28646-G01 0 EERE Company TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC & PRECISION DRIVE SYSTEM™ PERSONAL VEHICLES & FLEET GOLF CAR STARTING MODEL YEAR: 2001SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact an E-Z-GO representative for clarification, Always replace any damaged or missing labels. ‘On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed ‘on level ground. (See vehicle specification.) Limit speed by applying the service brake. Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of vehicle contol, is costly, is considered abuse and will not be covered under warranty. Use extra caution when towing the vehicle(s). Do not tow a single vehicle at speeds in excess of 12 mph (19 kph). Do not tow more than three vehicles at a time. Do not exceed 5 mph (8 kph) while towing multiple vehicles. Towing the vehicle at above the recommended speed may result in personal injury and/or damage to the vehicle and other prop- erty. Vehicles equipped with Precision Drive System’ (PDS) must be towed with the Run-Tow/Maintenance switch, located under the passenger seat, in the ‘Tow’ position. If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition. PT aed BATTERIES ere CORRE PEE WARNING || WARNING || WARNING terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. WASH HANDS: AFTER HANDLING! WASH HANDS AFTER HANDLING! ‘TO LIMIT SPEED }| TO LIMIT SPEED || TO LIMIT SPEED Be sure that this manual remains as part of the permanent service record should the vehicle be resold. NOTES, CAUTIONS AND WARNINGS Throughout this guide NOTE, CAUTION and WARNING — Please observe these NOTES, CAUTIONS and WARN- will be used. INGS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be [INTE] A.NOTE inccats «contin hat shoud be Fecrdage improper sekice or tops may damage he vehicle or reer unsala EFA TTET NY 4 CAUTION inicates« contin that patlery posts, terminals moyresutindamogetote vei, ORPRRNINNRIIA,Batery posts, terminals A WARNING indicates a contain lead and lead WNW ENEIINEY hazardous condition that compounds. Wash hands after handling. could result in severe injury or death, (NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC & PRECISION DRIVE SYSTEM™ (PDS) PERSONAL VEHICLES & FLEET GOLF CARS VEHICLES FREEDOM PDS FREEDOM FLEET GOLF CAR PDS FLEET GOLF CAR SHUTTLE 2+2 ho ight to make design changes without obligation to make these changes on uns previously sold and te Infomation ange winout ree oc ero inthis manual or for incident or consequential damages that result rom the use othe materia inthis manual CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124 OUTSIDE USA PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609 E-Z-GO DIVISION OF TEXTRON, INC., P.0.BOX 388, AUGUSTA, GEORGIA USA 30903-0388 Repair and Service Manual Page iNOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non original equipment manufacturer (OEM) parts may void the warranty. Overfilling of batteries may void the warranty. BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C). For winter storage, the batteries must be clean, fully charged and disconnected from any source of electrical drain. The battery charger and the controller are both sources of electrical drain. Unplug the battery charger DC plug from the vehicle receptacle. On Precision Drive System™ vehicles, disconnect the controller from the battery set by selecting the ‘TOW/MAINTENANCE’ position on the RUN-TOW/MAINTENANCE SWITCH located under the passenger seat. As with all electric vehicles, the batteries must be checked and recharged as required, or at a minimum of 30 day intervals. Refer to the ‘Prolonged Storage’ section within the BATTERIES AND CHARGING section of this manual. Repair and Service Manual Page iiTABLE OF CONTENTS TITLE PAGE Salety scoccsenennnnentnnnnsene Notes ii sss: Inside Covers Safety Information .. WV TITLE SECTION General Information & Routine Maintenance Safety Body...... Wheels and Tires ... Electronic Speed Control (Non-PDS) Electronic Speed Control (PDS) .....::nnisnnnnntnnstinninnnninnnstnisnnansinnsnesenee Front Suspension and Axle Mounted Steering.... Front Suspension and Frame Mounted Steering...... Motor Batteries and Charging..... Battery Charger Brakes scccsssesssesseesseenseeneeeneen Direction Selector Electrical Wiring Rear Suspension... Rear Axle. Weather Protection. onDnOVZErReETHOO9AMIOD>D Paint..... Troubleshooting... 