Cushman Shuttle 2, Service Manual

Page 1: ...ELECTRIC POWERED UTILITY VEHICLE 625610 ISSUED MAY 2011 REVISED AUGUST 2012 TECHNICIAN S REPAIR AND SERVICE MANUAL 625614 ...

Page 2: ...red on a flat surface To prevent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS Limit speed by applying the service brake Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessive speed may caus...

Page 3: ...ormation contained in this Manual may be revised periodically by E Z GO and therefore is subject to change without notice E Z GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and E Z GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual TO CONTACT US NORTH AMERICA TECHNICAL ASSISTANCE WARRANTY PHONE 1 80...

Page 4: ...he United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE 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 B...

Page 5: ...NFORMATION ROUTINE MAINTENANCE A SAFETY B BODY C WHEELS AND TIRES D FRONT SUSPENSION AND STEERING E ELECTRONIC SPEED CONTROL F BRAKES FRONT DISC G BRAKES REAR MECHANICAL H ELECTRICAL SYSTEM J MOTOR K BATTERIES AND CHARGING L REAR SUSPENSION M REAR AXLE N WEATHER PROTECTION P TROUBLESHOOTING Q LIGHTING PROTECTION AND GROUNDING R GENERAL SPECIFICATIONS S ...

Page 6: ...Page iv Repair and Service Manual NOTES TABLE OF CONTENTS ...

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

Page 8: ...oval of a battery wire insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Remove the batteries or cover exposed terminals with an insulating material check the polarity of each battery terminal and be sure to rewire the batteries correctly use specified replacement parts Never use replacement...

Page 9: ...d 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 hea...

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

Page 11: ... THE ELECTRIC VEHICLE A 1 ROUTINE MAINTENANCE A 2 REAR AXLE A 2 BRAKES A 2 TIRES A 2 LIGHT BULB REPLACEMENT A 2 VEHICLE CLEANING AND CARE A 2 VEHICLE CARE PRODUCTS A 3 SUN TOP AND WINDSHIELD A 3 HARDWARE A 4 TORQUE SPECIFICATIONS A 4 PERIODIC SERVICE SCHEDULE A 5 LIST OF ILLUSTRATIONS Fig 1 Initial Service Chart A 2 Fig 2 Lubrication Points A 2 Fig 3 Torque Specifications A 4 Fig 4 Periodic Servic...

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

Page 13: ...ely secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehicle see GENERAL SPECIFICA TIONS for vehicle weight and load plus 1000 lbs 454 kg Lock the park brake and secure the vehicle using ratchet tie downs SERVICING THE ELECTRIC VEHICLE To prevent severe injury or death resulting from improper servicing techniques observe the following Warnings Do...

Page 14: ...r axle lubricant level is in the REAR AXLE section BRAKES After the vehicle has been put into service it is recom mended that the brakes be checked daily by performing a brake test To prevent severe injury or death resulting from operating a vehicle with improperly oper ating brake system the braking system must be properly maintained All driving brake tests must be done in a safe location with re...

Page 15: ...mmended that the underbody be flushed occa sionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas should be loosened to ease its removal taking care not to chip or otherwise damage paint VEHICLE CARE PRODUCTS To help maintain the vehicle there are several products available through local Distributors authorized Branches or the Ser...

Page 16: ...e 2 TORQUE SPECIFICATIONS Fig 3 Torque Specifications ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten all hardware in accordance with this chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque requi...

Page 17: ... condition loose terminals corrosion hold down hardware CL CL CL CL Batteries check electrolyte level fill if required C A C A C A C A Brakes smooth operation of pedal Fluid stopping distance Brakes aggressive stop test does brake hold on a hill Accelerator smooth operation Wiring loose connections broken or missing insulation Charger Receptacle clean connections CL CL CL CL Steering Assembly exce...

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

Page 19: ...TIONS WARNINGS AND DANGERS B 1 IMPORTANT SAFETY WARNING B 1 MODIFICATIONS TO VEHICLE B 1 GENERAL MAINTENANCE B 1 BEFORE SERVICING THE VEHICLE B 1 Additional Warnings B 2 BATTERY REMOVAL INSTALLATION B 3 LIFTING THE VEHICLE B 4 LIST OF ILLUSTRATIONS Fig 1 Battery Connections B 3 Fig 2 Lifting the Vehicle B 4 ...

Page 20: ...Page B ii Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SAFETY ...

Page 21: ...orrosive explosive or may produce high amperage or reach high temperatures Battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed in the t...

Page 22: ...arks away from the batteries Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement Be sure that the key switch is off and all electrical accessories are turned of...

Page 23: ...ng the hardware and lifting the retainer from the batteries Remove the batteries using a commercial battery carrier If the batteries have been cleaned and any acid in the battery rack area neutralized on a regular basis no corrosion to the battery racks or surrounding area should be present If any corrosion is found it should be immediately removed with a putty knife and wire brush The area should...

Page 24: ...lifting process When lifting the vehicle position jack stands only in the areas indicated To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 2 Center jack under the rear frame crossmember Raise vehicle and locate a jack stand under outer ends of rear axle Lower the jack and test the stability of the vehicle on the two jack stands Fig 2 Lifting the Vehicle Place...

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

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

Page 27: ...moval C 11 Load Deck Removal C 11 Bulkhead Removal C 12 Seat Back Removal C 12 Bed Frame Removal C 13 Seat Frame Removal C 13 Mid Support Removal C 14 Rear Bed Bracket Removal C 14 PAINTING C 15 Minor Scratches C 15 Large Scratches C 15 Complete Panel Repair C 15 LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Body Components Front C 2 Fig 3 Body Components Seats and Rear C 3 Fig 4 Bod...

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

Page 29: ...ll provide additional protection In general body component replacement can be accom plished with a minimum of specialized tools Most body components are held in place with conventional remov able hardware nuts bolts washers and screws Some components are mounted with pop rivets which require that the rivet head be removed in order to push out the shank of the rivet The rivet head is easily removed...

Page 30: ...ODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 2 Body Components Front 15 6 4 16 1 3 17 13 12 14 18 22 21 139 143 140 144 145 142 149 2 10 141 ...

Page 31: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 Body Components Seats and Rear 27 25 34 SHUTTLE 4 MODEL ONLY 69 72 68 73 67 75 76 71 70 46 47 32 34 33 55 53 54 49 50 56 53 54 51 52 44 43 45 26 18 ...

Page 32: ... of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 4 Body Components Cargo Box Seat Foot Rest Seat Bed Seat Back Support or Bed Frame 38 43 41 42 41 43 39 35 36 37 40 38 ...

Page 33: ...the key switch plate and push it through the instrument panel opening freeing the panel for removal Reassembly is the reverse order of disassembly and will require new drive rivets Cowl Replacement Tool List Qty Electric air Drill 1 Drill Bit 7 32 1 Wrench 5 16 1 Phillips Screwdriver 1 Rivet Gun 1 Duct Tape 1 Allen Key 3 16 1 Drill out the rivets 13 across the top of instrument panel 1 attaching i...

