Ezgo EXPRESS L6 2012, Technician'S Repair And Service Manual

Page 1: ...ELECTRIC POWERED UTILITY VEHICLE TECHNICIAN S REPAIR AND SERVICE MANUAL 625610 625621 REVISED AUGUST2012 ISSUED JUNE 2012...

Page 2: ...ery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm BATTERY WARNING WASH HANDS AFTER HANDLING WARNING Battery posts termin...

Page 3: ...ion 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 DISCLA...

Page 4: ...e 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 dischar...

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

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 f...

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

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

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

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

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

Page 13: ...ly secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehicle see GENERAL SPECIFICA TIONS for vehicle weight and load plus 1000 lbs 454 kg Lock the pa...

Page 14: ...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 in...

Page 15: ...mended 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 remo...

Page 16: ...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...

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

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

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

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

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

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

Page 23: ...d 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 basi...

Page 24: ...ifting process When lifting the vehicle position jack stands only in the areas indicated To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 2 Center jack under the...

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

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

Page 27: ...ent C 6 Rear Body Replacement C 6 Foot Rest Replacement C 7 Rear Bumper Replacement C 7 Front Seat Replacement C 7 Front Facing Rear Seat C 7 Rear Facing Rear Seat C 8 Cargo Bed Replacement C 8 Seat C...

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: ...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 hardwa...

Page 30: ...Y 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 48 16 5 1 8 7 BRUSH GUARD FRONT B...

Page 31: ...Read all of Section B 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 B B 55 49 50 56 1...

Page 32: ...Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 4 Body Components Cargo Box and Seat Foot Rest Seat Bed Seat Back Supp...

Page 33: ...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 Drill 1 Drill Bit 7 32 1 Wrench 5 16 1 Phill...

Page 34: ...32 1 Socket 3 8 1 Socket 1 2 1 Socket 9 16 deepwell 3 8 drive 1 Ratchet 3 8 drive 1 Wrench 3 8 1 Wrench 1 2 1 Wrench 9 16 1 Rivet gun 1 Phillips screwdriver 1 Pry Bar 1 To prevent possible injury or d...

Page 35: ...cedure on other seat back support Remove the nut 41 securing the vertical foot rest bracket 42 to each frame support 39 Ref Fig 4 Leave the bolt in place Remove the nut 43 securing the horizontal foot...

Page 36: ...t tighten components to specified torque until adjustment with mating components has been achieved Refer to TORQUE SPECIFICATIONS in Section A for non spec ified appropriate values The rear facing rea...

Page 37: ...for a minimum of one minute to mix the paint and achieve the best color match 4 After painting allow to dry overnight Smooth the mask lines using 400 grit wet sand paper to blend touch up area level...

Page 38: ...Page C 10 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 39: ...S FOR SECTION D SECTION TITLE PAGE NO Page D i Repair and Service Manual WHEELS AND TIRES WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 2 LIST OF ILLUSTRATIONS Fig 1 Wheel and Tire I...

Page 40: ...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 41: ...ould cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor applications with...

Page 42: ...he cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tight...

Page 43: ...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 44: ...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 45: ...Fig 1 Axle Mounted Steering and Front Suspension E 1 Fig 2 Axle Mounted Steering and Front Suspension E 2 Fig 3 Lubrication Points E 3 Fig 4 Bearing Adjustment E 4 Fig 5 Wheel Alignment E 5 Fig 6 Dis...

Page 46: ...E ii Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 47: ...ular attention to Notices Cautions Warnings and Dangers Fig 1 Axle Mounted Steering and Front Suspension Front of Vehicle EXPRESS L6 King Pin Tube Thrust Washer Spindle King Pin Bushing Part of Frame...

Page 48: ...procedure Pay particular attention to Notices Cautions Warnings and Dangers Front of Vehicle Rack Pinion Unit Spindle King Pin Bushing Rack Ball Joint Rack Extension Intermediate Shaft with U Joints W...

