- DL manuals
- E-Z-GO
- Utility Vehicle
- Commander 2100
- Technician's Repair And Service Manual
E-Z-GO Commander 2100 Technician's Repair And Service Manual
Summary of Commander 2100
Page 1
A textron company electric powered utility vehicles revised date: oct 2006 technician’s repair and service manual 28838-g01.
Page 2: Safety
Safety (notes, cautions and warnings continued on inside of back cover) notes, cautions and warnings throughout this guide note, caution and warning will be used. A note indicates a condition that should be observed. A caution indicates a condition that may result in damage to the vehicle. A warning...
Page 3: Technician’S Repair and
Page i repair and service manual technician’s repair and service manual electric utility vehicles mpt ™ 800 industrial ™ 800 mpt ™ 1000 industrial ™ 1000 commander ™ 280 commander ™ 2100 hauler ™ 800 hauler ™ 1000 starting model year: 2004 e-z-go division of textron, inc. Reserves the right to make ...
Page 4: General Information
Page ii general information repair and service manual this vehicle has been designed and manufactured in the united states of america (usa) as a ‘world vehicle’. The standards and specifications listed in the following text originate in the usa unless otherwise indicated. The use of non original equ...
Page 5: Table Of Contents
Page iii repair and service manual table of contents title page safety ........................................................................................................................... Inside covers notes ........................................................................................
Page 6: Table Of Contents
Page iv repair and service manual table of contents notes:.
Page 7: Safety Information
Repair and service manual safety information page v this manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the...
Page 8: Safety Information
Repair and service manual safety information page vi always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles. Always reduce speed in wet areas. Always use extreme caution when ap...
Page 9: Safety Information
Repair and service manual safety information page vii ventilation hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five...
Page 10: Safety Information
Repair and service manual safety information page viii notes:.
Page 11
Table of contents for section ‘a’ section title page no. Page a-i repair and service manual a general information & routine maintenance serial number plate location ............................................................................................A - 1 transporting vehicle ...................
Page 12
General information & routine maintenance page a-ii repair and service manual notes:.
Page 13
A general information & routine maintenance page a-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings serial number plate location the serial number and manufacture date code label are on th...
Page 14
General information & routine maintenance page a-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings this vehicle will give years of satisfactory service provid- ing it receives regular maint...
Page 15
General information & routine maintenance page a-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings ally with plain water. Thoroughly clean any areas where mud or other debris can collect. S...
Page 16
General information & routine maintenance page a-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings hardware periodically the vehicle should be inspected for loose fasteners. Fasteners shoul...
Page 17
General information & routine maintenance page a-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings periodic service schedule ✓ check ♦ clean, adjust, etc. ▲ replace note: some maintenance i...
Page 18
General information & routine maintenance page a-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings front wheel alignment ✓ check for unusual tire wear, align if required park brake ✓ check ...
Page 19: Safety
Table of contents for section ‘b’ section title page no. Page b-i repair and service manual b safety general (asme/ansi b56.8-1988 part ii) ................................................................................B - 1 notes, cautions and warnings ................................................
Page 20: Safety
Safety page b-ii repair and service manual notes:.
Page 21: Safety
B safety page b-1 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, general the following text is provided as recommended by part ii of asme/ansi b56.8-1988. The manufacturer strongly endorses the contents of this...
Page 22: Safety
Safety page b-2 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings 4.8 control of noxious gases and fumes 4.8.1 when equipment powered by internal com- bustion engines is used in enclosed area...
Page 23: Safety
Safety page b-3 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings 5.4.8 operators shall not add to, or modify, the car- rier. 5.4.9 carriers shall not be parked or left unattended such that t...
Page 24: Safety
Safety page b-4 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings trained personnel, and procedures shall be provided. Such facilities may be on or off the premises. 6.2 maintenance procedure...
Page 25: Safety
Safety page b-5 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings notes, cautions and warnings throughout this manual, the following notes, cau- tions and warnings are used. For the protectio...
Page 26: Safety
Safety page b-6 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings before servicing the vehicle before attempting to inspect or service a vehicle, be sure to read and understand the following ...
Page 27: Safety
Safety page b-7 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings and flushed with water. Wrap wrenches with vinyl tape to prevent t h e p o s s i b i l i t y o f a dropped wrench from ‘short...