Page 34: ... 9 16 1 Rivet Gun 1 Phillips Screwdriver 1 Pry Bar 1 Torque Wrench 1 Refer to TORQUE SPECIFICATIONS in Section A for standard torque values unless otherwise noted in manual text To prevent possible injury or death from battery explosion The battery should always be removed before any servicing that will generate sparks It is important to use a sharp drill bit when removing the rivets on the side o...

Page 35: ...hardware 35 attaching rear option cargo bed or rear facing seat to the seat back supports 36 Remove the screws 37 that secure the seat back sup port to the vehicle frame Remove the hardware 38 that secures the seat back support to the frame support 39 Remove each seat back support and spacer 40 from rear body Repeat procedure on other seat back support Remove the nut 41 securing the vertical foot ...

Page 36: ... Wrench 1 2 2 The rear facing rear seat is attached to the vehicle at the seat pivot Ref Fig 4 Remove the hardware from the seat pivot Replacement is in the reverse order of removal Cargo Bed Replacement Tool List Qty Wrench 1 2 2 Ratchet 1 Torque Wrench ft lbs 1 Socket 1 2 2 The cargo bed is heavy and awkward to handle To prevent possible personal injury it is strongly recommended that adequate h...

Page 37: ... edge of the bracket Check latch tab adjustment to ensure latch assembly fully engages tab when in locked position Adjust as necessary by moving tab to the front or back to allow full engagement of latch assembly on tab SHUTTLE 2 REAR BODY Fig 5 Shuttle 2 Rear Body Seat Support Removal Tool List Qty 3 8 Drill 1 3 16 Drill Bit 1 Rivet Gun 1 Torque Wrench ft lbs 1 Phillips Bit 1 Phillips Screwdriver...

Page 38: ...3 Pull back the floormat enough to access the bottom of the seat support panel Drill out the five rivets 6 that secure the seat support 3 to the floor panel 4 Drill out the six rivets 8 9 10 that secure the seat filler panels 11 to the side panels 5 and remove Remove the cargo filler panels 12 Reassembly is the reverse of disassembly and requires the use of new rivets Rear Fender Removal Tool List...

Page 39: ...the frame Ref Fig 8 Fig 8 Rear Valence Panel Removal Reassembly is the reverse of disassembly and requires the use of new ratchet fasteners Side Panel Removal Tool List Qty 3 8 Drill 1 3 16 Drill Bit 1 Rivet Gun 1 Drill out the two horizontal rivets 1 at the rear of the side panel 2 remove the rivets and note the location of the two washers 3 Ref Fig 9 Fig 9 Side Panel Removal Reassembly is the re...

Page 40: ...isassembly Nuts 3 securing the bulkhead 4 to the bed frame 5 are to be tightened to 8 5 9 0 ft lbs 11 5 12 2 Nm torque It is recommended that new lock nuts be used Seat Back Removal Tool List Qty Torque Wrench ft lbs 1 Ratchet 1 Socket 1 2 1 Wrench 1 2 1 It is not necessary to remove the seat back from the seat back support brackets Remove the four bolts washers and lock nuts 1 2 3 and remove seat...

Page 41: ...d into the tapped holes in the upper rear cross member of the vehicle frame Remove the two horizontal bolts washers and nuts 9 10 11 securing the rear of the bed frame to the vertical rear bed brackets 12 The bed frame 4 may now be lifted vertically and removed Reassembly is the reverse of disassembly 5 16 18 Nuts 3 are to be tightened to 14 18 ft lbs 19 24 Nm torque 3 8 16 Torx head bolts 6 are t...

Page 42: ...hers and lock nuts 4 5 6 securing the battery rack 7 to the mid support 3 electric vehicle only Remove the two washer head bolts 8 securing the mid support 3 to the vehicle frame cross member and lift out the mid support Reassembly is the reverse of disassembly Refer to TORQUE SPECIFICATIONS in Section A for appropriate values When tightening the fuel pump mounting bolts gas vehi cles only tighten...

Page 43: ...ly clean the surface to be repaired with alco hol and dry 2 Mask the area to be painted common masking tape is adequate prior to repair and use aerosol type touch up paint 3 Apply spray touch up paint in light even overlapping strokes Multiple coats may be applied to provide ade quate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the ...

Page 44: ...Page C 16 Repair and Service Manual B BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 45: ...TS FOR SECTION D SECTION TITLE PAGE NO Page D i Repair and Service Manual WHEELS AND TIRES WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 2 LIST OF ILLUSTRATIONS Fig 1 Wheel and Tire Installation D 2 ...

Page 46: ...Page D ii Repair and Service Manual B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 47: ...could cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor applications with major use on grassy areas the follow ing should be considered On hard turf it is desirable to have a slightly higher inflation pressure On very soft turf a lower pressure prevents tires from cutting ...

Page 48: ...the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten lug nuts as shown Then tighten lug nuts to 50 85 ft lbs 70 115 Nm torque in 20 ft lbs 30 Nm increments following the same pattern Fig 1 Wheel and Tire Installation NOTICE ITEM NO TORQUE SPECIFICAT...

Page 49: ...Page D 3 Repair and Service Manual B B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 50: ...Page D 4 Repair and Service Manual B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 51: ...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 8 Fi...

Page 52: ... E ii Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 53: ...ticular attention to Notices Cautions Warnings and Dangers Fig 1 Axle Mounted Steering and Front Suspension Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate Shaft with U Joints Rack Pinion Unit King Pin Tube Thrust Washer Spindle King Pin Bushing Formed Axle Tie Rod Spacer Rack Ball Joint Rack Extension ...

Page 54: ...ints Do not use more than three 3 pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Wheel Bearing and King Pin Bushing inspection To prevent possible injury or death resulting from a vehicle falling from a jack follow the lift ing procedure in Section B of this manual Be sure vehicle is on ...

Page 55: ...pin 2 and loosen castellated nut 3 If performing a wheel bearing adjustment as part of another procedure make sure wheel is mounted to hub hand tight with lug nuts 4 and hub is loosely retained on spindle 5 with castellated nut Ref Fig 3 Seat bearings by rotating wheel while tightening castel lated nut until slight resistance is felt Rotate the wheel 2 3 more turns to displace excess grease If req...

Page 56: ...he flat area on the threaded tube has left hand threads clock wise to loosen while the end without the flat has conventional right hand threads counter clockwise to loosen To adjust wheel alignment loosen tie rod jam nuts 1 and turn tie rod 2 until correct alignment is achieved Tighten jam nuts to 36 40 ft lbs 49 54 Nm torque Test drive vehicle and confirm steering wheel is correctly centered If i...

Page 57: ... List Qty Wrench 9 16 1 Remove the nut 1 from the bottom of the shock absorber 2 at the front axle 3 Ref Fig 6 Compress shock absorber to clear the mounting bracket Loosen the nut securing the top of the shock absorber to the vehicle frame and then rotate the shock absorber while holding the nut in place with a wrench Remove the shock absorber NOTE Tie Rod Not Shown for Clarity Part of Frame Part ...