4 Lightning Protection and Grounding General Specifications..... be made with both drive wheels raised. Wear eye protection when working on M the vehicle. In particular, use care when working around batteries, or #7 using solvents or compressed air. To reduce the possibilty of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the batteries before removing any heavy gauge battery wires. To prevent the possibility of motor disintegration, never operate vehicle at full throttle for more than 4-5 seconds while vehicle is in a “no load” condi- tion. “ lezen) Repair and Service Manual Page A-tGENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings Itis in the best interest of both vehicle owner and servic- ing dealer to carefully follow the procedures. recom- mended in this manual. Adequate preventative maintenance, applied at regular intervals, is the best {uarantee for keeping the E-2-GO vehicle both depend- able and economical EERIE 22,217 sti srvie is por formed on PDS model vehicles, the Run-TowiMaintenance switch must be placed in the ‘Tow Mainte- ‘nance’ position. a power wire (battery, motor or controller) is disconnected for any reason on the PDS model vehicle, the Run-Tow Maintenance ‘switch must be left in the TowrMaintenance’ position for atleast 30 seconds after the circuit is restored. Before a new vehicle is put into operation, itis recom- mended that the items shown in the INITIAL SERVICE CHART be performed (Ref Fig. 3 on page A-2). ITEM ‘SERVICE OPERATION Batteries | Charge batteries ‘Seats | Remove protective plastic covering Brakes | Check operation and adjust necessary Establish new vehicle braking distance Tires | Check air pressure (see SPECIFICATIONS} Portable Charger Remove from vehicle and properly mount Fig. 3 Initial Service Chart Vehicle batteries must be fully charged before intial use. ROUTINE MAINTENANCE This vehicle wil give years of satisfactory service provid- ing it receives regular maintenance, Refer to the Periodic Service Schedule (Ret Fig. 6 on page A-5) for appropri- ate service intervals. Refer to FRONT SUSPENSION, AND STEERING section for lubrication points. LE LXETTET AT °° 212% ore than tree) pus ‘of grease in each grease fiting at any fone time, Excess grease may cause grease seals to fail or {grease migration into areas that could damage components. Some maintenance items must be serviced REAR AXLE The only maintenance required for the first five years is the periodic inspection of the lubricant level. The rear axle is provided with a lubricant level checkifill plug ‘ocated on the bottom of the differential. Unless leakage s evident, the lubricant need only be replaced after five years. The procedure to follow for checking the rear axle ubricant level s in the REAR AXLE section. BRAKES After the vehicle has been put into service, it is recom- ‘mended that the brakes be checked periodically by per- ‘orming a brake test. To prevent severe injury FAY ZNGINISE Wor death resulting trom operating a vehicle with improperly operating brake system, the braking sys tem must be properly maintained. All driving brake tests must be done in a safe location with regard for the safety of all personnel. Over time, a subtle loss of performance may NOTE take place. Therefore, it is important to estab- fish the normal braking stance with a new vehicle For information on conducting a brake test, refer to MECHANICAL BRAKES section. PDS MODEL VEHICLES At monthly intervals, test the PDS operating system by sonducting a simple test contained in the ELECTRONIC. SPEED CONTROL -PDS section, TIRES Tite condition should be inspected on a daily basis. Infla- ‘ion pressures should be checked on a weekly basis ‘when the tires are cool. Be sure to reinstall valve dust 2ap after checking or inflating tire. For additional informa- ‘ion, refer to WHEELS AND TIRES section, CARE AND CLEANING OF THE VEHICLE When pressure washing vice, donot ce use pressure in excess of 700 psi. To arevent cosmetic damage, donot use any abrasive or reactive NOTE) rove requenty on vehicles used under severe solvents to clean plastic pats. dtving conetions Page A-2 Repair and Service Manual (alGENERAL INFORMATION & ROUTINE MAINTENANCE Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings itis important that proper techniques and cleaning mate- fials be used. Using excessive water pressure may cause damage to seals, plastics, the electrical system, body finish or seat material. Do not use pressure in excess of 700 psi to wash vehicle. Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of cil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinylirubber cleaner. The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water is the best method of pre serving the painted surfaces. Do not use hot water, strong soap or harsh chemical detergents. Rubber parts should be cleaned with nonabrasive house- hold cleaner. Occasional cleaning and waxing with nonabrasive prod- ucts designed for ‘clear coat’ automotive finishes will enhance the appearance and durability of the painted surfaces. Corrosive materials used as fertilizers or for dust control ‘can collect on the underbody of the vehicle. These mate- rials will accelerate corrosion of underbody parts. It is recommended that the underbody be flushed occasion- ally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to ease its removal, taking care not o chip or otherwise damage paint. VEHICLE CARE PRODUCTS. E-Z-GO has several products, available through a local Distributor, an E-2-GO Branch, or the E-2-GO Service Parts Department, to help maintain the vehicle. * Touch-up paint specially formulated to match vehi- cle colors for use on TPE (plastic) bodies. (PIN 28140-G" and 28432-G"*) * Multipurpose Battery Protectant formulated to form a long-term, flexible, nontacky, dry coating that will not crack, peel or flake over a wide tem- perature range. (PIN 75500-G01) * White Lithium Grease designed to provide lubrica- tion protection in areas where staining or discolor- ing is a problem, or in areas of extreme temperature ranges. (P/N 75502-G01) * Penetrant/Lubricant, a 4-in-1 product that pene- trates the most stubborn of frozen parts, lubricates leaving a light lubricating film, prevents corrosion by adhering to wet or dry surfaces and displaces moisture, sealing against future moisture return. (PIN 75503-G01) * Multi-purpose Cleaner and Degreaser that con- tains natural, environmentally safe solvents. (P/N 75504-G01) © Multi-purpose Hand Cleaner is an_ industrial strength cleaner containing no harsh solvents, yet gently its grease off hands. May be used with or without water. (P/N 75505-GO1) * Battery Cleaner that promotes easy, non-violent neutralization of battery acids and battery acid crystals. The resulting sodium salts are water sok Uble and easily washed away. (P/N 75506-G01) * Battery Maintenance Kit for complete battery cleaning and watering, with battery maintenance instructions. (P/N 25587-G01) * Biodegradable Cleaner that cleans the toughest dirt and heavy soils by breaking down grease to be easily wiped or rinsed away. (P/N 75507-G01) © Multi-purpose Value Pack sampler package including 4 ounce (118 ml) aerosol cans of Battery Protector, Penetrant/Lubricant, White Lithium Grease, and Carburetor and Choke Cleaner. (P/N 75508-G01) * Plexus plastic cleaner and polish removes minor scratches from windshield. (P/N 28433-G"*) TOP AND WINDSHIELD The top does not provide PF INUZNSISINTE NW protection from roll over or falling objects, The windshield does not provide protection from tree limbs or flying objects. The top and windshield are designed for weather protec- tion only Clean with lots of water and a clean cloth, Minor scratches may be removed using a commercial plastic polish or Plexus plastic cleaner available from E-2-GO, lezen) Repair and Service Manual Page A:3GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings TRAILERING To prevent personal inju- PINZNESISTEY ry to occupants of other : highway vehicles, be ‘sure that the vehicle and contents are adequately secured to trailer. Do not ride on vehicle being trailered. Remove windshield before trailering. Maximum speed with top is 50 mph (80 kph). If the vehicle is to be transported on a trailer at highway speeds, the windshield must be removed and the seat bottom secured. Always check that the vehicle and con- tents are adequately secured before trailering the vehi- cle. The rated capacity of the trailer must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS: for vehicle weight) and load plus 1000 Ibs. (454 kg). Lock the parking brake and secure the vehicle to the traller using ratchet tie downs. TORQUE SPECIFICATIONS HARDWARE Periodically the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref Fig. 5 on page 4-4). Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific ‘orque values. Generally, two grades of hardware are used in the vehi- sie. Grade 5 hardware can be identified by the three ‘marks on the hexagonal head. Unmarked hardware is Srade 2 (Ref Fig. 4 on page A-4) Grade 2 Grade 5 Fig. 4 Bolt Grades ‘ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted intext, tighten all hardware in accordance with this chart The table below specifies ‘lubricated torque figures. Fasteners that are plated or lubricated when installed ‘are considered ‘wet and require approximately 80% of the torque required for dry’ fasteners. BouTsize| ma | sie | oe | me" | 12 | one | se | om | me | 1 cae | 4) 8 | 3s | | 95 | ss | 75 | 190 | 105 | 100 © | on | em | ex | a7 | cs | coe | ce) | ces) | 58 cues | 6 | % | @ | 3 | 55 | 80 | 110 | 200 | a20 | 400 @ | ce | en | am | cs | cos | aaa | ern | cam | 51 Fig. 5 Torque Specifications Page As Repair and Service Manual ar)GENERAL INFORMATION & ROUTINE MAINTENANCE Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings PERIODIC SERVICE SCHEDULE 7 Check # Clean, Adjust, ete ‘A Replace NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY BODY ‘Clean body components as required (See text inthis section) REVERSE WARNING DEVICE 7 Check operation when direction selector isin reverse (See DIRECTION SELECTOR) Examine for cuts, excessive wear and pressure uae (See WHEELS AND TIRES and GENERAL SPECIFICATIONS) WHEELS 7 Check for bentrims, missing or loose lug nuts (See WHEELS AND TIRES) * Recharge tofu sate of charge alter each day's use SATTERIES (See BATTERIES AND CHARGING) (CHARGER / RECEPTACLE ~7 Inspect connedor system at each charge (See BATTERY CHARGER) MONTHLY - 20 HOURS (includes items listed in previous table & the following) * Giean bate & trminae with, 14 cup (69m) baking soda 01 gallos © BATTERIES Iters) water soution, rise with clear water (See BATTERIES AND CHARGING) J Check charge ondition and al connections 7 Check all wing for loose connections and broken/missing insulation es (Seo ELECTRICAL WinING) ‘+ Clean connections, Keep receplacies free of dit and foreign matter CHARGER / RECEPTACLE lean conmertions, Keep rep D Poceiennron 7 Check for smooth movement and adjust or replace as required (See ELECTRONIC SPEED CONTROL) SERVICE BRAKE Check brake performance and adjust as required (See MECHANICAL BRAKES) PARKING BRAKE 7 Check brake performance and adjust as required (See MECHANICAL BRAKES) DIRECTION SELECTOR ¥ Check attachment, tighten as required (See DIRECTION SELECTOR) ‘STEERING ASSEMBLY 7 heck or abnermal play, ohiness of al hardware (See FRONT SUSPENSION AND STEERING) TIE RODSILINKAGES 1 heck for excessive play, bent comoonents or loose connections (See FRONT SUSPENSION AND STEERING) ros ste “ SERETRRE EERE ro REMRARLE 7 Chaco oa, a scart (GA 20 oh oad on PEAR DAE QUARTERLY - 50 HOURS (includes items listed in previous tables & the following) FRONT ALE / SEB AUR BRET S Ea ee ee (See FRONT SUSPENSION AND STEERING) Fig. 6 Periodic Service Schedule lezen) Repair and Service Manual Page AS,GENERAL INFORMATION & ROUTINE MAINTENANCE Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings FRONT SPRINGS Check for loose hardware, cracks at attachments (See FRONT SUSPENSION AND STEERING) FRONT WHEEL ALIGNMENT 7 Check for unusual ire wear, align as required (See FRONT SUSPENSION AND STEERING) PARKING (PARK) BRAKE ‘7 Check for bentibinding linkage rod (See BRAKES) ‘7 Check for damage ot wear to latch arm or catch bracket (See BRAKES) ‘Lubricate, use light ol. DO NOT LUBRICATE CABLES OR BRAKE LATCH REAR SHOCK ABSORBERS 7 Check for oil leakage, loose mounting hardware (See REAR SUSPENSION) POWERWISE™ CHARGER PLUG ‘Clean auxliary contact (See