Page 49: ...in accordance with the Periodic Service Sched ule or if a bearing replacement is required Routine examination of tires will provide indications if an align ment is required Lubrication Tool List Qty...

Page 50: ...ny time the bearing is removed for inspection It is recom mended that a bearing packer attached to a grease gun be used however manual packing is acceptable if done correctly To pack a bearing manuall...

Page 51: ...sition Measure the distance between the chalk lines at both the front and rear of the tires Ref Fig 5 The measure ment taken at the front of the tires should be 0 1 8 0 3 mm less than the rear Fig 5 W...

Page 52: ...ticular attention to Notices Cautions Warnings and Dangers FRONT SUSPENSION Fig 7 Express L6 Front Suspension Components 6 13 3 17 16 5 23 21 24 24 14 Part of Frame 7 20 25 Part of Frame 26 28 18 19 1...

Page 53: ...he front axle 3 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 nu...

Page 54: ...rmediate 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 fro...

Page 55: ...nut 21 and washer 22 in their original locations Use new lock nuts 15 19 27 to secure the rack and pinion unit 16 two short bolts 18 and rear bolts 25 To detach passenger side spring Remove the hardw...

Page 56: ...ghten lug nuts Fig 10 Hub Replacement Adjust bearing See Wheel Bearing Adjustment on page E 4 Replace the dust cap 1 Lower vehicle per SAFETY section and tighten front wheel s per WHEELS AND TIRES sec...

Page 57: ...Y section and tighten front wheel s per WHEELS AND TIRES section Axle Linkage Rod Replacement Raise the front of the vehicle See Lifting Vehicle Remove old axle linkage rod by removing each ball joint...

Page 58: ...s section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers STEERING Fig 14 Express L6 Steering Components 1 4 5 8 7 7 6 6 Flat Section 16 20 15 14 3 2...

Page 59: ...n to Notices Cautions Warnings and Dangers Fig 15 Express S6 Steering Components Rack Ball Joint Replacement Tool List Qty Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hamm...

Page 60: ...or servicing steering components always verify that an 1 8 gap exists between large hex of rack extension and rack and pinion unit when steering is turned fully to the right forcing passenger spindle...

Page 61: ...st if necessary See Wheel Alignment on page E 5 Jam nut should be tightened to 36 40 ft lbs 49 54 Nm torque Bellows Replacement Tool List Qty Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1...

Page 62: ...bricate pinion and lip of seal wit grease The bore has a positive stop to correctly locate the seal during installation Place seal over pinion and tap carefully with socket and hammer to start seal st...

Page 63: ...k that spindle turns freely on king pin tube after tightening Tighten lock nut 2 to 36 ft lbs 50 Nm Maximum torque is 50 ft lbs 70 Nm Install front wheels per WHEELS AND TIRES section and lower vehicl...

Page 64: ...k extension to rack and pinion unit clearance Install tensioner and tighten bolts 13 to 100 120 in lbs 11 14 Nm torque Thread jam nut and rack ball joint to original location on rack extension and set...

Page 65: ...1 8 Thick 1 Crowfoot Socket 3 4 1 Torque Wrench ft lbs 1 Wire Tie 10 long 1 Check for proper rack extension to rack and pinion unit clearance by first turning steering wheel fully to the right The rea...

Page 66: ...O NOT REMOVE NUT AT THIS TIME Apply upward pressure to the steering wheel Place a plastic faced hammer against the steering wheel nut and strike plastic faced hammer sharply with a ball peen hammer Fi...

Page 67: ...taining ring 11 and press bearing from steering shaft To assemble steering shaft first press new bearing onto shaft until it stops against shoulder Then with small retaining ring oriented with arch up...

Page 68: ...E 22 Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 69: ...OR 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...

Page 70: ...e 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 NOT...

Page 71: ...e 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...