Page 58: ...nt pulling apart intermediate shaft Remove the three 1 3 4 long bolts 18 two 1 1 2 long bolts 28 spring plate 24 and five lock nuts 19 secur ing axle to springs and discard lock nuts At the 3 1 2 long bolt 20 securing front of left spring note location of washer 22 and remove it from end of bolt Remove nut 21 3 1 2 long bolt 20 spring plate 24 and spacer 23 and retain them for assembly at their or...

Page 59: ...re 25 27 securing rear of spring 17 to vehicle frame and discard lock nuts 27 To prevent stress and possible damage to the rack and pinion unit the driver side spring must be mounted to the axle with the hardware 20 23 installed in its original location Ref Fig 6 Driver side spring installation is the reverse order of dis assembly making sure to install the long bolt 20 spring plate 24 spacer 23 n...

Page 60: ...o the bore Tap gently into place until seal is flush with end of hub Lubri cate lips of seal and spindle with grease Ref Fig 10 Place new hub onto spindle and fill the area between the two wheel bearings about 1 2 3 4 full with grease and apply a light coating to the outer bearing race Install outer wheel bearing 4 and secure hub loosely with castellated nut Place wheel onto hub and hand tighten l...

Page 61: ...re of hub 1 is clean and place new race over bore of hub Evenly tap with hammer and bearing driver to drive race fully in bore Repeat on other side of hub Clean spindle 2 and pack new bearings with grease Wheel Bearing Packing on page E 2 Fig 11 Wheel Bearing Replacement Install inner wheel bearing 4 and new grease seal in hub and mount hub to spindle Hub Replacement on page E 8 Adjust bearing Whe...

Page 62: ...et 11 16 1 To remove rack ball joint 1 loosen passenger side front wheel and lift and support front of vehicle per SAFETY section Ref Fig 12 Remove passenger side front wheel and turn steering wheel fully to the left Remove the cotter pin 2 and loosen the castellated nut 3 until rack ball joint 1 threads are protected Using a ball joint separator as a lever apply pressure to ball joint and tap nut...

Page 63: ...tion Check front wheel alignment and adjust if necessary Wheel Alignment on page E 3 Tie Rod Inspection Replacement Tool List Qty Tape Measure 1 Wrench 3 4 1 Wrench 9 16 1 Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hammer 1 Socket 11 16 1 Torque Wrench ft lbs 1 Crowfoot Socket 3 4 1 Grasp the tie rod 8 at ball joints 6 and check for any vertical motion which would ind...

Page 64: ...le per SAFETY section Remove passenger side front wheel and turn steering wheel fully to the left Remove rack ball joint 2 and jam nut 3 from rack extension 4 Rack Ball Joint Replacement on page 10 Cut wire ties 5 6 and slide bellows off rack extension Install new bellows aligning small end over groove in rack extension and secure with new wire tie 5 Leave large end loose until rack extension to r...

Page 65: ...ol List Qty Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hammer 1 Wrench 3 4 1 Socket 3 4 1 Socket 11 16 1 Torque Wrench ft lbs 1 The spindle bearings are designed to be used dry Lubrication attracts dirt and will ruin the bearings Do not apply grease to the spindle bearings Loosen front wheel Lift and support front of vehicle per SAFETY section and remove front wheel I...

Page 66: ...they are found to be damaged or excessively worn a new rack and pinion unit must be installed Secure rack and pinion unit in vice by the mounting ears only The rack and pinion unit is made of aluminum and can be damaged if held otherwise Remove rack and pinion unit from vehicle Anchor in vice by clamping on the mounting ears of the unit Disassemble rack and pinion unit 1 by first removing screw 13...

Page 67: ...16 1 Torque Wrench in lbs 1 To remove rack and pinion unit 12 Ref Fig 12 loosen front wheels and lift and support front of vehicle per SAFETY section Remove front wheels Remove bolt 13 and washer 14 securing intermediate shaft 15 to rack and pinion unit 12 Remove cotter pin 2 and loosen castellated nut 3 until rack ball joint 1 threads are protected Using a ball joint separator as a lever apply pr...

Page 68: ... as a gauge by turn ing shaft of rack extension with wrench to create the 1 8 gap Tighten jam nut 5 to 35 45 ft lbs 47 61 Nm torque Secure bellows to rack and pinion unit with new wire tie 14 Steering Wheel Replacement Tool List Qty Socket 15 16 1 Ratchet 1 2 drive 1 Plastic Faced Hammer 1 Ball Peen Hammer 1 Anti seize Compound 1 Torque Wrench ft lbs 1 To maintain correct orientation when replacin...

Page 69: ...head position align the steering wheel on the steering shaft and slide wheel on shaft Tighten the steering wheel nut 6 to 15 20 ft lbs 20 27 Nm torque Inspect the four retaining tabs on the clipboard 5 for white stress lines Ref Fig 22 If stress lines are pres ent replace clipboard Install by carefully pressing first the top two then the bottom two retaining tabs into the matching slots in steerin...

Page 70: ...ve washer into base of steering column To install steering shaft and bearing assembly apply wheel bearing grease to lip of seal in bushing 12 at top of column and press steering shaft and bearing assem bly into column base Secure with large retaining ring making sure it is fully seated in groove of column Place steering column on vehicle and tighten column bolts 5 to 29 ft lbs 39 Nm torque Tighten...

Page 71: ...E 19 Repair and Service Manual B B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 72: ... E 20 Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 73: ...SOR 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 ...

Page 74: ...ge F ii Repair and Service Manual B ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 75: ... following events occur a the vehicle is being driven down a slope b the accelerator pedal is released for more than one second the pedal up feature will slow the vehicle the warning beeper will not sound until either the vehicle speed is reduced to 8 mph 13 kph at which it freely coasts between 8 and 3 mph 5 kph or the accelerator pedal is applied When pedal up feature is activated by this sequen...

Page 76: ...UN position If all of the following events occur with the switch in RUN posi tion a the vehicle has been stopped for more than one second b the accelerator pedal has been released for more than one second c the vehicle begins to roll above 2 mph 3 kph the electronic braking will limit speed to approximately 2 mph 3 kph and the warning beeper will sound When the accelerator pedal is depressed the e...

Page 77: ...ssed by removing the four screws and top cover from the enclosed pedal box Fig 3 Access to Pedal Box Speed Sensor The speed sensor uses a sealed sensor to read the impulses of a ring magnet attached to the armature shaft of the motor Magnetic pulses are converted into electri cal signals which the controller uses to determine the motor speed Controller The controller is a solid state unit that act...

Page 78: ...ctions for the use and care of the meter To assure accurate readings be sure to set the meter to the closest voltage reading above the expected voltage To prevent injury resulting from unexpected movement of the vehicle always raise the rear wheels before conducting any tests To prevent possible motor damage never operate vehicle at full throttle for more than 4 5 seconds while vehicle is in a no ...