BATTERY CHARGER) SEMI-ANNUAL - 125 HOURS \cludes items listed in previous tables & the follo. ) DIRECTION SELECTOR Check for wear and smooth movement (lubricate shalt with light olf required) 'Y Check for excessive play and tightness of retaining nuts KING PINS, + Lubricate, if equippec with grease fitting, with wheel bearing grease (See FRONT SUSPENSION AND STEERING) ‘ Lubricate linkage, use wheel bearing grease STEERING ASSEMBLY ‘7 Check bellows and pinion seal for damage or grease leakage (See FRONT SUSPENSION AND STEERING) TIE RODSILINKAGES REAR AXLE + Lubricate, use wheel bearing grease (See FRONT SUSPENSION AND STEERING) 7 Check for noise during operation ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following) FRONT WHEEL BEARINGS ‘¢ Adjust (See FRONT SUSPENSION AND STEERING) + Pack, use whee! bearing grease (See FRONT SUSPENSION AND STEERING) REAR AXLE ‘7 Check lubricant, add lubricant (SAE 30 oil) as required (See REAR AXLE) ‘4 Replace lubricant after § years (See REAR AXLE) ‘SERVICE BRAKES Clean and adjust (See BRAKES) Check brake shoe linings (See BRAKES) Fig. 6 Periodic Service Schedule Page AG Repair and Service Manual ar)SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE GENERAL (Part lof ANSI/ NGCMA 2130.1 - 1983), GENERAL (Part of ASNE / ANSI 856.6 - 1988) NOTES, CAUTIONS AND WARNINGS IMPORTANT SAFETY WARNING, MODIFICATIONS TO VEHICLE GENERAL MAINTENANCE. BEFORE SEAVICING THE VEHICLE ‘Adational Warnings, PAGE NO. 1 8 BATTERY REMOVAL & NSTALLATION 2 LIFTING THE VEHICLE 8-10 LIST OF ILLUSTRATIONS Fig. 1 Batry Connections. 3-10 Fg 2 Lit he Venice 3-10 ar) Repair and Service Manual Page BiSAFETY Notes: Page Bi Repair and Service ManualSAFETY ‘Read ll of Section A and this section before attempting any procedure. Pay particular atenton tol Notes, Cautions and Warnings GENERAL ‘The following text is provided as recommended by part Il of ANSI / NGCMA 2130.1 - 1993, The manufacturer, as a member of the National Golf Car Manufacturers Associa- tion (NGCMA), strongly endorses the contents of this specification. PART II MAINTENANCE AND OPERATIONS 5. GENERAL SAFETY PRACTICES. 5.1. Introduction Like other machines, golf cars can cause injury if improp- erly used or maintained. This section contains broad safety practices recommended for safe golf car opera- tions. Before operation, the controlling party should establish such additional specific safety practices as may be reasonably required for safe operations. Experience has shown that golf cars which comply with the provisions stated in Part Il of this Standard are safe when properly operated in accordance with the safety and operation warnings affixed to every golf car. The safe operation is enhanced when the golf cars are operated within a specific set of operation instructions, safety rules and practices established to meet actual operating ter- rain and conditions, ‘The safety information contained in Part Il is intended to provide the controlling party with basic safety information and to encourage the controlling party to implement a golf car safety program, It is suggested and recommended that Part I be reprinted in the golf car manufacturer’s operation and service manuals to encourage safe operations and prac- tices at the controlling party's facility 5.2. Safety Survey The controlling party shall perform a safety survey peri- odically, and as conditions warrant to their premises, to identity areas where golf cars should not be operated and to identity possible hazards. 5.2.1. Steep Grade In areas where steep grades exist, golf car operations should be restricted to the designated golf car pathways where possible, and shall be identified with a suitable warning giving the following information: “Warning, steep grade, descend slowly with one foot on brake.” 