Page 28: Safety
Safety page b-8 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings lifting the vehicle tool list qty. Required floor jack ..................................................................... ...
Page 29: Safety
Safety page b-9 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings to raise the entire vehicle, install chocks in front and behind each front wheel (ref fig. 3 on page b-8). Center jack under ...
Page 30: Safety
Safety page b-10 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings notes:.
Page 31: Body
Table of contents for section ‘c’ section title page no. Page c-i repair and service manual c body body .............................................................................................................................................. C - 1 general...........................................
Page 32: Body
Body page c-ii repair and service manual notes:.
Page 33: Body
C body page c-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings body in the following text, there are references to removing/installing bolts etc. Additional hard- ware (nuts, washers etc.)...
Page 34: Body
Body page c-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 2 body components (front).
Page 35: Body
Body page c-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 3 body components (rear) 84 85.
Page 36: Body
Body page c-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 4 battery rack components.
Page 37: Body
Body page c-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 5 ashtray and hitches vehicle rear bumper.
Page 38: Body
Body page c-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 6 metal truckbed part of truckbed metal bed.
Page 39: Body
Body page c-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 7 plastic truckbed a a b b c c.
Page 40: Body
Body page c-8 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 8 electric dump actuator may be rotated 90˚ on some models.
Page 41: Wheels And Tires
Table of contents for section ‘d’ section title page no. Page d-i repair and service manual d wheels and tires wheel and tire service ......................................................................................................... D - 1 tire repair..............................................
Page 42: Wheels And Tires
Wheels and tires page d-ii repair and service manual notes:.
Page 43: Wheels And Tires
D wheels and tires page d-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings wheel and tire service tools list qty. Required lug wrench, 3/4" ...................................................
Page 44: Wheels and Tires
Wheels and tires page d-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 1 wheels and tires wheel and/or tire style may vary 1 2 3 4 1 2 5 3 4.
Page 45
Table of contents for section ‘e’ section title page no. Page e-i repair and service manual e front suspension and steering maintenance .............................................................................................................................. G - 2 lubrication ......................
Page 46
Front suspension and steering page e-ii repair and service manual notes:.
Page 47
E front suspension and steering page e-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 1 axle mounted steering and front suspension part of frame part of frame wave washer bearing ou...
Page 48
Front suspension and steering page e-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings maintenance in the following text, there are references to removing/installing bolts etc. Additional h...
Page 49
Front suspension and steering page e-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings the bearing is removed for inspection. It is recommended that a bearing packer attached to a grease gu...
Page 50
Front suspension and steering page e-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings to hold threaded tube while loosening jam nut, use a wrench on the center, flat section of tube. The t...
Page 51
Front suspension and steering page e-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings front suspension front shock absorber replacement tool list qty. Required wrench, 9/16" .................
Page 52
Front suspension and steering page e-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings front axle replacement tool list qty. Required ratchet, 1/2" drive ......................................
Page 53
Front suspension and steering page e-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings failure of a single spring will result in over- stressing the other spring; therefore, replace front s...
Page 54
Front suspension and steering page e-8 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings replace upper portion of floor mat in plastic trim retain- ers. Install front wheels per wheels and ti...
Page 55
Front suspension and steering page e-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings install inner wheel bearing (4) and new grease seal in hub and mount hub to spindle. See ‘hub replacem...
Page 56
Front suspension and steering page e-10 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings steering rack ball joint replacement tool list qty. Required needle nose pliers.........................
Page 57
Front suspension and steering page e-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings to install new rack ball joint close to its correct position, measure amount of threads exposed from ...
Page 58
Front suspension and steering page e-12 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings remove lock nut (10) until tie rod ball joint (6) threads are protected. Using a ball joint separator...
Page 59
Front suspension and steering page e-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings page e-15. Anchor in vice by clamping on the mounting ears of the rack and pinion unit. Slide a small...
Page 60
Front suspension and steering page e-14 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings check front wheel alignment and adjust if necessary. See ‘wheel alignment’ on page e-3. Rack and pini...
Page 61
Front suspension and steering page e-15 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings ion unit until instructed to do so after setting proper rack extension-to-rack and pinion unit cleara...
Page 62
Front suspension and steering page e-16 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings adjust, using an 1/8" thick washer as a gauge, by turning shaft of rack extension with wrench to crea...