Page 79: ...k for continuity set the DVOM to the KW setting and select Continuity The meter will give an audible signal when it detects continuity If the meter does not have a continuity setting set it to KW the meter will indi cate 0 when it detects continuity Testing a Switch for Continuity Place one probe on one contact of the switch place the second probe on the second terminal of the switch Ref Fig 6 Fig...

Page 80: ...failed and the solenoid must be replaced Fig 7 Continuity Check of Solenoid 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 electrical wiring Ref Fig...

Page 81: ...ace 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 1 5 Motor stall Vehicle stopped Remove mech...

Page 82: ... contact did not close Vehicle will not run Replace controller 4 5 Welded auxiliary con tact Vehicle runs slowly Replace controller 5 1 Keyswitch SRO Vehicle will not run Check keyswitch wiring Replace keyswitch 5 2 Main coil open Vehicle will not run Check coil connections wiring Replace solenoid if necessary 5 3 Aux driver on Vehicle will not run Check walkaway relay wiring Replace controller 5 ...

Page 83: ...3 14 15 16 17 18 19 20 21 22 23 24 J1 1 2 3 4 5 6 J2 1 2 3 4 J3 F2 To Hand Held Diagnostic MAIN Charger Interlock Switch Optional Walkaway Fuse 20A RUN STORE SWITCH 20 A B M B F1 F R N A2 Key Switch Forward Reverse Mode M1 M2 Reverse Alarm Pedal Interlock Brake Light Relay A1 A F2 Logic Enable Pot High Ground Input 15V Throttle Pot Pot Low Pot Wiper Ground LED Driver Fuse Sense Walk Away Return Wa...

Page 84: ...Connector Diagnostics 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 J1 1 2 3 4 5 6 J2 1 2 3 4 J3 F2 Charger Interlock Switch Optional Walkaway Fuse 20A B M B F1 F R N Key Switch Forward Reverse Mode M1 M2 Reverse Alarm Pedal Interlock Brake Light Relay Logic Enable Pot High Throttle Pot Pot Low Pot Wiper Ground LED Driver Fuse Sense Walk Away Return Walk Away Driver KSI Logic Powe...

Page 85: ...ing and pin 8 voltage J1 3 BRV Verify tow switch and aux power wiring J1 7 BRV Verify wire connections Possible controller failure J1 8 BRV Verify wiring Possible faulty controller J1 20 Performance option plug wiring No need to check Performance option plug wiring No need to check Performance option plug wiring No need to check J1 23 J1 24 J1 9 Performance option plug wiring No need to check J1 1...

Page 86: ...ative 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 Pin number Voltage If not Then J2 1 Spare J2 2 Spare J2 4 0 volts Verify sensor harness and connection This connection serves as...

Page 87: ... battery discharge test Verify the chrager process Negative probe on BL and positive probe on battery side of solenoid BRF Verify wire connection quality Positive probe on B and negative probe on B BRF Verify solenoid function Check wiring Negative probe on BL and positive probe on solenoid B BRF with solenoid engaged Verify primary voltage at Pin 5 17 If BRF is found on the primary terminals repl...

Page 88: ...e solenoid clicks and 2 7V 0 5 volts at full pedal Ref Fig 17 If the reading is out of specification the ITS sensor must be replaced The ITS attaches to the plastic pedal box using two plastic studs and two speed nuts Use care not to over tighten the nuts which could strip the plastic studs while tightening the nuts enough to prevent movement of the ITS Carefully remove the two wires that attach t...

Page 89: ...gs and Dangers Fig 16 ITS Adjustment Sheet 1 of 2 Use 7 32 drill to measure gap between plunger and ITS Micro switch disengaged Micro switch disengaged Pedal bracket rest against front of pedal frame opening 1 2 ITS Plunger Plunger has not entered ITS Lock Nut PEDAL UP To adjust plunger Loosen lock nut Rotate plunger until desired dimension Is achieved Tighten Lock Nut PEDAL PRE TRAVEL ...

Page 90: ...ces Cautions Warnings and Dangers Fig 17 ITS Adjustment Sheet 2 of 2 Micro switch activated Plunger enters ITS Plunger fully activated Pedal bracket rests on rear of pedal frame opening 3 4 SOLENOID ACTIVATED PEDAL ALL THE WAY DOWN With pedal all the way down Plunger should be flush with or extend beyond rear of ITS No Adjustment Here 1 0 0 3 volts 2 7 0 5 volts Cam ...

Page 91: ... Mount new controller to mount and reconnect wiring Tighten the controller mounting bolts to 108 132 in lbs 12 15 Nm torque and the M6 F1 and F2 bolts to 80 90 in lbs 9 10 Nm torque and M8 B M B bolts to 120 130 in lbs 14 15 Nm torque Replace controller mount assembly in vehicle Replace and tighten nuts to 6 8 ft lbs 8 11 Nm torque Reconnect the BL battery cable and replace the seat SOLENOID REPLA...

Page 92: ...oller Wiring J1 J2 F1 F2 B B M 10 Black From Motor F2 Power Harness 4 Black From Motor A1 Power Harness 18 Red From Tow Switch and Reverse Buzzer Control Harness 10 White From Charger Receptacle 4 Black From Battery Power Harness 4 Black From Charger Charger Harness 18 Red White From Tow Switch Control Harness To Ignition Interlock Charger Receptacle Charger Receptacle Harness Speed Sensor Harness...

Page 93: ...e F 19 Repair and Service Manual B B ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 94: ...ge F 20 Repair and Service Manual B ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 95: ...EMENT G 1 BRAKE MASTER CYLINDER FLUID G 2 Check Brake Fluid G 2 ROUTINE MAINTENANCE G 2 REPLACEMENT OF WEAR ITEMS G 2 Brake Pad Replacement G 2 Rotor Replacement G 2 Spindle Replacement G 2 Actuator Linkage Bushings G 2 Actuator Pivot Bushings G 3 BLEEDING BRAKES G 3 LIST OF ILLUSTRATIONS Fig 1 Master Cylinder Replacement G 1 Fig 2 Bleeding Brakes G 3 ...

Page 96: ...Page G ii Repair and Service Manual B BRAKES FRONT DISC Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 97: ...eely against their guide pins while removing all pressure against the rotors MASTER CYLINDER REPLACEMENT During this process it is likely that brake fluid will leak from the master cylinder Avoid allowing brake fluid to contact the painted body components of the vehicle Wipe off immediately Removing the front shield may improve access See BODY To remove the master cylinder Remove the bolts securin...

Page 98: ...raise the vehicle per Lifting the Vehicle in the SAFETY section Loosen both of the bolts securing the caliper to the spindle but only remove one Swing the caliper free from the rotor Push out the two guide retainer pins from the caliper and remove the pads being careful to note the orientation of the brake pads Install a new set of pads If the pads have been correctly oriented the guide pins will ...