5. . Wet Areas Wet grassy areas may cause a gol car to lose traction and may affect stability. Wet areas shall be chained or roped off to prevent golt car operations or be identiied by a suitable waming not to operate golf cars in this area due to wet terrain, 5.2.3. Sharp Approaches Turns, Blind Corners, Bridge Sharp turns, blind spots, bridge approaches and other potentially hazardous areas shall ba either chained or roped off to prevent goif car operations or identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard, 5. . Loose Terrain Loose terrain may cause a golf car to lose traction and may affect stability. Areas of loose terrain should be repaired if possible, or chained or roped off to prevent olf car operation or identified by a sultable warning to ‘operators not to operate golf cars in this area due to loose terrain or possible hazardous conditions. 5.2.5. Golf Car/Pedestrian Interference Areas ‘Areas where pedestrians and golf cars interfere shall be avoided whenever possible by rerouting the golf car traf- fic or the pedestrian traffic to eliminate the interference. It ‘elimination of the interference is not possible or is highly impractical, signs shall be erected warning pedestrians of the golf car traffic and golf car operators of the pedes- trian traffic and to drive slowly and use extreme caution. lezen) Repair and Service Manual Page B-1SAFETY Read all of Secon A and this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings 6. MAINTENANCE 6.1. Introduction 6.1.1. Golf cars may become hazardous if maintenance is neglected or improperly performed. Therefore mainte- nance facilities, trained personnel and procedures in accordance with the manufacturer's recommendations. should be provided by the controlling party 6.2. Preventive Maintenance A regularly scheduled inspection and preventive mainte- nance program in accordance with the manufacturer's recommendations should be established. Such a pro- gram will be a valuable tool in providing the golfing patron with a safe, properly operating golf car and thereby help to avoid accidents. 6.2.1. Personnel (Only qualified, trained and authorized personnel shall be permitted to inspect, adjust and maintain golf cars. 6.2.2. Parts and Materials (Only manufacturer's recommended replacement parts and materials shall be used. 6.2.3. Ventilation Maintenance and storage areas shall be properly venti- lated to avoid fire hazards in accordance with applicable fire codes and ordinances. 6.2.3.1. Ventilation for gasoline powered golf cars shall be provided to remove flammable vapors, fumes and other flammable materials. Consult applicable fire codes for specific levels of ventilation. 6.2.32. Ventilation for electric powered golf cars shall be provided to remove the accumulation of flammable hydrogen gas emitted during the charging process. The amount of hydrogen gas emitted depends upon a num- ber of factors such as the condition of the batteries, the output rate of the battery charger and the amount of time the batteries are on charge. Hydrogen emissions are generally considered to be in the area of 10 to 20 cubic liters per car per charge. Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air changes per hour is recommended. The controlling party shall consult applicable fire and safety codes for the spe- sific ventilation levels required as well as the use of axplosion proof electrical apparatus. 3.2.4. Maintenance Procedures All maintenance shall be performed in accordance with the manufacturer's recommended maintenance proce- dures as outlined in the manufacturer's operation and service manuals. 5.2.5. Maintenance Safety Procedures All maintenance shall be performed in accordance with the manufacturer's recommended safety procedures as outlined in the manufacturer's operation and service ‘manuals. The following list of recommended safety pro- sedures are general in nature and in no way supersede the manufacturer's specific instructions. 5.2.5.1. Follow manufacturer's instructions for immobi- izing golf car before beginning any maintenance. 8.2.5.2. Block chassis before working underneath golf var. 5.2.5.3. Before disconnecting any part of the fuel sys- ‘em, drain the system and turn all shut off valves to the OFF’ position to prevent leakage or accumulation of ‘lammable fuels in the work area. 8.2.5.4. Avoid fire hazards and have fire protection aquipment available. 8.2.5.5. Before performing any maintenance on an elec- ‘ric golf car, disable the electrical system in accordance with the manufacturer's instructions. 8.2.5.6. Use only properly insulated tools when working an electrically powered golf cars or around batteries. 