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- Technician's Repair And Service Manual
Ezgo ELECTRIC POWERED PERSONNEL CARRIERS Technician's Repair And Service Manual
Summary of ELECTRIC POWERED PERSONNEL CARRIERS
Page 1
A textron company electric powered personnel carriers and golf car technician’s repair and service manual 600938 issued september 2004 revised october 2007.
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 owner’s manual and service guide technician’s repair and service manual electric utility vehicles shuttle 2 shuttle 4 shuttle 6 bellhop 2 bellhop 4 bellhop 6 txt 5e starting model year: 2005 the e-z-go division of textron inc. Reserves the right to incorporate engineering and design changes t...
Page 4
Page ii notes owner’s manual and service guide 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 equipment ...
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
Table of contents for section ‘a’ section title page no. Page a-i repair and service manual a general information & routine maintenance serial number label location ............................................................................................A - 1 transporting vehicle ...................
Page 8
General information & routine maintenance page a-ii repair and service manual notes:.
Page 9
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, serial number label location two serial number and manufacture date code label are on the vehicle. One is plac...
Page 10
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 routine maintenance some maintenance items must be serviced more frequently on vehicles us...
Page 11
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 rubber parts should be cleaned with non-abrasive household cleaner. Occasional cleaning an...
Page 12
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 13
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 3 check clean, adjust, etc. S replace note: some maintenance ite...
Page 14
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 3 check for unusual tire wear, align if required park brake 3 check ...
Page 15: Safety
Table of contents for section ‘b’ section title page no. Page b-i repair and service manual b safety generalansi / ngcma z130.1-1993, part ii ..............................................................................B - 1 general (asme / ansi b56.8 - 1988)...........................................
Page 16: Safety
Safety page b-ii repair and service manual notes:.
Page 17: 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 ansi / ngcma z130.1 - 1993. The manufacturer, as a member of the national gol...
Page 18: 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 6. Maintenance 6.1. Introduction 6.1.1. Golf cars may become hazardous if maintenance is neglected or improperly performed. T...
Page 19: 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 6.2.5.7. Brakes, steering mechanisms, warning devices, governors and all other safety devices shall be inspected and maintain...
Page 20: 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 general the following text is provided as recommended by part ii of asme/ansi b56.8-1988. The manufacturer strongly endorses ...
Page 21: 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 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 22: 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 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 23: 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 6 maintenance practices 6.1 introduction 6.1.1 carriers may become hazardous if mainte- nance is neglected. Therefore, mainte...
Page 24: 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 notes, cautions and warnings throughout this manual, the following notes, cau- tions and warnings are used. For the protectio...
Page 25: 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 before servicing the vehicle before attempting to inspect or service a vehicle, be sure to read and understand the following ...
Page 26: 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 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 ‘shor...
Page 27: Safety
Safety page b-11 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 28: Safety
Safety page b-12 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 29: 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 30: Body
Body page c-ii repair and service manual notes:.
Page 31: 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, body in the following text, there are references to removing/installing bolts etc. Additional hard- ware (nuts, washers etc.) that are removed must...
Page 32: 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) 1 4 5 6 7 8 9 10 11 12 13 14 15 16 frame 52 53 54 55 56.
Page 33: 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 (seats and rear) 29 30 31 28 18 26 27 25 34 45 50 54 53 49 34 33 32 47 46 44 43 23 22 a a shuttle 4 mode...
Page 34: 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 body components (cargo box, seat, foot rest) 43 36 37 35 38 38 40 43 39 41 41 42 seat bed seat back support or bed frame.
Page 35: 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 instrument panel replacement tool list qty. Reqd. Electric/air drill..............................................................
Page 36: 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 rocker panel end replacement tool list qty. Reqd. Phillips screwdriver...................................................... 1 ...
Page 37: 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 remove the rear rocker panel ends as described above. Remove the rear seat from the rear body (32) (ref fig. 3 on page c-3). Re...