Page 99: ...acement or when the fluid level in the master cylinder reservoir is very low Air in the system will give the brake pedal a spongy feeling upon application An assistant will be necessary to perform this procedure Use a clean cloth to wipe off the master cylinder reser voir and wheel cylinder bleeder valves Ref Fig 1 Clean each fitting before opening to prevent contaminat ing the system Open the mas...

Page 100: ...Page G 4 Repair and Service Manual B BRAKES FRONT DISC Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 101: ...te Entire Wheel Brake Assembly Removal and Installation K 17 Brake Shoe and Adjuster Replacement K 17 Brake Cable and Equalizer Assembly Removal and Installation K 18 Compensator Assembly Removal and Installation K 19 Brake Pedal Removal and Installation K 19 Parking Brake Catch Bracket Removal and Installation K 20 Parking Brake Pedal Removal and Installation K 20 Pedal Bumper Adjustment K 20 Par...

Page 102: ...ing Brake Latching Pressure K 15 Fig 20 Brake Assembly K 16 Fig 21 Wheel Brake Lubrication Points K 17 Fig 22 Backing Plate Removal and Installation K 17 Fig 23 Brake Shoes and Springs K 18 Fig 24 Setting Adjuster Screw K 18 Fig 25 Brake Cable Equalizer and Compensator K 19 Fig 26 Brake Pedal Removal and Installation K 19 Fig 27 Catch Bracket and Latch Arm K 20 Fig 28 Pedal Bumper Adjustment K 20 ...

Page 103: ...n the system and still apply the shoes to the drums the braking effort at the wheel brake will not be adequate The self adjusting mechanism in the wheel brakes requires enough cable travel at the wheel brake to work reliably When the brake is released there must be slack in the system so the brakes will release fully and the adjusters will function Free pedal travel pedal force shoe to drum cleara...

Page 104: ... to adjuster will result Adjustment takes place only when the brake is fully applied and released while the vehicle is moving Ref Fig 2 It is very important that the brake cables permit the brake levers to release fully when the brake pedal is in the released position How the Parking Brake Works The parking brake is operated by a smaller pedal which extends across the top of the service brake peda...

Page 105: ...from the catch bracket This is the preferred method which minimizes wear on components 2 Pressing the accelerator pedal rotates the kick off cam which forces the pedal latch arm to move away from the catch bracket The spring loaded Parking Brake pedal returns to its original position releasing the brake Compensator Assembly The compensator assembly contains a spring which is compressed until the s...

Page 106: ...vis pins will not be under tension by the brake cables Test Result Fails 2 out of 3 Fails 2 out of 3 Perform the Periodic Brake Performance Test PBPT 3 Times 3 Aggressive Stop Test 10 times 4 2 Bad Seal and Thrust Washer Condition Good Remove Excess Brake Dust from Brake Components 8 Yes Return To Service Go to 2 Go to 6 Remove Both Drums Don t Disturb Brake Mechanism 6 9 Visually Inspect Drums 7 ...

Page 107: ...ing that some braking function exists Then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start driving at maximum speed and brake aggressively 10 times At the spherical nut readjust the free travel Drive and brake aggressively 10 more times Repeat until the pedal free travel stabilizes within the specified range 19 Return t...

Page 108: ...heck and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace In excess of 1 1 8 2 9 cm free pedal travel Soft Pedal In Excess of 2 1 4 5 4 cm free peda travel Soft Pedal Low pedal force at parking brake latch Adjust per manual Brake cables damaged Replace Brake return bumper out of adjustment Adjust per manual End of brake cable loose from an...

Page 109: ...quires complete adjustment Adjust entire system Brake pedal not returning Check for binding of brake pedal Check brake pedal free travel Grabbing brakes oversensitive Moisture has caused surface rust on drums Apply moderate force to pedal while at maximum level ground speed to remove rust until condition is relieved Brake Pivot binding Check and replace poor components Parking brake hard to latch ...

Page 110: ... need for routine brake testing and inspection as shown on the Periodic Service Schedule in Section A Contin ued proper brake operation depends on periodic main tenance Brake Pedal and Linkage Inspection 1 Inspect brake pedal return bumper Be sure that the brake pedal is contacting the pedal return bumper when released that the bumper is in good condition and that a 1 4 3 8 6 9 5 mm gap exists bet...

Page 111: ...se conditions are found replace both cables and equalizer as a set 5 Check the clevis pins Check clevis pin attaching the brake cables to the brake levers They must be loose when the brake pedal has been released If the clevis pins are not loose but brake pedal free travel is correctly adjusted and the brake cables move freely the problem is likely in the wheel brake 6 Inspect the brake cable equa...

Page 112: ...resulting from operating a vehicle with improperly oper ating brake system the braking system must be properly maintained All driving brake tests must be done in a safe location with regard for the safety of all personnel The Periodic Brake Performance Test PBPT should be performed regularly see Periodic Service Schedule in the GENERAL INFORMATION AND ROUTINE MAIN TENANCE section of this manual as...

Page 113: ...the Periodic Brake Performance Test three more times second set of three If the vehicle passes two of three Periodic Brake Perfor mance Tests check that the clevis pins at the brake levers are loose If they are loose return vehicle to ser vice If they are tight adjust free travel Free Travel Adjustment on Page M 15 Then repeat the Periodic Brake Performance Tests If vehicle fails remove from servi...

Page 114: ...sms Remove excess dust and dirt from the drum with a brush The drum must not be turned to true a worn friction surface Turning will make the drum too thin causing drum failure and a loss of brakes which could cause severe injury or death 2 Inspect the brake drum Look for a blue coloration or blistered paint that would indicate that it has overheated Check for evidence of scoring Check for excessiv...

Page 115: ... shoes and by the moving anchor assembly Replace both backing plates if any gouges or galling is found 9 Measure the brake shoe thickness Measure at the most worn area Brake shoe thickness must never be less than 060 1 5 mm at any point on the shoe It is normal for the shoes to show more wear at the leading and trailing edges Ref Fig 15 If the brake shoe thickness is approaching 060 1 5 mm it is r...

Page 116: ...he condition of worn components is critical to the operation of the brake system In some cases component replacement may be more cost effective than the removal cleaning inspec tion and reassembly of the component s Adjusting Brake Pedal Free Travel Brake pedal free travel MUST be checked and adjusted any time that the brake system is serviced or when parts are replaced Brake pedal free travel is ...

Page 117: ...t The parking brake latching force can be checked as verifi cation after setting brake pedal free travel To check park ing brake latching force place a bathroom scale on the service and parking brake pedals Using both feet press the scale down against the parking brake pedal until it latches The parking brake should latch between 65 and 75 lbs 29 34 kg indicated on the scale Fig 18 Check Clevis Pi...

Page 118: ...ll cotter pin Install the remaining hardware and tighten the nut to 80 90 ft lbs 108 122 Nm torque Continue to tighten until a new cotter pin can be installed through the castel lated nut and the hole in the axle Maximum torque is 140 ft lbs 190 Nm Wheel Brake Service Wheel brake service consists of disassembly cleaning inspection lubrication and re assembly of the wheel brake Worn or damaged comp...