Page 63
Front suspension and steering page e-17 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings hammer. Internal damage to rack and pinion unit can result. When steering wheel is loosened, remove r...
Page 64
Front suspension and steering page e-18 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 25 small retaining ring orientation install with arch up as shown small retaining ring groove be...
Page 65
Table of contents for section ‘f’ section title page no. Page f-i repair and service manual f electronic speed control (36v and 48v) 36 volt system vehicles general .....................................................................................F - 1 pedal box .....................................
Page 66
Page f-ii electronic speed control (36v and 48 v) repair and service manual table of contents for section ‘f’ (cont.) section title page no. Testing a solenoid for continuity.........................................................................................F - 23 troubleshooting diagrams ........
Page 67
F electronic speed control (36v) page f-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings general the electronic speed control system consists of two separate units, the pedal box and the c...
Page 68
Electronic speed control (36v) page f-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings socket, 3/8", 3/8" drive ................................................ 1 ratchet, 3/8" drive ........
Page 69
Electronic speed control (36v) page f-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings continuity check to prevent possible inju- r y o r d e a t h r es u l ti n g from a battery explo- si...
Page 70
Electronic speed control (36v) page f-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings troubleshooting diagrams the simplified troubleshooting diagram is a quick esc diagnosis (ref fig. 6 ...
Page 71
Electronic speed control (36v) page f-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 7 detailed troubleshooting diagram (sheet 1 of 8) key off direction selector in n reference volt...
Page 72
Electronic speed control (36v) page f-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 8 detailed troubleshooting diagram (sheet 2 of 8) verify continuity - replace microswitch refere...
Page 73
Electronic speed control (36v) page f-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 9 detailed troubleshooting diagram (sheet 3 of 8) key on, direction selector in f pedal depresse...
Page 74
Electronic speed control (36v) page f-8 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 10 detailed troubleshooting diagram (sheet 4 of 8) key on, direction selector in f pedal depress...
Page 75
Electronic speed control (36v) page f-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 11 detailed troubleshooting diagram (sheet 5 of 8) key on, direction selector in f pedal fully d...
Page 76
Electronic speed control (36v) page f-10 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 12 detailed troubleshooting diagram (sheet 6 of 8) remove b+ wire from battery no (outside rang...
Page 77
Electronic speed control (36v) page f-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 13 detailed troubleshooting diagram (sheet 7 of 8) key on, direction selector in f key on, dire...
Page 78
Electronic speed control (36v) page f-12 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 14 detailed troubleshooting diagram (sheet 8 of 8) remove orange wire from controller key on, d...
Page 79
Electronic speed control (36v) page f-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings inductive throttle sensor (its) testing and replacement tool list qty. Required phillips screwdriver...
Page 80
Electronic speed control (36v) page f-14 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 17 its adjustment (sheet 1 of 2) use 17/64" drill to measure gap between plunger and 'its' micr...
Page 81
Electronic speed control (36v) page f-15 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 18 its adjustment (sheet 2 of 2) micro switch activated plunger enters 'its' plunger fully acti...
Page 82
Electronic speed control (36v) page f-16 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings controller replacement tool list qty. Required socket, 3/8", 3/8" drive ...............................
Page 83
Electronic speed control (36v) page f-17 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 19 wiring diagram + + + + + + - - - - - - bl+ bl- blu blu blk blu 250 5w key switch grn pedal b...
Page 84
Electronic speed control (36v) page f-18 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings notes:.
Page 85
F electronic speed control (48v) page f-19 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings 48 volt system vehicles general 48 volt vehicles are operated in one of four modes or “performance...
Page 86
Electronic speed control (48v) page f-20 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings at monthly intervals, test the 48 volt system by allowing the vehicle to roll down an incline with t...
Page 87
Electronic speed control (48v) page f-21 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings the electrical power to the motor will be interrupted inter- mittently allowing the vehicle to roll ...
Page 88
Electronic speed control (48v) page f-22 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings general troubleshooting tool list qty. Required floor jack.............................................
Page 89
Electronic speed control (48v) page f-23 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings continuity check to prevent possible inju- r y o r d e a t h r es u l ti n g from a battery explo- s...
Page 90
Electronic speed control (48v) page f-24 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings troubleshooting diagrams the following diagrams will assist in servicing the vehi- cle. By utilizing...
