...............................................................................................E - 10
Tie Rod Inspection/Replacement ........................................................................................E - 11
Bellows Replacement ..........................................................................................................E - 12
Pinion Seal Replacement ....................................................................................................E - 12
Spindle Replacement ..........................................................................................................E - 13
Rack and Pinion Unit Disassembly and Inspection .............................................................E - 14
Rack and Pinion Unit Replacement.....................................................................................E - 15
Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance ...........................E - 15
Steering Wheel Replacement..............................................................................................E - 16
Steering Shaft and Column Replacement ...........................................................................E - 17
LIST OF ILLUSTRATIONS
Fig. 1 Axle Mounted Steering and Front Suspension......................................................................E - 1
Fig. 2 Lubrication Points..................................................................................................................E - 2
Fig. 3 Bearing Adjustment ...............................................................................................................E - 3
Fig. 4 Wheel Alignment ...................................................................................................................E - 4
Fig. 5 Disconnect Intermediate Shaft to Center Steering Wheel.....................................................E - 4
Fig. 6 Front Suspension Components.............................................................................................E - 5
Fig. 7 Axle Linkage Rod Replacement ............................................................................................E - 7
Fig. 8 Front Axle Alignment .............................................................................................................E - 7
Fig. 9 Hub Replacement..................................................................................................................E - 8
Fig. 10 Seal Installation ...................................................................................................................E - 8
Fig. 11 Wheel Bearing Replacement...............................................................................................E - 9
Fig. 12 Steering Components........................................................................................................E - 10
Fig. 13 Rack Ball Joint Installation ................................................................................................E - 11
Fig. 14 Tie Rod Replacement........................................................................................................E - 11
Fig. 15 Bellows Replacement........................................................................................................E - 12
Fig. 16 Pinion Seal Replacement ..................................................................................................E - 13
Fig. 17 Removing Brake Caliper ...................................................................................................E - 13
Fig. 18 Spindle Replacement ........................................................................................................E - 14
Fig. 19 Rack and Pinion Unit Disassembly ...................................................................................E - 14
Fig. 20 Spindle Contact with Front Axle ........................................................................................E - 16
Fig. 21 Checking Gap....................................................................................................................E - 16
Fig. 22 Clipboard Removal............................................................................................................E - 16
Fig. 23 Steering Wheel Replacement............................................................................................E - 16
Fig. 24 Steering Shaft and Column ...............................................................................................E - 17
Fig. 25 Small Retaining Ring Orientation ......................................................................................E - 18
Repair and Service Manual Page E-i
--- Page 8 ---
FRONT SUSPENSION AND STEERING
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Front of Vehicle
2
1
3
4
6
5
7
Fig. 11 Wheel Bearing Replacement
To install race (5), make sure bore of hub (1) is clean and
place new race over bore of hub. Evenly tap with ham-
mer and bearing driver to drive race fully in bore. Repeat
on other side of hub.
Clean spindle (2) and pack new bearings with grease.
See ‘Wheel Bearing Packing’ on page E-2.
Install inner wheel bearing (4) and new grease seal in
hub and mount hub to spindle. See ‘Hub Replacement’
on page E-7.Adjust bearing. See ‘Wheel Bearing Adjust-
ment’ on page E-3.
Replace the dust cap (7).
Lower vehicle per SAFETY section and tighten front
wheel(s) per WHEELS AND TIRES section.
Repair and Service Manual Page E-9
--- Page 9 ---
ELECTRONIC SPEED CONTROL
TABLE OF CONTENTS FOR SECTION ‘F’
SECTION TITLE
F
PAGE NO.
OPERATION ....................................................................................................................................F - 2
Pedal Box ..............................................................................................................................F - 3
Speed Sensor........................................................................................................................F - 3
Controller ...............................................................................................................................F - 3
GENERAL TROUBLESHOOTING ...................................................................................................F - 4
Symptoms..............................................................................................................................F - 4
Testing...................................................................................................................................F - 4
Testing Battery Voltage .........................................................................................................F - 4
Continuity Check ...................................................................................................................F - 5
Testing a Switch for Continuity ..............................................................................................F - 5
Testing a Solenoid for Continuity...........................................................................................F - 5
TROUBLESHOOTING DIAGRAMS .................................................................................................F - 6
INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT..................................F - 14
CONTROLLER REPLACEMENT...................................................................................................F - 17
SOLENOID REPLACEMENT.........................................................................................................F - 17
LIST OF ILLUSTRATIONS
Fig. 1 Performance Characteristics .................................................................................................F - 1
Fig. 2 Run-Tow/Maintenance Switch...............................................................................................F - 2
Fig. 3 Access to Pedal Box .............................................................................................................F - 3
Fig. 4 Controller and Solenoid.........................................................................................................F - 3
Fig. 5 Battery Reference Voltage ....................................................................................................F - 5
Fig. 6 Continuity Check of Switch....................................................................................................F - 5
Fig. 7 Continuity Check of Solenoid ................................................................................................F - 6
Fig. 8 48 volt Fault Codes ...............................................................................................................F - 7
Fig. 9 Controller Connectors and Connections ...............................................................................F - 8
Fig. 10 48 Volt Wiring Diagram ......................................................................................................F - 9
Fig. 11 J-1 Pin Connector Diagnostics ..........................................................................................F - 10
Fig. 12 J-1 Pin Connector Diagnostics (Continued) ......................................................................F - 11
Fig. 13 J-2 Pin Connector Diagnostics ..........................................................................................F - 12
Fig. 14 Secondary Wiring Diagnostics ..........................................................................................F - 13
Fig. 15 ITS and Plunger ................................................................................................................F - 14
Fig. 16 ITS Adjustment (Sheet 1 of 2) ...........................................................................................F - 15
Fig. 17 ITS Adjustment (Sheet 2 of 2) ...........................................................................................F - 16
Fig. 18 Controller Wiring................................................................................................................F - 18
Repair and Service Manual Page F-i
--- Page 10 ---
ELECTRONIC SPEED CONTROL
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Ground
Speed Input To Hand
F2
Held MAIN