Page 38: 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 front seat replacement tool list qty. Reqd. Wrench, 7/16".............................................................. 2 the f...
Page 39: Body
Body page c-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 adjust as necessary by moving tab to the front or back to allow full engagement of latch assembly on tab. Shuttle / bellhop 2 r...
Page 40: Body
Body page c-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 inadvert- ent movement that c o u l d r e s u l t i n s e v e r e i n j u r y o r death, remove the negative (-) ba...
Page 41: Body
Body page c-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 rocker panel removal tool list qty. Required phillips screwdriver bit, 3/8" drive ............................... 1 phillips s...
Page 42: Body
Body page c-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 drill out the two rivets (item 1) securing the fuse block (item 2) to the fender (item 3). Remove the two bolts, washers and l...
Page 43: Body
Body page c-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 are to be tightened to 8.5 - 9.0 ft.Lbs (11.5 -12 nm) torque. It is recommended that new lock nuts be used. Bulkhead removal t...
Page 44: Body
Body page c-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 bed frame removal tool list qty. Required torque wrench, 3/8" drive, ft. Lbs ................................. 1 phillips scre...
Page 45: Body
Body page c-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 remove the two torx head bolts, washers and lock nuts (items 6, 7 & 8) from the rear legs of the seat frame. The front seat fr...
Page 46: Body
Body page c-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 remove the two horizontal bolts, washers and lock nuts (items 4, 5 & 6) securing the battery rack (item 7) to the mid support ...
Page 47: 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 48: Wheels and Tires
Wheels and tires page d-ii repair and service manual notes:.
Page 49: 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, wheel and tire service tools list qty. Required lug wrench, 3/4" ......................................................... 1 impact wre...
Page 50: 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 pattern when installing lug nuts. This will assure even seating of the wheel against the hub. With the valve stem t...
Page 51
Table of contents for section ‘e’ section title page no. Page e-i repair and service manual e front suspension and steering maintenance ...............................................................................................................................E - 2 lubrication ......................
Page 52
Front suspension and steering page e-ii repair and service manual notes:.
Page 53
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, fig. 1 axle mounted steering and front suspension part of frame part of frame wave washer bearing outer snap ring inner sn...
Page 54
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 55
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 replaced. See ‘wheel bearing and race replacement’ on page e-8. The front wheel bearings are tapered r...
Page 56
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 measurement taken at the front of the tires should be 0" - 1/8" (0 - 3 mm) less than the rear. To hold...
Page 57
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 58
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 59
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 socket, 5/8", 1/2" drive................................................ 1 wrench, 5/8" .................
Page 60
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 ball peen hammer ....................................................... 1 needle nose pliers............
Page 61
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 to install race (5), make sure bore of hub (1) is clean and place new race over bore of hub. Evenly ta...
Page 62
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 63
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 64
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 hand threads (counter-clockwise to loosen) (ref fig. 14 on page e-11). Remove lock nut (10) until tie...
Page 65
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 can be damaged if held otherwise. To access the pinion seal, remove rack and pinion unit from vehicle...
Page 66
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 install front wheels per wheels and tires section and lower vehicle per safety section. Check front w...
Page 67
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 (8). Do not secure large end of bellows to rack and pin- ion unit until instructed to do so after set...
Page 68
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 slide bellows away from rack and pinion unit to see large hex of rack extension. An 1/8" gap should e...
Page 69
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 do not strike steering nut or end of steering shaft directly with ball peen hammer. Internal damage t...
Page 70
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 install front wheel(s) per wheels and tires section and lower vehicle per safety section install stee...
Page 71: Electronic Speed Control
Table of contents for section ‘f’ section title page no. Page f-i repair and service manual f electronic speed control operation ....................................................................................................................................F - 2 pedal box ..........................
Page 72: Electronic Speed Control
Electronic speed control page f-ii repair and service manual notes:.