Page 91
Electronic speed control (48v) page f-25 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fault code fault vehicle operation change corrective action - - - direction selector fault vehicle o...
Page 92
Electronic speed control (48v) page f-26 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings 4 - 1 current sense fault vehicle will not run • replace controller 4 - 3 m- fault vehicle will not ...
Page 93
Electronic speed control (48v) page f-27 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 9 48 volt wiring diagram 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 a2 a...
Page 94
Electronic speed control (48v) page f-28 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 10 j-1 pin 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...
Page 95
Electronic speed control (48v) page f-29 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 11 j-1 pin connector diagnostics (continued) all tests are to be performed with the negative le...
Page 96
Electronic speed control (48v) page f-30 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 12 j-2 pin 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...
Page 97
Electronic speed control (48v) page f-31 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 13 secondary wiring 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 ...
Page 98
Electronic speed control (48v) page f-32 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings inductive throttle sensor (its) testing and replacement tool list qty. Required phillips screwdriver...
Page 99
Electronic speed control (48v) page f-33 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 15 its adjustment (sheet 1 of 2) use 7/32" drill to measure gap between plunger and 'its' micro...
Page 100
Electronic speed control (48v) page f-34 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 16 its adjustment (sheet 2 of 2) micro switch activated plunger enters 'its' plunger fully acti...
Page 101
Electronic speed control (48v) page f-35 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings controller replacement tool list qty. Required socket, 10mm, 3/8" drive ...............................
Page 102
Electronic speed control (48v) page f-36 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 17 controller wiring j1 j2 j3 f1 f2 b+ b- m- #10 black from motor f2 (power harness) #4 black f...
Page 103: Motor
Table of contents for section ‘g’ section title page no. Page g-i repair and service manual g motor general ....................................................................................................................................... G - 1 motor removal .......................................
Page 104: Motor
Motor page g-ii repair and service manual notes:.
Page 105: Motor
G motor page g-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings general do not hold vehicle on hill by using accelerator and motor. Leaving the motor in a stalled condition for more than 3...
Page 106: Motor
Motor page g-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 3 motor components 15 17 8 11 9 14 12 3 2 48v only 1 6 7 4 13 5 x 1 x 2 a 1 a 2.
Page 107: Motor
Motor page g-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings motor disassembly tool list qty. Required straight blade screwdriver........................................... 1 ratchet, 3/8...
Page 108: Motor
Motor page g-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings remove brushes and replace with new brush replace- ment kit. Locate springs against the side of each brush. Install terminals ...
Page 109: Motor
Motor page g-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 6 motor wiring 36v fig. 7 motor wiring - 48v motor terminal wire marker from a1 a2 s1 s2 a1 a2 s1 s2 direction selector "...
Page 110: Motor
Motor page g-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings.
Page 111: Batteries and Charging
Table of contents for section ‘h’ section title page no. Page h-i repair and service manual h batteries and charging safety .......................................................................................................................................... H - 1 battery...........................
Page 112: Batteries and Charging
Batteries and charging page h-ii repair and service manual notes:.
Page 113: Batteries and Charging
H batteries and charging page h-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, safety always observe the following warnings when working on or near batteries: to prevent battery explosion that could result in...
Page 114: Batteries and Charging
Batteries and charging page h-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings charger to a vehicle that is to be unattended beyond the normal charging cycle. Over- charging could cause da...
Page 115: Batteries And Charging
Batteries and charging page h-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings above top of plates. Cleaning batteries to reduce the possibility of dam- age to vehicle or floor, neutralize...
Page 116: Batteries and Charging
Batteries and charging page h-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings sion to the battery racks or surrounding area should be present. Any corrosion found should be immediately re...
Page 117: Batteries And Charging
Batteries and charging page h-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings battery charging the battery charger is designed to fully charge the bat- tery set. If the batteries are seve...
Page 118: Batteries and Charging
Batteries and charging page h-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings hydrometer a hydrometer (p/n 50900-g1) is used to test the state of charge of a battery cell (ref fig. 7 on p...
Page 119: Batteries And Charging
Batteries and charging page h-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings and replaced with a good battery of the same brand, type and approximate age. Battery charger description the...
Page 120: Batteries and Charging
Batteries and charging page h-8 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings charger maintenance the charging (dc) cord is equipped with a polarized con- nector which fits into a matchin...