Page 119: ...ube Ref Fig 22 Fig 22 Backing Plate Removal and Installation Remove the clevis pin securing the brake cable to the brake lever Installation is the reverse of removal Connect the brake cable to the wheel brake with the clevis pin installed from the top down and a new cotter pin Install the brake assembly or backing plate to the axle tube flange Install new hardware locknut should only be used once ...

Page 120: ...f Fig 23 The opposite end of the adjuster spring is hooked to the adjuster with the hook end facing out The brake shoe springs must be installed with the light spring closest to the adjuster mechanism with the hook installed down through the rear brake shoe and up through the front brake shoe The heavy top spring is installed with both spring hooks installed down through the brake shoes Check to s...

Page 121: ...ake pedal free travel Adjusting Brake Pedal Free Travel on Page M 14 Brake Pedal Removal and Installation Disconnect the compensator assembly 1 from the brake pedal by removing the cotter pin 2 and the clevis pin 3 Unplug the wiring harness on models equipped with brake lights Unhook the torsion spring 4 by insert ing a thin blade screwdriver between the small hook and the bracket Move the hook ba...

Page 122: ...king brake arm latch is a hardened part Do not grind or file it as doing so will cause the part to lose its hardness char acteristics A new part must be used Installation is in the reverse order of disassembly Use a new push nut or push nuts If required adjust the kick off cam 3 See If required adjust the kick off cam 6 on 20 Pedal Bumper Adjustment Loosen the bumper lock nut and adjust the bumper...

Page 123: ... and Kick Off Cam Removal and Installation Installation is in the reverse order of disassembly With the parking brake engaged and fully latched there mus be no gap between the top of the cam and the latch arm To adjust the kick off cam 6 engage the parking brake and loosen the two cam setscrews 5 and rotate the cam until it contact the latch arm Tighten the set screws to 45 55 in lbs 5 6 Nm torque...

Page 124: ...Page K 22 Repair and Service Manual B MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 125: ... Wires J 3 Check battery Condition J 3 Check Green Power Wire J 3 Check Fuse J 3 ACCESSORY WIRING J 3 LIGHT BULB REPLACEMENT J 3 FUSE REPLACEMENT J 3 LIST OF ILLUSTRATIONS Fig 1 DVOM J 1 Fig 2 Wiring Diagram J 2 Fig 3 Headlight Turn Signal Light Bulb Replacement J 4 Fig 4 Tail Brake Light Bulb Replacement J 4 Fig 5 Ignition Switch Fuse Block J 5 Fig 6 Horn J 6 Fig 7 Turn Signal Hour Meter J 6 ...

Page 126: ...Page J ii Repair and Service Manual B ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 127: ...ghting circuit Example 2 If a problem occurs in the lighting circuit that results in only one of the headlights not working there is no reason to check battery wiring or the fuse since it is obvious that voltage is present Since bulbs will burn out over time the obvious place to start is at the headlight that is not functioning If power is present at the connec tor and the ground wiring is satisfa...

Page 128: ...5 AMP 15 AMP BLU WHT BLU WHT Light Switch Part of Key Switch RED RED RED BRN BLK YEL Turn Signal Switch GRN WHT YEL WHT BLK Flasher YEL BLU WHT BLK BRN BRN BRN WHT BRN WHT WHT RED RED Turn Signal Turn Signal Taillight Taillight YEL BRN GRN Driver Side Passenger Side State Of Charge Meter 48V RED For Vehicles Without Turn Signals Remove WHT Wire from Left Rear Turn Signal RED Wire and YEL Wire from...

Page 129: ... on the side of the fuse block where the green wire is con nected A reading of battery voltage indicates that the green wire is in good condition The green wire supplies power to the entire fuse block 4 CHECK FUSE Place the red probe to each wire terminal on the fuse block A reading of battery voltage indicates that the fuse is in good condition No reading indicates a faulty fuse replace with a go...

Page 130: ...e tail and brake light bulb roll the rubber bezel from around the edge of the taillight and remove lens Install replacement bulb and replace lens Fig 4 Tail Brake Light Bulb Replacement FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new automotive type fuse Headlight and taillight bulbs and fuses are available from a local Di...

Page 131: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 5 Ignition Switch Fuse Block STATE OF CHARGE METER AND KEY SWITCH ON OFF GRN RED ORN WHT BLU WHT Battery BL Light Switch Horn Switch Brake Light Switch FUSE BLOCK ...

Page 132: ... Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 6 Horn Fig 7 Turn Signal Hour Meter Front of Vehicle BLK YEL HO R N Floorboard Floormat TURN SIGNAL HOUR METER HOUR METER Solenoid BLK YEL ...

Page 133: ...Page J 7 Repair and Service Manual B B ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 134: ...Page J 8 Repair and Service Manual B ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 135: ... Disassembly K 1 Bearing Replacement K 2 Field Coil Replacement K 3 Brush Replacement K 3 Motor Assembly K 3 Motor Tests K 4 Motor Installation K 4 LIST OF ILLUSTRATIONS Fig 1 Disconnect Battery Cable K 1 Fig 2 Mark Axle and Motor K 1 Fig 3 Motor Components K 2 Fig 4 Brush Wear K 3 Fig 5 Securing Brushes K 3 Fig 6 Motor Wiring K 4 ...

Page 136: ...Page K ii Repair and Service Manual B MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 137: ...in SAFETY section of this manual The shorting of motor wires could cause an explosion Tool List Qty Insulated wrench 9 16 1 Chalk or paint pen 1 Socket 7 16 1 Ratchet 1 Internal snap ring pliers 1 Using an insulated wrench disconnect the negative battery cable from the battery Ref Fig 1 Remove all wires from motor Fig 1 Disconnect Battery Cable Mark both the axle and motor housings to permit reali...

Page 138: ...d or uneven support will cause the end cover to fracture To aid disassembly heat only the commutator end cover before attempting removal of the armature Once heated place the commutator end cover armature assembly in press giving as much support to the end cover as possible and press the armature out of the bearing Push back each brush until its spring 15 is resting against the side of the brush T...

Page 139: ...ils are installed in reverse order of disassembly Brush Replacement Tool List Qty Wrench 1 2 1 Ratchet 1 Socket 5 16 1 Brushes should be measured as shown and replaced when the minimum dimension of 62 16 mm is reached Ref Fig 4 Fig 4 Brush Wear Remove brush terminal hardware 12 at A1 and A2 Ref Fig 3 Remove screws 13 securing brush plate 14 Remove brushes rigging and brush plate Pull back each bru...

Page 140: ...system is operating correctly and the vehicle either does not run or runs poorly the motor is the only remaining component and must be replaced Motor Installation Tool List Qty Socket 7 16 3 8 drive 1 Torque wrench in lbs 3 8 drive 1 Be sure that a bumper spline is installed between the motor input pinion shaft and splines Apply a small quantity of molybdenum grease to the male portion of the spli...