Page 73: Electronic Speed Control
F electronic speed control 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, performance the vehicle will operate only when the run - tow/maintenance switch is in the ’run’ posi- tion. See ‘diagnostic mod...
Page 74: Electronic Speed Control
Electronic speed control 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 b) the brake is engaged so as to prevent vehicle motion the controller will sense a stalled motor condition...
Page 75: Electronic Speed Control
Electronic speed control 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 if the operator attempts to override the electronic braking feature by moving the direction selector or key...
Page 76: Electronic Speed Control
Electronic speed control 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 general troubleshooting tool list qty. Required floor jack....................................................
Page 77: Electronic Speed Control
Electronic speed control 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 continuity check to prevent possible i n j u r y o r d e a t h resulting from a bat- tery explosion, use an...
Page 78: Electronic Speed Control
Electronic speed control 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 troubleshooting diagrams the following diagrams will assist in servicing the vehi- cle. By utilizing the fa...
Page 79: Electronic Speed Control
Electronic speed control 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 fault code fault vehicle operation change corrective action - - - direction selector fault vehicle operates...
Page 80: Electronic Speed Control
Electronic speed control 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 4 - 1 current sense fault vehicle will not run • replace controller 4 - 3 m- fault vehicle will not run • c...
Page 81: Electronic Speed Control
Electronic speed control 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. 10 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 a1 f1 f...
Page 82: Electronic Speed Control
Electronic speed control 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. 11 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 j1 it...
Page 83: Electronic Speed Control
Electronic speed control 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. 12 j-1 pin connector diagnostics (continued) all tests are to be performed with the negative lead of ...
Page 84: Electronic Speed Control
Electronic speed control 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. 13 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 j1 wh...
Page 85: Electronic Speed Control
Electronic speed control 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 fig. 14 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 j1 a2 ...
Page 86: Electronic Speed Control
Electronic speed control 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 inductive throttle sensor (its) testing and replacement tool list qty. Required phillips screwdriver.........
Page 87: Electronic Speed Control
Electronic speed control 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. 16 its adjustment (sheet 1 of 2) use 7/32" drill to measure gap between plunger and 'its' micro switc...
Page 88: Electronic Speed Control
Electronic speed control 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 fig. 17 its adjustment (sheet 2 of 2) micro switch activated plunger enters 'its' plunger fully activated ...
Page 89: Electronic Speed Control
Electronic speed control 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 controller replacement tool list qty. Required socket, 10mm, 3/8" drive .....................................
Page 90: Electronic Speed Control
Electronic speed control 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 fig. 18 controller wiring j1 j2 j3 f1 f2 b+ b- m- #10 black from motor f2 (power harness) #4 black from mo...
Page 91: Brakes - Front Disc
Table of contents for section ‘g’ section title page no. Page g-i repair and service manual g brakes - front disc system description ................................................................................................................ G - 1 master cylinder replacement .......................
Page 92: Brakes - Front Disc
Brakes - front disc page g-ii repair and service manual notes:.
Page 93
G brakes - front disc 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, system description to assure correct braking performance, all peri- odic maintenance, inspections and procedures must be performed a...
Page 94
Brakes - front disc 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 routine maintenance tool list qty. Required shop rag...............................................................
Page 95
Brakes - front disc 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 the actuator linkage must be removed from the lower actuator pivot and the linkage rod (see actuator linkage bus...
Page 96
Brakes - front disc 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 notes:.
Page 97: Mechanical Brakes
Table of contents for section ‘h’ section title page no. Page h-i repair and service manual h mechanical brakes brake system overview ........................................................................................................ H - 1 general description.......................................
Page 98: Mechanical Brakes
Page h-ii mechanical brakes repair and service manual table of contents for section ‘h’ (cont.) section title page no. Fig. 21 brake assembly................................................................................................................ H - 16 fig. 22 wheel brake lubrication points ...
Page 99: Mechanical Brakes
H mechanical brakes 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, brake system overview general description this vehicle is equipped with a mechanically activated rear drum brake system. The brake sys...