Page 121: Electrical System
Table of contents for section ‘j’ section title page no. Page j-i repair and service manual j electrical system digital volt ohm meter .......................................................................................................... J - 1 troubleshooting .......................................
Page 122: Electrical System
Electrical system page j-ii repair and service manual notes:.
Page 123: Electrical System
J electrical system page j-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings digital volt ohm meter a typical digital volt ohm meter (dvom) is shown (ref fig. 1 on page h-1). A recommended ...
Page 124: Electrical System
Electrical system page j-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 2 36 volt wiring diagram turn turn marker marker headlight headlight grn blk blk blk blk blk red red blk yel ...
Page 125: Electrical System
Electrical system page j-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 3 48 volt wiring diagram driver side passenger side marker marker headlight headlight grn blk blk blk blk blk...
Page 126: Electrical System
Electrical system page j-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings power supply tool list qty. Required dvom............................................................................
Page 127: Electrical System
Electrical system page j-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 4 ignition switch, direction selector, state of charge meter red grn/ blk reverse buzzer dash mounted directi...
Page 128: Electrical System
Electrical system page j-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 5 horn, fuse block, hour meter floor mounted horn button ho rn floorboard floormat horn hour meter detail fus...
Page 129: Electrical System
Electrical system page j-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 6 turn signal, headlight, tail light rear fender taillight headlight turn signal or.
Page 130: Electrical System
Electrical system page j-8 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings.
Page 131: Brakes
Table of contents for section ‘k’ section title page no. Page k-i repair and service manual k brakes brakes - rear mechanical brake system overview .........................................................................................................K - 1 general description.........................
Page 132: Brakes
Page k-ii brakes repair and service manual table of contents for section ‘k’ (cont.) section title page no. Fig. 19 check clevis pins............................................................................................................. K - 15 fig. 20 checking parking brake latching pressure ....
Page 133: Brakes - Rear Mechanical
K brakes - rear mechanical page k-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings brake system overview general description this vehicle is equipped with a mechanically activated rear dru...
Page 134: Brakes - Rear Mechanical
Brakes - rear mechanical page k-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings requires enough cable travel at the wheel brake to work reliably. When the brake is released, there must be...
Page 135: Brakes - Rear Mechanical
Brakes - rear mechanical page k-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings bracket. The service brake pedal is held in the applied (down) position by the catch bracket. The latch arm...
Page 136: Brakes - Rear Mechanical
Brakes - rear mechanical page k-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings troubleshooting flowchart fig. 5 troubleshooting flowchart do steps through to one side at a time 1 bad vis...
Page 137: Brakes - Rear Mechanical
Brakes - rear mechanical page k-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 5 troubleshooting flowchart adjuster tries to move star wheel? Star wheel rotates? Free movement of sl...
Page 138: Brakes - Rear Mechanical
Brakes - rear mechanical page k-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings troubleshooting table refer to the following troubleshooting table only after the thorough visual inspectio...
Page 139: Brakes - Rear Mechanical
Brakes - rear mechanical page k-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings neither wheel locks when park brake is latched. (note: at full speed the wheels may not lock, but should br...
Page 140: Brakes - Rear Mechanical
Brakes - rear mechanical page k-8 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings troubleshooting and inspection new vehicles a new vehicle will undergo an initial break-in of compo- nents ...
Page 141: Brakes - Rear Mechanical
Brakes - rear mechanical page k-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings adjustment of free travel depends on manufac- turing date. The correct brake pedal free travel setting vari...
Page 142: Brakes - Rear Mechanical
Brakes - rear mechanical page k-10 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings to prevent serious injury or death from the use of worn parking brake com- ponents, do not attempt to re-n...
Page 143: Brakes - Rear Mechanical
Brakes - rear mechanical page k-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings ping location or measure the vehicle stopping distance from the point at which the brakes were latched. Th...
Page 144: Brakes - Rear Mechanical
Brakes - rear mechanical page k-12 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings wheel brake inspection wear a dust mask and eye protection whenever w o r k i n g o n w h e e l brakes. Do...
Page 145: Brakes - Rear Mechanical
Brakes - rear mechanical page k-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings 9. Measure the brake shoe thickness. Measure at the most worn area. Brake shoe thick- ness must never be l...
Page 146: Brakes - Rear Mechanical
Brakes - rear mechanical page k-14 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings maintenance and repairs tool list qty. Required hydraulic floor jack ........................................