Page 72: ...N 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 sec...

Page 73: ...sed 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...

Page 74: ...tions 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 movem...

Page 75: ...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 m...

Page 76: ...ailed 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 considerab...

Page 77: ...ce 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 co...

Page 78: ...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...

Page 79: ...WHT RED RED RED RED RED WHT YEL YEL Solenoid Reed Switch Motor Speed Sensor OUT To Hand Held Diagnostic Unit SPARE SPARE SPARE ORN RED RED YEL YEL RED WHT RED WHT RED WHT GRY GRN WHT GRN VIO ORN WHT...

Page 80: ...nnector Pedal Box ITS MS3 GRN RED BLK BLK WHT RED RED RED RED WHT YEL YEL Solenoid Reed Switch ORN RED RED YEL YEL RED WHT RED WHT RED WHT GRY GRN WHT GRN VIO ORN WHT FWD REV N Direction Selector Swit...

Page 81: ...ng 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 op...

Page 82: ...nnected to the negative side of battery pack voltage The positive lead of the DVOM is used to probe the controller connections Leave connections plugged in the controller Armature will need to be rota...

Page 83: ...BL BRF preferably 48 Volt Perform 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 prob...

Page 84: ...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 an...

Page 85: ...s 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 o...

Page 86: ...es 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 AC...

Page 87: ...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...

Page 88: ...ller 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 Blac...

Page 89: ...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 NO...

Page 90: ...e 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 NOT...

Page 91: ...Disassembly G 1 Bearing Replacement G 2 Field Coil Replacement G 3 Brush Replacement G 3 Motor Assembly G 3 Motor Tests G 4 Motor Installation G 4 LIST OF ILLUSTRATIONS Fig 1 Disconnect Battery Cable...

Page 92: ...Page G 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 93: ...n 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 Usin...

Page 94: ...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 armat...

Page 95: ...ls 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...

Page 96: ...at the 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...

Page 97: ...Page G 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 98: ...Page G 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 99: ...s H 3 Battery Replacement H 4 Prolonged Storage H 4 Battery Charging H 5 AC Voltage H 5 TROUBLESHOOTING H 5 Hydrometer H 6 Using A Hydrometer H 6 LIST OF ILLUSTRATIONS Fig 1 Correct Electrolyte Level...

Page 100: ...ge H 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 NOTE...

Page 101: ...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 facilit...

Page 102: ...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 batte...

Page 103: ...atteries 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...

Page 104: ...t 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 10 11 Nm torque Pr...

Page 105: ...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 ratt...

Page 106: ...r 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 inte...

Page 107: ...sults indicate a weak cell the battery or batteries should be removed and replaced with a good battery of the same brand type and approximate age Fig 8 Hydrometer Temperature Correction 160 71 032 030...

Page 108: ...age H 8 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 NOTE...

Page 109: ...Page J i Repair and Service Manual BATTERY CHARGER BATTERY CHARGER J 1 Description J 1 Portable Charger Installation J 1 Charger Maintenance J 1 LIST OF ILLUSTRATIONS Fig 1 Charger Installation J 1 F...

Page 110: ...Page J ii Repair and Service Manual B BATTERY CHARGER Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 111: ...completely into the vehicle receptacle located on the panel underneath the driver seat Ref Fig 10 After inserting the polarized DC plug wait a few seconds and observe ammeter on charger to make sure i...

Page 112: ...Page J 2 Repair and Service Manual B BATTERY CHARGER Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 113: ...S K 14 Parts Replacement vs Repair K 14 Adjusting Brake Pedal Free Travel K 14 Brake Drum Removal and Installation K 15 Wheel Brake Service K 16 Backing Plate Entire Wheel Brake Assembly Removal and I...

Page 114: ...m Inspections K 10 Fig 12 Periodic Brake Performance Test K 11 Fig 13 Equally Load Vehicle K 12 Fig 14 Adjuster Mechanism K 13 Fig 15 Brake Shoe Wear K 13 Fig 16 Orientation of Brake Shoe Springs K 14...