Page 100: Mechanical Brakes
Mechanical brakes 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 requires enough cable travel at the wheel brake to work reliably. When the brake is released, there must be slack ...
Page 101: Mechanical Brakes
Mechanical brakes 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 bracket. The service brake pedal is held in the applied (down) position by the catch bracket. The latch arm is hel...
Page 102: Mechanical Brakes
Mechanical brakes 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 troubleshooting flowchart fig. 5 troubleshooting flowchart do steps through to one side at a time 1 bad visually c...
Page 103: Mechanical Brakes
Mechanical brakes 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 fig. 5 troubleshooting flowchart adjuster tries to move star wheel? Star wheel rotates? Free movement of sliding a...
Page 104: Mechanical Brakes
Mechanical brakes 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 troubleshooting table refer to the following troubleshooting table only after the thorough visual inspection, peri...
Page 105: Mechanical Brakes
Mechanical brakes 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 neither wheel locks when park brake is latched. (note: at full speed the wheels may not lock, but should brake agg...
Page 106: Mechanical Brakes
Mechanical brakes 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 troubleshooting and inspection new vehicles a new vehicle will undergo an initial break-in of compo- nents includi...
Page 107: Mechanical Brakes
Mechanical brakes page h-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 either condition can prevent the brakes from adjust- ing properly. Adjustment of free travel depends on manufac- t...
Page 108: Mechanical Brakes
Mechanical brakes page h-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 9. Check the condition and operation of the parking brake latching mechanism. The parking brake should latch firm...
Page 109: Mechanical Brakes
Mechanical brakes page h-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 over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with...
Page 110: Mechanical Brakes
Mechanical brakes page h-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 ing. Wheel brake inspection wear a dust mask and eye protection whenever working on wheel brakes. Do not use pres...
Page 111: Mechanical Brakes
Mechanical brakes page h-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 against the backing plate, replace both of the wheel brake assemblies. A b a c k i n g p l a t e a s s e m b l y ...
Page 112: Mechanical Brakes
Mechanical brakes page h-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 orientation of brake shoe springs heavy shoe spring light shoe spring adjuster spring adjuster spring lig...
Page 113: Mechanical Brakes
Mechanical brakes page h-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 maintenance and repairs tool list qty. Required hydraulic floor jack................................................
Page 114: Mechanical Brakes
Mechanical brakes page h-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 tively, start driving at maximum speed and brake aggressively 10 times. At the spherical nut, adjust the free tra...
Page 115: Mechanical Brakes
Mechanical brakes page h-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 blade screwdriver to raise the adjuster arm just above the star wheel. Loosen the star wheel to retract the brake...
Page 116: Mechanical Brakes
Mechanical brakes page h-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 the actuator components, adjuster components and brake shoes. See ‘brake shoe and adjuster replace- ment’...
Page 117: Mechanical Brakes
Mechanical brakes page h-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 clean the backing plate with a commercial brake cleaner. Allow to dry completely. Lubricate the friction points o...
Page 118: Mechanical Brakes
Mechanical brakes page h-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 installation is the reverse of removal. Use new cotter pins in the clevis pin. Adjust the brake pedal free travel...
Page 119: Mechanical Brakes
Mechanical brakes page h-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 not attempt to re-new worn components. The parking brake arm latch is a hardened part. Do not grind or file it as...
Page 120: Mechanical Brakes
Mechanical brakes page h-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 new epoxy patch setscrews when replacing the kick-off cam..
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, digital volt ohm meter a typical digital volt ohm meter (dvom) is shown (ref fig. 1 on page j-1). A recommended dvom is available thro...
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 wiring diagram driver side passenger side marker marker headlight headlight grn blk blk blk blk blk red red...
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 power supply tool list qty. Required dvom ...........................................................................
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 fig. 3 headlight, turn signal & marker light bulb replacement fig. 4 tail and brake light bulb replacement marker ...