Page 147: Brakes - Rear Mechanical
Brakes - rear mechanical page k-15 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings at the spherical nut, adjust the free travel as noted above. Drive again and brake aggressively 10 times. ...
Page 148: Brakes - Rear Mechanical
Brakes - rear mechanical page k-16 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings pay particular attention to the location of the inner brake drum washer (6) inside the brake drum, which m...
Page 149: Brakes - Rear Mechanical
Brakes - rear mechanical page k-17 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings be sure that the adjusting screw is screwed into the star wheel nut until only 1 - 2 threads are exposed (...
Page 150: Brakes - Rear Mechanical
Brakes - rear mechanical page k-18 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings install adjuster mechanism (driver side silver, passenger side gold). Be sure that the two teflon coated w...
Page 151: Brakes - Rear Mechanical
Brakes - rear mechanical page k-19 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings ing a thin blade screwdriver between the small hook and the bracket. Move the hook back and to the side to...
Page 152: Brakes - Rear Mechanical
Brakes - rear mechanical page k-20 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings to prevent serious injury or death resulting from the use of worn parking brake components, to not attempt...
Page 153: Brakes - Front Disc
K brakes - front disc page k-21 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings system description to assure correct braking performance, all peri- odic maintenance, inspections and procedu...
Page 154: Brakes - Front Disc
Brakes - front disc page k-22 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings routine maintenance tool list qty. Required shop rag..............................................................
Page 155: Brakes - Front Disc
Brakes - front disc page k-23 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings actuator pivot and the linkage rod (see actuator linkage bushings). The clevis pin joining the brake cylinder c...
Page 156: Brakes - Front Disc
Brakes - front disc page k-24 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings notes:.
Page 157: Battery Charger
Table of contents for section ‘l’ section title page no. Page l-i repair and service manual l battery charger 48 v battery charger ............................................................................................................. L - 1 description.............................................
Page 158: Battery Charger
Battery charger page l-ii repair and service manual notes:.
Page 159: Battery Charger
L battery charger page l-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings 48 volt battery charger description the battery charger accompanying this vehicle is 120 volt ac, 60 hz input with...
Page 160: Battery Charger
Battery charger page l-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings looping the dc cord through the steering wheel when charging serves as a good reminder to store the cord out of the ...
Page 161: Battery Charger
Battery charger page l-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings troubleshooting tool list qty. Required dvom ..........................................................................
Page 162: Battery Charger
Battery charger page l-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 6 troubleshooting sequence relay clicks plug ac cord into known good socket finish check vehicle batteries amme...
Page 163: Battery Charger
Battery charger page l-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 7 diode test procedure low resistance high resistance reverse bias select forward bias dvom's shown are for ref...
Page 164: Battery Charger
Battery charger page l-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 8 powerwise™ wiring diagram power input board ac input line cord blk wht grn grn ground control board orn brn r...
Page 165: Rear Suspension
Table of contents for section ‘m’ section title page no. Page m-i repair and service manual m rear suspension rear suspension...................................................................................................................... M - 1 general .............................................
Page 166: Rear Suspension
Rear suspension page m-ii repair and service manual notes:.
Page 167: Rear Suspension
M rear suspension page m-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings rear suspension in the following text, there are references to removing/installing bolts etc. Additional hard- war...
Page 168: Rear Suspension
Rear suspension page m-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 1 rear suspension 8 4 5 6 7 6 7 7 6 7 1 11 2 3 12 6 9 10 13.
Page 169: Rear Axle
Table of contents for section ‘n’ section title page no. Page n-i repair and service manual n rear axle rear axle removal ......................................................................................................................... N - 1 rear axle installation...............................
Page 170: Rear Axle
Rear axle page n-ii repair and service manual notes:.
Page 171: Rear Axle
N rear axle page n-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings rear axle removal the rear axle assembly is top heavy. To reduce the possibility of personal injury while removing the r...
Page 172: Rear Axle
Rear axle page n-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings axle shaft removal and disassembly tool list qty. Required arbor press.......................................................
Page 173: Rear Axle
Rear axle page n-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings axle shaft replacement carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline...
Page 174: Rear Axle
Rear axle page n-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings.
Page 175: Weather Protection
Table of contents for section ‘p’ section title page no. Page p-i repair and service manual p weather protection top and windshield..................................................................................................................P - 1 trailering..........................................