Page 115: ...travel in 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...

Page 116: ...to adjuster will result Adjustment takes place only when the brake is fully applied and released while the vehicle is moving Ref Fig 2 It is very important that the brake cables permit the brake lever...

Page 117: ...rom the catch bracket This is the preferred method which minimizes wear on components 2 Pressing the accelerator pedal rotates the kick off cam which forces the pedal latch arm to move away from the c...

Page 118: ...is pins will not be under tension by the brake cables Test Result Fails 2 out of 3 Fails 2 out of 3 Perform the Periodic Brake Performance Test PBPT 3 Times 3 Aggressive Stop Test 10 times 4 2 Bad Sea...

Page 119: ...ng that some braking function exists Then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start driving at maximum speed and br...

Page 120: ...eck and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace In excess of 1 1 8 2 9 cm free pedal travel Soft Pedal In Excess of 2 1 4 5 4 cm fre...

Page 121: ...uires complete adjustment Adjust entire system Brake pedal not returning Check for binding of brake pedal Check brake pedal free travel Grabbing brakes oversensitive Moisture has caused surface rust o...

Page 122: ...t eliminate the 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...

Page 123: ...e conditions are found replace both cables and equalizer as a set 5 Check the clevis pins Check clevis pin attaching the brake cables to the brake levers They must be loose when the brake pedal has be...

Page 124: ...esulting from operating a vehicle with improperly oper ating brake system the braking system must be properly maintained All driving brake tests must be done in a safe location with regard for the saf...

Page 125: ...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 t...

Page 126: ...ms Remove excess dust and dirt from the drum with a brush The drum must not be turned to true a worn friction surface Turning will make the drum too thin causing drum failure and a loss of brakes whic...

Page 127: ...shoes and by the moving anchor assembly Replace both backing plates if any gouges or galling is found 9 Measure the brake shoe thickness Measure at the most worn area Brake shoe thickness must never b...

Page 128: ...the 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...

Page 129: ...The parking brake latching force can be checked as verifi cation after setting brake pedal free travel To check park ing brake latching force place a bathroom scale on the service and parking brake p...

Page 130: ...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...

Page 131: ...tube 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 wh...

Page 132: ...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 a...

Page 133: ...edal free travel See Adjusting Brake Pedal Free Travel on Page M 14 Brake Pedal Removal and Installation Disconnect the compensator assembly 1 from the brake pedal by removing the cotter pin 2 and the...

Page 134: ...ing brake arm latch is a hardened part Do not grind or file it as doing so will cause the part to lose its hardness char acteristics A new part must be used Installation is in the reverse order of dis...

Page 135: ...and Kick Off Cam Removal and Installation Installation is in the reverse order of disassembly With the parking brake engaged and fully latched there mus be no gap between the top of the cam and the la...

Page 136: ...the master cylinder Remove the bolts securing the brake actuator assembly housing cover and remove cover The clevis pin joining the brake cylinder clevis and the upper actuator pivot must be removed b...

Page 137: ...ue NOTE Unless fluid is lost or a brake line is dis connected there is no need to bleed the system Rotor Replacement The rotor disc brake hub is not designed to be trued turned If the rotor has deep g...

Page 138: ...dard automotive DOT 3 brake fluid Never reuse any excess fluid or return to the original container Dispose of brake fluid prop erly Brake fluid should never be returned to the original con tainer and...

Page 139: ...Page K 25 Repair and Service Manual B 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 140: ...Page K 26 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 141: ...Wires L 3 Check battery Condition L 3 Check Green Power Wire L 3 Check Fuse L 3 ACCESSORY WIRING L 3 LIGHT BULB REPLACEMENT L 3 FUSE REPLACEMENT L 4 LIST OF ILLUSTRATIONS Fig 1 DVOM L 1 Fig 2 Wiring D...