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. 5 ignition switch, fuse block grn red orn/wht blu/wht battery bl+ (light switch) (horn switch) (brake light s...
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. 6 horn fig. 7 turn signal, headlight, tail light front of vehicle blk yel horn floorboard floormat turn signa...
Page 129: Motor
Table of contents for section ‘k’ section title page no. Page k-i repair and service manual k motor general ........................................................................................................................................K - 1 motor removal .......................................
Page 130: Motor
Motor page k-ii repair and service manual notes:.
Page 131: Motor
K motor 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, general do not hold vehicle on hill by using accelerator and motor. Leaving the motor in a stalled condition for more than 3-4 seconds will raise ...
Page 132: Motor
Motor 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 fig. 3 motor components 15 17 8 11 9 14 12 3 2 1 6 7 4 13 5 x 1 x 2 a 1 a 2.
Page 133: Motor
Motor 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 bearing replacement tool list qty. Required heat gun or lamp ........................................................ 1 arbor ...
Page 134: Motor
Motor 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 heat to aid installation. Position brushes against commu- tator. Ensure the springs are seated against the rear of the brushes...
Page 135: Batteries and Charging
Table of contents for section ‘l’ section title page no. Page l-i repair and service manual l batteries and charging safety ........................................................................................................................................... L - 1 battery..........................
Page 136: Batteries and Charging
Batteries and charging page l-ii repair and service manual notes:.
Page 137: Batteries and Charging
L batteries and charging 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, safety always observe the following warnings when working on or near batteries: to prevent battery explosion that could result in...
Page 138: Batteries and Charging
Batteries and charging 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 charger to a vehicle that is to be unattended beyond the normal charging cycle. Over- charging could cause da...
Page 139: Batteries And Charging
Batteries and charging 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 above top of plates. Cleaning batteries to reduce the possibility of dam- age to vehicle or floor, neutralize...
Page 140: Batteries and Charging
Batteries and charging 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 sion to the battery racks or surrounding area should be present. Any corrosion found should be immediately re...
Page 141: Batteries And Charging
Batteries and charging 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 battery charging the battery charger is designed to fully charge the bat- tery set. If the batteries are seve...
Page 142: Batteries and Charging
Batteries and charging 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 sulfuric acid to water in a new golf car battery is 1.280 which means that the electrolyte weighs 1.280 times...
Page 143: Batteries And Charging
Batteries and charging page l-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 airways as overheating may result which could cause serious damage to the charger and create the potential fo...
Page 144: Batteries and Charging
Batteries and charging page l-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. 11 charger plug main contact auxiliary contact.
Page 145: 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 146: Rear Suspension
Rear suspension page m-ii repair and service manual notes:.
Page 147: 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, rear suspension in the following text, there are references to removing/installing bolts etc. Additional hard- ware (nuts, washers etc.)...
Page 148: 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 remove the spring. Rear spring installation tool list qty. Required torque wrench, ft. Lbs., 1/2" drive ...............
Page 149: 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 150: Rear Axle
Rear axle page n-ii repair and service manual notes:.
Page 151: 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, for further axle information, see electric rear axle man- ual p/n 28148-g01. Rear axle removal tool list qty. Required wrench, 1/2" insulated ...
Page 152: 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 rear axle installation tool list qty. Required torque wrench, ft. Lbs., 1/2" drive ................................ 1 sock...
Page 153: 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 line up the hole in the axle shaft flange with the backing plate nuts and remove backing plate nuts which hold the axle sh...
Page 154: 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 support the axle shaft assembly in a suitable press. Press on the end of the axle shaft until the wheel bearing assembly a...
Page 155: 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 transporting .......................................
Page 156: Weather Protection
Weather protection page p-ii repair and service manual notes:.
Page 157: 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, top and windshield t h e t o p d o e s n o t provide protection from roll over or fall- ing objects. The windshield does not provide ...