5.2.5.7. Brakes, steering mechanisms, warning devices, governors and all other safety devices shall be inspected and maintained in a safe and proper operating condition and shall not be modified as supplied by the manutac- ‘urer. Page B-2 Repair and Service Manual Gass)SAFETY ead allof Section A and this secton beer attempting any pocedure. Pay patcular attention foal Notes, Caution and Warnings 6.2.5.8. After each maintenance or repair the golf car shall be driven by qualified, trained and authorized per- sonnel to ensure proper operation and adjustment. 6.2.5.9. Driving golf car to check for proper operation and adjustment after repair shall be performed in an area that is free of vehicular and pedestrian traffic. 6.2.5.10. Record all maintenance performed in a mainte- nance record log by date, name of person performing ‘maintenance and type of maintenance. Controlling party management should periodically inspect maintenance log to ensure currency and completeness of entries. 6.2.5.1. Provide operator comment cards to assist in identifying non-periodic maintenance needs for specific golt cars, 6.2.5.12. The controling party shall maintain in a legible condition all nameplates, warnings and instructions which are supplied by the manufacturer. 6.2.5.13. The controlling party shall not perform any mod- ification or addition which affects capacity or safe opera- tion, or make any change not in accordance with the owner's manual without the manufacturer's prior written authorization. Where authorized modifications have been made, the controlling party shall ensure that capacity, operation, warning and maintenance instruction plates, tags or decals are changed accordingly. 6.2.5.14. As required under paragraphs 6.2.6 and 6.2.7 the manufacturer shall be contacted to secure new nameplates, wamings or instructions which shall then be atfixed in their proper place on the golf car. 7.FUELS HANDLING AND STORAGE/ BATTERY CHARGING 7.1, The controlling party shall supervise the storage and handling of liquid fuels in accordance with applicable fire and safety requirements. 7.2. Storage and handling of liquefied petroleum gas fuels shall be in accordance with American Gas Associa- tion recommendations and applicable fire safety require- ments. 7.3. The controlling party shall require battery chang- ing and charging facilities and procedures to be in accor- dance with applicable ordinances or regulations (also see paragraph 6.2.3.2). 7.4. The controlling party shall periodically inspect facilities and review procedures to be certain that the procedures in paragraphs 6.2.3.2 and 7.3 are being fol- lowed. 8. OPERATING SAFETY RULES AND PRACTICES ications 8.1. Operator Qual 8.1.1. Only authorized persons shall be allowed to oper fate golf cars. It is recommended that no persons be allowed to operate golf cars except those persons who posses a valid motor vehicle drivers license. 8.1.2. The controlling party shall display the operation and safety instructions as recommended by the golf car manufacturers and the golf course safety rules in a con- spicuous place near the golf car rental area or golf car pick-up area. It is also recommended, as with all motor vehicles, that the warming *Do not operate golf cars when Under the influence of alcohol or drugs.” be posted in a conspicuous location. End of ANSI / NGCMA 2130.1 - 1993, Part I lezen) Repair and Service Manual Page B-3SAFETY Read all of Secon A and this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings GENERAL ‘The following text is provided as recommended by part Il of ASME/ANSI B56.8-1988. The manufacturer strongly ‘endorses the contents of this specification. PART Il FOR THE USER 4 GENERAL SAFETY PRACTICES. 4.1. Introduction 4.1.1 Like other machines, carriers can cause injury it improperly used or maintained. Part Il contains broad safety practices applicable to carrier operations. Before operation, the user shall establish such additional spe- cific safety practices as may reasonably be required for safe operation. 