Page 176: Weather Protection
Weather protection page p-ii repair and service manual notes:.
Page 177: Weather Protection
P weather protection page p-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings top and windshield the top does not provide protection from roll over or falling objects. The windshield does n...
Page 178: Weather Protection
Weather protection page p-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 1 sun top 17 front of vehicle (rear) front of vehicle (front) front of vehicle 8 8 1 16 14 14 15 14 14 15 13...
Page 179: Weather Protection
Weather protection page p-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings split windshield remove protective covering from the windshield (item 3 or 4) (ref fig. 2 on page p-3). Install s...
Page 180: Weather Protection
Weather protection page p-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings fig. 3 one piece windshield 6 5 strut 3 7 4 2 front of vehicle.
Page 181: Paint
Table of contents for section ‘q’ section title page no. Page q-i repair and service manual q paint painting ....................................................................................................................................... Q - 1 minor scratches.....................................
Page 182: Paint
Paint page q-ii repair and service manual notes:.
Page 183: Paint
Q paint page q-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings painting follow the paint manufacturer’s recommendations for specific painting procedures and information. A ll pa in t i ng...
Page 184: Paint
Paint page q-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings notes:.
Page 185: Troubleshooting
Table of contents for section ‘r’ section title page no. Page r-i repair and service manual r troubleshooting electrical system ................................................................................................................. R - 1 basic electrical power system troubleshooting .........
Page 186: Troubleshooting
Troubleshooting page r-ii repair and service manual notes:.
Page 187: Troubleshooting
R troubleshooting page r-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings electrical system condition possible cause correction vehicle will not move (36volt vehicles) refer to section f (...
Page 188: Troubleshooting
Troubleshooting page r-2 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings basic electrical power system troubleshooting to diagnose electrical problems in the electrical power system, refer ...
Page 189: Troubleshooting
Troubleshooting page r-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings suspension and steering condition possible cause correction uneven tire wear incorrect tire pressure inflate to reco...
Page 190: Troubleshooting
Troubleshooting page r-4 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings steering pulls to one side incorrect tire pressure inflate to recommended pressure dragging wheel brake service brak...
Page 191
Table of contents for section ‘s’ section title page no. Page s-i repair and service manual s lightning protection and grounding grounding requirements ................................................................................................................S - 1 ground systems ..................
Page 192
Lightning protection and grounding page s-ii repair and service manual notes:.
Page 193
Page s-1 repair and service manual gs-726-006 effective: 10/19/92 revision: a supercedes: title: general specification: lightning protection and grounding rev -, ecn 027194 s lightning protection and grounding read all of section b and this section before attempting any procedure. Pay particular att...
Page 194
Page s-2 repair and service manual gs-726-006 effective: 10/19/92 revision: a supercedes: title: general specification: lightning protection and grounding rev -, ecn 027194 lightning protection and grounding read all of section b and this section before attempting any procedure. Pay particular atten...
Page 195
Page s-3 repair and service manual gs-726-006 effective: 10/19/92 revision: a supercedes: title: general specification: lightning protection and grounding rev -, ecn 027194 lighting protection and grounding read all of section b and this section before attempting any procedure. Pay particular attent...
Page 196
Page s-4 repair and service manual gs-726-006 effective: 10/19/92 revision: a supercedes: title: general specification: lightning protection and grounding rev -, ecn 027194 lightning protection and grounding read all of section b and this section before attempting any procedure. Pay particular atten...
Page 197: General Specifications
Table of contents for section ‘t’ section title page no. Page t-i repair and service manual t general specifications mpt™ 800 .......................................................................................................................................T - 1 mpt™ 1000 ..........................
Page 198: General Specifications
General specifications page t-ii repair and service manual notes:.
Page 199: General Specifications
Page t-1 repair and service manual t general specifications mpt ™ 800 standard equipment: weight (without batteries) 675 lbs. (306 kg) tires 18 x 8.50 x 8 (4 ply rated) tire pressure 18 - 22 psi (120 - 150 kpa) load capacity 800 lbs. (362 kg) (including operator, passenger, cargo and accessories) gr...