Page 142: ...Page L 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 143: ...hting 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 th...

Page 144: ...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...

Page 145: ...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...

Page 146: ...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 REPLACEMEN...

Page 147: ...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 REVERSE BUZZER ON OFF GR...

Page 148: ...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 Flo...

Page 149: ...Page L 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 150: ...Page L 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 151: ...er Installation Express S6 M 1 Rear Spring Removal Express S6 M 1 Rear Spring Installation Express S6 M 1 Shock Absorber Express L6 M 3 Shock Absorber Removal Express L6 M 3 Shock Absorber Installatio...

Page 152: ...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 153: ...absorber Shock Absorber Installation Express S6 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 b...

Page 154: ...USPENSION 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 Express S6 Front of the Vehicle...

Page 155: ...er bushing 29 in place until the bottom stud can be installed into the lower mounting plate Install a rubber shock absorber bushing 29 and shock absorber washer 28 cupped surface facing down on the up...

Page 156: ...nut 5 to secure the forward end of the leaf spring in the bracket Install one set of the smaller flanged urethane bushings 11 and spacer 10 in the rear frame mounting holes Position the shackle plates...

Page 157: ...ocedure Pay particular attention to Notices Cautions Warnings and Dangers Removal and installation of the leaf spring is the same for both sides of the vehicle Replace any worn or damaged hardware wit...

Page 158: ...Page M 6 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: ...1 Axle Shaft Seal Removal and Replacement N 2 Axle Shaft Replacement N 3 LIST OF ILLUSTRATIONS Fig 1 Add Check and Drain Rear Axle Lubricant N 1 Fig 2 Removing Installing Outer Snap Ring N 1 Fig 3 Rem...

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

Page 161: ...le is a precision assembly and therefore any repair or replacement of parts must be done with extreme care in a clean environment Before attempting to perform any service on the axle read and understa...

Page 162: ...ment Tools List Qty Internal snap ring pliers 1 Seal puller 1 Seal installer P N 18739 G1 1 Ball peen hammer 1 Use care to prevent damage to the inner surface of the axle tube at the sealing area Remo...

Page 163: ...ter snap ring Coat the outboard spline of the axle with a commercially available anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 8 on Page N 3 Fig 7 Ins...

Page 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: ...ir and Service Manual WEATHER PROTECTION TOP AND WINDSHIELD P 1 Transporting P 1 SUN TOP P 1 Rear Support Installation P 1 Front Support Installation P 1 Sun Top Installation P 1 SPILT WINDSHIELD P 3...

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: ...tion Tap end caps item 7 into top of the rear support items 1 and 2 with plastic faced mallet Ref Fig 1 See Detail A At driver side align holes in the rear support item 1 with holes in seat back suppo...

Page 168: ...ore attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Sun Top Driver Side Rear Shown Front Of Vehicle D B A C 36 Driver Side Shown Front Of Vehicle A 3 4...

Page 169: ...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 into place See Details B and C Repeat...

Page 170: ...Page P 4 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 171: ...TION Q SECTION TITLE PAGE NO Page Q i Repair and Service Manual HANDHELD DIAGNOSTICS HOW TO USE THE HANDHELD PROGRAMMER Q 1 Primary Connection Q 1 Alternate Connection Q 1 Navigation Q 1 Changing Data...

Page 172: ...age Q ii Repair and Service Manual B HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES...

Page 173: ...ow position and also when the battery charger is con nected to the vehicle The main menu appears after the data is uploaded from the unit controller charger etc the main menu will not be displayed if...

Page 174: ...the value of the parame ter BOOKMARK To set a position in the Menu hold a Book mark Key down for four seconds until the Bookmark set screen is displayed To jump to a selected Bookmark position press...