Page 158: 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 shuttle 4 and shuttle 6 sun top tool list qty. Required plastic faced mallet .......................................
Page 159: 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 fig. 1 shuttle 4 and shuttle 6 sun top sun top 11 18 20 front strut 18 19 front of vehicle 2 14 15 12 13 (inside)...
Page 160: 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 txt 5e sun top tool list qty. Required plastic faced mallet ........................................................
Page 161: Weather Protection
Weather protection page p-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. 2 txt 5e sun top 6 1 4 3 (driver side shown) front of vehicle 7 5 4 8 10 9 12 11 13 14 17 16 front of vehicl...
Page 162: Weather Protection
Weather protection page p-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 fold down windshield tool list qty. Required plastic faced mallet ..................................................
Page 163: Weather Protection
Weather protection page p-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 full front windshield tool list qty. Required plastic faced mallet .................................................
Page 164: Weather Protection
Weather protection page p-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 rear windshield tool list qty. Required plastic faced mallet .......................................................
Page 165: 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 166: Paint
Paint page q-ii repair and service manual notes:.
Page 167: 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, painting follow the paint manufacturer’s recommendations for specific painting procedures and information. All painting must be done in an area wi...
Page 168: 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 169: 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 170: Troubleshooting
Troubleshooting page r-ii repair and service manual notes:.
Page 171: 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, electrical system for non-pds vehicles, see electronic speed control section. For pds vehicles, see electronic speed control (pds) secti...
Page 172: 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 173: 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 174: 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 notes:.
Page 175
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 176
Lightning protection and grounding page s-ii repair and service manual notes:.
Page 177
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 178
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 179
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 180
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 181: General Specifications
Table of contents for section ‘t’ section title page no. Page t-i repair and service manual t general specifications shuttle 2 ......................................................................................................................................T - 1 shuttle 4 ..........................
Page 182: General Specifications
General specifications page t-ii repair and service manual notes:.
Page 183: General Specifications
Page t-1 repair and service manual t general specifications shuttle 2 electric powered personnel / cargo carrier weight (without batteries) ..................................................... 710 lbs. (322 kg) tires .....................................................................................
Page 184: General Specifications
Page t-2 repair and service manual general specifications shuttle 4 electric powered personnel / cargo carrier weight (without batteries) ..................................................... 710 lbs. (322 kg) tires .......................................................................................
Page 185: General Specifications
Page t-3 repair and service manual general specifications shuttle 6 electric powered personnel carrier weight (without batteries) ..................................................... 710 lbs. (322 kg) tires ..................................................................................... 18 x 8...
Page 186: General Specifications
Page t-4 repair and service manual general specifications txt 5e pds txt 5e pds electric powered 5 passenger golf car weight (without batteries) ..................................................... 710 lbs. (322 kg) tires ................................................................................
Page 187: General Specifications
Page t-5 repair and service manual general specifications 46.5 in. (118 cm) 122 in. (310 cm) 132.5 in. (337 cm) 134.5 in. (342 cm) 93.5 in. (237 cm) shuttle 4 shuttle 6 46.5 in. (118 cm) 122 in. (310 cm) 93.5 in. (237 cm) txt 5e lowest clearance at differential 4.25 in. (10.8 cm) (all models) fig. 2...
Page 188: General Specifications
Page t-6 repair and service manual general specifications fig. 28 vehicle dimensions and incline specifications recommended max ramp grade 25% or 14˚ max recommended max side tilt 25% or 14˚ max front 33.5 in. (85 cm) rear 38 in. (97 cm) 49 in. (123 cm) 67 in. (170 cm).
Page 189: General Specifications
Page t-7 repair and service manual general specifications fig. 29 vehicle turning clearance 94 in. (240 cm) 94 in. (240 cm) intersecting aisle clearance turning clearance diameter txt 5e shown 29 ft. (8.8 m).
Page 190: General Specifications
Page t-8 repair and service manual general specifications notes:.
Page 191
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 192
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