Page 141: ...Page K 5 Repair and Service Manual B B MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 142: ...Page K 6 Repair and Service Manual B MOTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 143: ...OUBLESHOOTING L 5 Hydrometer L 6 Using A Hydrometer L 6 BATTERY CHARGER L 7 Description L 7 Portable Charger Installation L 7 Charger Maintenance L 8 LIST OF ILLUSTRATIONS Fig 1 Correct Electrolyte Level L 2 Fig 2 Water Purity Table L 2 Fig 3 Automatic Watering Gun L 3 Fig 4 Preparing Acid Neutralizing Solution L 3 Fig 5 Battery Connections L 4 Fig 6 Freezing Point of Electrolyte L 5 Fig 7 Hydrome...

Page 144: ...age L ii Repair and Service Manual B BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 145: ... and flushed with water Overfilling batteries may result in electro lyte being expelled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aerosol containers of battery terminal pro tectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which could result in an explosion Wrap w...

Page 146: ... will gas with the majority of the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas however this loss is minimal If the battery electrolyte level is too high the electrolyte will block the vent tube and the gas will force it out of the vent tube and batt...

Page 147: ...or After hosing down the batteries a residue will be left on the batteries which is conductive and will contribute to the discharge of the batteries To prevent battery damage be sure that all battery caps are tightly installed The correct cleaning technique is to spray the top and sides of the batteries with a solution of sodium bicarbon ate baking soda and water This solution is best applied with...

Page 148: ...ult in an explosion Use care to connect the battery wires as shown Ref Fig 5 Ensure that all battery terminals are installed crimp up Tighten the battery post hardware to 50 70 in lbs 6 8 Nm torque Protect the battery terminals and battery wire terminals with a commercially available protective coating Fig 5 Battery Connections Prolonged Storage Battery charger and controller and other electronic ...

Page 149: ...t disconnect cycle and therefore no electrical arc is generated at the DC plug receptacle contacts In some portable chargers there will be a rattle present in the body of the charger DC plug This rattle is caused by an inter nal magnet contained within the charger plug The magnet is part of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the ve...

Page 150: ... to permit the water to ade quately mix with the electrolyte The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80 F 27 C High quality hydrometers are equipped with an inter nal thermometer that will measure the temperature of the electrolyte and will include a conversion scale to cor rect the float reading It is important to recognize that the electr...

Page 151: ... overheating may result which could cause serious damage to the charger and create the potential for fire If the charger is operated in an outdoor location rain and sun protection must be provided Fig 9 Charger Installation A dedicated circuit is required for the charger Refer to the charger manual for appropriate circuit protection The charger may remain plugged into the AC outlet To charge the v...

Page 152: ...lly charged and the DC plug can be removed to permit use of the vehicle The charger may remain plugged into the AC outlet To charge the vehicle refer to the instruction label on char ger Charger Maintenance The charging DC cord is equipped with a polarized connector which fits into a matching receptacle on the vehicle Ref Fig 11 The power AC cord is equipped with an appropriate plug If the charger...

Page 153: ...d Service Manual REAR SUSPENSION REAR SUSPENSION M 1 General M 1 Shock Absorber Removal M 1 Shock Absorber Installation M 1 Rear Spring Removal M 1 Rear Spring Installation M 1 REAR AXLE REMOVAL M 3 Rear Axle Installation M 3 LIST OF ILLUSTRATIONS Fig 1 Rear Suspension M 2 ...

Page 154: ...Page M ii Repair and Service Manual B REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 155: ...e the shock absorber Shock Absorber Installation Shock absorber installation is in the reverse order of dis assembly except that the shock absorber nuts 1 3 must be tightened until the shock absorber bushings 4 expand to the diameter of the shock absorber washer 5 Rear Spring Removal To reduce the possibility of personal injury fol low the lifting procedure in section B of this manual Place wheel ...

Page 156: ... REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Rear Suspension Front of the Vehicle 4 4 5 1 3 5 4 10 11 6 9 9 9 4 5 7 2 8 8 5 ...

Page 157: ...t supporting the differential to the engine frame Remove the U bolts holding axle to engine frame Remove the drive belt and driven clutch see CLUTCHES section Remove the F R shifter bracket nut and loosen the cable nuts then remove the cable and bracket from the differ ential Remove the accelerator cable from the accelerator bracket and take off the push nut holding the cable on the governor and r...

Page 158: ...Page M 4 Repair and Service Manual B REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 159: ...emoval and Disassembly N 2 Axle Shaft Seal Removal and Replacement N 3 Axle Shaft Replacement N 3 LIST OF ILLUSTRATIONS Fig 1 Add Check and Drain Rear Axle Lubricant N 1 Fig 2 Removing Installing Outer Snap Ring N 2 Fig 3 Removing Installing Axle Shaft N 2 Fig 4 Pressing Bearing from Axle Shaft N 2 Fig 5 Removing Installing Seal N 3 Fig 6 Cut Away of Outer Bearing and Brake Drum N 3 ...

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

Page 161: ...xle is a precision assembly and therefore any repair or replacement of parts must be done with extreme care in a clean environment Before attempting to perform any service on the axle read and understand all of the following text and illustrations before disassembling the unit Handle all splines with extreme care Snap rings must be removed installed with care to prevent damage of bearings seals an...

Page 162: ...ement Tools List Qty Internal snap ring pliers 1 Seal puller 1 Seal installer P N 18739 G1 1 Ball peen hammer 1 Use care to prevent damage to the inner surface of the axle tube at the sealing area Remove the inner snap ring Ref Fig 5 on Page N 2 Use a puller to remove the seal Ref Fig 6 on Page N 2 Fig 5 Removing Installing Inner Snap Ring Fig 6 Removing Seal To install the seal use the special se...

Page 163: ...uter snap ring Coat the outboard spline of the axle with a commercially available anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 8 on Page N 3 Fig 7 Installing Seal Tighten the castellated axle nut to 70 ft lbs 95 Nm torque minimum 140 ft lbs 190 Nm torque maximum Continue to tighten until the slot in the nut aligns with the cotter pin hole Fig 8 Cu...

Page 164: ...Page N 4 Repair and Service Manual Notes REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers ...

Page 165: ...ROTECTION TOP AND WINDSHIELD P 1 Trailering P 1 SHUTTLE 4 AND SHUTTLE 6 SUN TOP P 1 Rear Support Installation P 1 Front Struts P 1 Sun Top P 1 SPILT WINDSHIELD P 3 FULL WINDSHIELD P 4 LIST OF ILLUSTRATIONS Fig 1 Shuttle 4 and Shuttle 6 Sun Top P 2 Fig 2 Spilt Windshield P 3 Fig 3 Full Windshield P 4 ...

Page 166: ...Page P ii Repair and Service Manual B WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 167: ...6 SUN TOP Tool List Qty Plastic faced mallet 1 Wrench 1 2 2 Wrench 9 16 2 Hex wrench 7 32 1 Straight blade screwdriver 1 Rear Support Installation Using a plastic faced hammer tap end caps 5 into the top of the rear struts 3 4 Ref Fig 1 See Detail B At driver side of vehicle align the holes in the rear strut 3 with the holes in the seat back support bracket being sure that the open end of the stru...