Page 175: ...mph Accel Selection 1 3 2 Braking Selection 1 3 3 5 Freedom Speed 14 5 19 5 18 5 mph Accel Selection 1 2 1 Braking Selection 1 2 1 Monitor Battery Amp Hours 0 100000 AmpHr Battery Voltage 0 100 V Elas...

Page 176: ...Speed Sensor Fault 0 100000 Hrs Main Driver On 0 100000 Hrs Main Coil Open 0 100000 Hrs Main Dropout 1 0 100000 Hrs Motor Stall 0 100000 Hrs Main Driver Off 0 100000 Hrs Main Dropout 2 0 100000 Hrs C...

Page 177: ...r Fault History YES NO Information OEM Info Display OEM information Reconfigured Display reconfigure status Model Number Display handheld model number Serial Number Display handheld serial number Manu...

Page 178: ...Page Q 6 Repair and Service Manual Notes HANDHELD DIAGNOSTICS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 179: ...Page R i Repair and Service Manual TABLE OF CONTENTS FOR SECTION R SECTION TITLE PAGE NO TROUBLESHOOTING 1206HB 5201 Controller Faults and Troubleshooting R 1...

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

Page 181: ...to cause Contactor to close 3 8 Condition clears 1 Controller defective MOTOR STALL High Armature Current when no Speed Pulses detected Contactor closed 6 Speed Pulses appear 1 Motor is stalled 2 Defe...

Page 182: ...d Throttle applied OR Throttle applied before Key and Direction switch applied KSI ON Forward or Reverse ON 8 Throttle 25 1 Incorrect sequence of Vehicle input controls 2 Defective Throttle device THE...

Page 183: ...Page R 3 Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 184: ...Page R 4 Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 185: ...NG GROUNDING REQUIREMENTS S 1 GROUND SYSTEMS S 1 LIGHTINIG PROTECTION REQUIREMENTS S 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM S 1 GROUND NETWORK REQUIREMENTS S 1 EXTERNAL GROUNDING REQUIREMENTS S...

Page 186: ...i 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 Danger...

Page 187: ...ms 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 co...

Page 188: ...east 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 b...

Page 189: ...or 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 in...

Page 190: ...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 Danger...

Page 191: ...L6 T 1 EXPRESS S6 T 4 LIST OF ILLUSTRATIONS Fig 1 EXPRESS L6 Vehicle Dimensions Incline Specifications T 2 Fig 2 EXPRESS L6 Incline Specifications Turning Clearance Diameter T 3 Fig 3 EXPRESS S6 Vehi...

Page 192: ...ge 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 NOTE...

Page 193: ...Differential Power Source Performance Steering Suspension Vehicle Power Drive Train Body Chassis Motor Shaft Direct Drive Differential with helical gears Dash Mounted Forward Neutral Reverse 14 7 1 S...

Page 194: ...is section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 52 5 in 133 5 cm Rear 38 5 in 98 0 cm Front 37 5 in 95 0 cm 76 0 in 193 0 cm RECOMMENDED MA...

Page 195: ...ction B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURNING CLEARANCE DIAMETER 25ft 6inches 7 8 m 6 5 ft 1 98 m INTERSECTING AISL...

Page 196: ...IGHLIGHTS PRODUCT OVERVIEW Overall Height Overall Height With Canopy Wheel Base Front Wheel Track Rear Wheel Track Gnd Clearance Differential Power Source Performance Steering Suspension Vehicle Power...

Page 197: ...this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 EXPRESS S6 Vehicle Dimensions 135 8 in 345 0 cm 99 5 in 253 0 cm 49 0 in 124 0 cm...

Page 198: ...fore attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 4 EXPRESS S6 Incline Specifications Turning Clearance Diameter TURNING CLEARANCE DIAMETER 35 ft 6inc...

Page 199: ...B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 5 Delta Q 48V Charger 4 9 12 45cm...

Page 200: ...age T 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 NOTE...

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Page 202: ...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 ar...