Page 200: General Specifications
Page t-2 repair and service manual general specifications mpt ™ 1000 standard equipment: weight (without batteries) 809 lbs. (374 kg) tires (4 ply rated) 18 x 8.50 x 8 (4 ply rated) tire pressure 18 - 22 psi (120 - 150 kpa) load capacity 1000 lbs. (454 kg) (including operator, passenger, cargo and a...
Page 201: General Specifications
Page t-3 repair and service manual general specifications industrial ™ 800 standard equipment: weight (without batteries) 675 lbs. (306 kg) tires 18 x 5.70 x 8 (4 ply rated) tire pressure 35 - 45 psi (241 - 310 kpa) load capacity 800 lbs. (362 kg) (including operator, passenger, cargo and accessorie...
Page 202: General Specifications
Page t-4 repair and service manual general specifications industrial ™ 1000 standard equipment: weight (without batteries) 809 lbs. (374 kg) tires (4 ply rated) 18 x 5.70 x 8 (4 ply rated) tire pressure 35 - 45 psi (241 - 310 kpa) load capacity 1000 lbs. (454 kg) (including operator, passenger, carg...
Page 203: General Specifications
Page t-5 repair and service manual general specifications commander ™ 280 standard equipment: weight (without batteries) 675 lbs. (306 kg) tires 18 x 8.50 x 8 (4 ply rated) tire pressure 18 - 22 psi (120 - 150 kpa) load capacity 800 lbs. (362 kg) (including operator, passenger, cargo and accessories...
Page 204: General Specifications
Page t-6 repair and service manual general specifications commander ™ 2100 standard equipment: weight (without batteries) 809 lbs. (374 kg) tires (4 ply rated) 18 x 8.50 x 8 (4 ply rated) tire pressure 18 - 22 psi (120 - 150 kpa) load capacity 1000 lbs. (454 kg) (including operator, passenger, cargo...
Page 205: General Specifications
Page t-7 repair and service manual general specifications jacobsen hauler ™ 800 standard equipment: weight (without batteries) 675 lbs. (306 kg) tires 18 x 8.50 x 8 (4 ply rated) tire pressure 18 - 22 psi (120 - 150 kpa) load capacity 800 lbs. (362 kg) (including operator, passenger, cargo and acces...
Page 206: General Specifications
Page t-8 repair and service manual general specifications jacobsen hauler ™ 1000 standard equipment: weight (without batteries) 809 lbs. (374 kg) tires (4 ply rated) 18 x 8.50 x 8 (4 ply rated) tire pressure 18 - 22 psi (120 - 150 kpa) load capacity 1000 lbs. (454 kg) (including operator, passenger,...
Page 207: General Specifications
Page t-9 repair and service manual general specifications fig. 1 vehicle dimensions mpt™ 800 industrial™ 800 cushman™ 280 jacobsen™ 800 mpt™ 1000 industrial™ 1000 cushman™ 2100 jacobsen™ 1000 103 in (262 cm) (rear) 38 in (97 cm) (front) 38 in (97 cm) 35 in (89 cm) 10 in (25 cm) 47 in (119 cm) 47 in ...
Page 208: General Specifications
Page t-10 repair and service manual general specifications fig. 2 vehicle dimensions, incline specifications and turning clearance diameter recommended max ramp grade 25% or 14 o max recommended max side tilt 25% or 14 o max turning clearance diameter mpt™ 800 19 ft (5.8 m) mpt™ 1000 22 ft (6.7 m) i...
Page 209: General Specifications
Page t-11 repair and service manual general specifications fig. 3 powerwise tm portable battery charger dimensions sized for 3/16 in. (5 mm) bolt rear side 10 ft. Dc cord (3 m) front 9 1/8 in. (23 cm) 2 1/4 in. (6 cm) 7 3/4 in. (20 cm) 10 7/8 in. (28 cm) 6 3/4 in. (17 cm) 4 7/8 in. (12 cm) 8 3/16 in...
Page 210: General Specifications
Page t-12 repair and service manual general specifications.
Page 211
Read and understand the following warnings before attempting to operate the vehicle: to prevent personal injury or death, observe the following: when vehicle is to be left unattended, engage parking (park) brake, move direction selector to neutral, turn key to ‘off’ position and remove key. Drive ve...
Page 212
Copyrighted material this manual may not be reproduced in whole or in part without the express permission of e-z-go division of textron, inc. Technical communications department e-z-go division of textron, inc., 1451 marvin griffin road, augusta, georgia usa 30906-3852 to contact us north america: t...