Page 168: ...re attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Shuttle 4 and Shuttle 6 Sun Top Driver Side Shown Front Of Vehicle A 3 6 7 7 8 9 21 27 4 Sun Top 11 18 20 Front Strut 18 Front of Vehicle 2 14 15 13 D C 18 18 5 19 10 1 Rear of Vehicle B C D A B 12 19 ...

Page 169: ...and press the sash starting at the bottom onto the front strut so that it snaps into place See Details B and C Repeat for opposite side of windshield Position top grips 8 as shown See Detail D at top hole on each side of front strut Secure with top grip fas teners 9 Fig 2 Split Windshield It may be necessary on early production sun tops to drill a 9 32 hole in front face of both sides of front str...

Page 170: ...d Using a plastic faced mallet gently tap sash to ensure wind shield seats properly See Detail A Insert screw 4 through washer 5 rubber grommet 6 and existing hole in front strut Secure with washer 5 and lock nut 7 See Detail B Do not over tighten or squeeze grommet Place bottom section of windshield on rubber grommets and press the sash starting at the bottom onto the front strut so that it snaps...

Page 171: ...Page P 5 Repair and Service Manual B B WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 172: ...Page P 6 Repair and Service Manual B WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 173: ...N Q SECTION TITLE PAGE NO Page Q i Repair and Service Manual TROUBLESHOOTING ELECTRICAL SYSTEM Q 1 Basic Electrical Power System Troubleshooting Q 2 Basic Electrical Troubleshooting for Accessories Q 2 SUSPENSION AND STEERING Q 3 ...

Page 174: ...Page Q ii Repair and Service Manual B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 175: ...ch or motor Clean tighten or replace faulty wiring Solenoid has failed Replace solenoid Key switch has failed Replace key switch Micro switch at direction selector switch has failed Replace micro switch Connector s loose or separated Install connector s correctly Faulty motor Repair or replace motor Test by checking continuity of field coils S1 S2 and armature A1 A2 Check for continuity of armatur...

Page 176: ...er to the ELECTRONIC SPEED CONTROL section Basic Electrical Troubleshooting for Accessories To diagnose electrical problems in the vehicle electrical wiring system refer to the ELECTRICAL SYSTEM sec tion Vehicle charger connector damaged Replace connector Battery case damage Replace battery Low electrolyte level Maintain correct electrolyte level Battery capacity deficient Perform hydrometer load ...

Page 177: ...feeler gauge will pass under the rack the rack must be replaced PLAY IN STEERING Steering wheel loose Inspect splines replace steering wheel if required Tighten steering wheel nut Steering components worn Replace Loose wheel bearings Adjust or replace Intermediate shaft loose Tighten hardware VIBRATION Steering components worn Replace Damaged wheel bearings Replace Out of round tires wheels or bra...

Page 178: ...Page Q 4 Repair and Service Manual B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 179: ...ING Grounding Requirements R 1 Ground Systems R 1 Lightning Protection Requirements R 1 Equipment Fault and Personal Safety System R 1 Ground Network Requirements R 1 External Grounding Requirements R 2 Materials R 2 Earth Electrode System R 2 Lightning Protection System R 2 Equipment Fault and Personal Safety System R 3 ...

Page 180: ...ii Repair and Service Manual B LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 181: ...hms 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 enhance...

Page 182: ...least 24 below grade and be at least 24 away from the structure 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 copper clad steel mesh utilizing a 12 x 12 cross pattern may be used All inter connections in the mesh shall be brazed or silver solde...

Page 183: ...tor 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 maintain continuity All mounting hardware and connectors shall be UL approved All DC chargers are to be grounded t...

Page 184: ... 4 Repair and Service Manual B LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 185: ...air and Service Manual GENERAL SPECIFICATIONS SHUTTLE 2 S 1 SHUTTLE 4 S 2 SHUTTLE 6 S 3 LIST OF ILLUSTRATIONS Fig 1 Vehicle Dimensions SHUTTLE 4 SHUTTLE 6 S 4 Fig 2 Vehicle Dimensions SHUTTLE 2 S 5 Fig 3 Incline Specifications S 6 Fig 4 Turning Clearance Diameter S 7 ...

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

Page 187: ...erential 4 75 in 12 0 cm Towing Capacity N A Cargo Bed Width 44 0 in 112 0 cm Steering Suspension Cargo Bed Length 68 5 in 174 0 cm Steering Self compensating rack and pinion Vehicle Power Front Suspension Leaf springs with hydraulic shock absorbers Power Source 4 Cycle 24 5 cu in 401 cc Low Emission Rear Suspension Leaf springs with hydraulic shock absorbers Valve Train Single Cylinder OHV Servic...

Page 188: ...5 in 108 0 cm Towing Capacity N A Cargo Box Length inside 32 0 in 80 0 cm Steering Suspension Cargo Box Depth inside 11 5 in 29 0 cm Steering Self compensating reduction rack and pinion Cargo Box Capacity 9 cu ft 25 0 m3 Front Suspension Leaf springs with hydraulic shock absorbers Cargo Box material Wood Stake Sides Rear Suspension Leaf springs with hydraulic shock absorbers Vehicle Power Service ...

Page 189: ...ng Capacity N A Gnd Clearance Differential 4 3 in 11 0 cm Steering Suspension Vehicle Power Steering Self compensating reduction rack and pinion Power Source 4 Cycle 24 5 cu in 401 cc Low Emission Front Suspension Leaf springs with hydraulic shock absorbers Valve Train Single Cylinder OHV Rear Suspension Leaf springs with hydraulic shock absorbers Horsepower kW 13 hp 9 7 kW Exceeds SAE J1940 Std S...

Page 190: ...Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 46 5 in 119 0 cm 122 0 in 310 0 cm 133 0 in 338 0 cm 93 5 in 237 0 cm SHUTTLE 4 SHUTTLE 6 Lowest Clearance At Differential 4 3 in 11 0 cm All Models ...

Page 191: ... B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 93 5 in 237 0 cm 122 in 310 0 cm 138 in 351 0 cm 46 5 in 119 0 cm SHUTTLE 2 ...

Page 192: ...this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers RECOMMENDED MAX RAMP GRADE 25 or 14 MAX RECOMMENDED MAX SIDE TILT 25 or 14 MAX 48 6 in 123 0 cm 72 0 in 183 0 cm Rear Wheel Track 38 0 in 97 cm Front Wheel Track 34 2 in 86 7 cm ...

Page 193: ...l of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURNING CLEARANCE DIAMETER 22 0 ft 6 7 m RECOMMENDED MAX RAMP GRADE 25 or 14 MAX RECOMMENDED MAX SIDE TILT 25 or 14 MAX CAUTION HOT SURF ACE ...

Page 194: ...Page S 8 Repair and Service Manual B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

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Page 196: ... of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine E Z GO Parts Accessories Department or at www shopezgo com ...