4.2 Stability 4.2.1 Experience has shown that this vehicle, which complies with this standard, is. stable when properly ‘operated and when operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard. Some of the conditions which may affect stability are failure of the user to follow safety practices; also, ground and floor conditions, grade, ‘speed, loading, the operation of the carrer with improper loads, battery weight, dynamic and static forces, and the judgement exercised by the carrier operator. (a) The user shall train carrier operators to adhere strictly to the operating instructions stated in this Stan- dard (b) The user shall survey specific operating conditions and environment, and establish and train carrier opera- tors to comply with additional, specific safety practices. 4.3. Nameplates, Markings, Capacity, and Modifica- tions 4.3.1 The user shall maintain in a legible condition all nameplates, warnings, and instructions which are supplied by the manufacturer. 4.3.2 The user shall not perform any modification or addition which affects capacity or safe operation, or make any change not in accordance with the owner's ‘manual without the manufacturer's prior written authori- zation. Where authorized modifications have been made, ‘the user shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are shanged accordingly. 4.3.3. As required under paras. 4.3.1 or 4.3.2, the ‘manufacturer shall be contacted to secure new name- alates, warnings, or instructions which shall then be affixed in their proper place on the carrier. 4.4 Fuel Handling and Storage 4.4.1 The user shall supervise the storage and han- dling of liquid fuels (when used) to be certain that itis in accordance with appropriate paragraphs of ANSVNFPA 505 and ANSI/NFPA 30. 4.4.2. Storage and handling of liquefied petroleum gas fuels shall be in accordance with appropriate para- graphs of ANSINFPA 505 and ANSI/NFPA 58. If such Storage or handling is not in compliance with these stan- dards, the user shall prevent the carrier from being used ntil such storage and handling is in compliance with ‘hese standards. 4.5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 4.5.1 The user shall require battery changing and charging facilities and procedures to be in accordance with appropriate paragraphs of ANSUNFPA 505. 4.5.2 The user shall periodically inspect facilities and review procedures to be certain that appropriate aaragraphs of ANSIINFPA 505, are strictly complied with, and shall familiarize cartier operators with i. 4.6 Hazardous Locations 4.6.1 The user shall determine the hazard classifi- zation of the particular atmosphere or location in which the carrier is to be used in accordance with ANSIINFPA, 505. 46.2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSUNFPA 505. 4.7 Lighting for Operating Areas 4.7.1 The user, in accordance with his responsibility 10 survey the environment and operating conditions, shall determine if the carrier requires lights and, if so, shall aquip the carrier with appropriate lights in accordance with the manufacturer's recommendations, Page B-4 Repair and Service Manual Gass)SAFETY ead allof Section A and this secton beer attempting any pocedure. Pay patcular attention foal Notes, Caution 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 areas, the atmo- sphere shall be maintained within limits specified in the ‘American Conference of Governmental Industral Hygienists publication, “Threshold Limit Values. for Chemical Substances and Physical Agents in the Work- room Environment’. This shall be accomplished by venti- lation provided by the user, and/or the installation, use, and proper maintenance of emission control equipment recommended or provided by the manufacturer of the equipment. 4.9 Warning Device(s) 4.9.1 The user shall make periodic inspections of the carrier to be certain that the sound-producing and/or visual device(s) are maintained in good operating condi- tion. 4.9.2 The user shall determine i operating condi- tions require the carrier to be equipped with additional sound-producing and/or visual devices and be responsi- ble for providing and maintaining such devices, in accor- dance with the manufacturer's recommendations. 5 OPERATING SAFETY RULES AND PRACTICES 5.1 Personnel and Burden Carrier Operator Qualifications 5.1.1. Only persons who are trained in the proper operation of the carrier shall be authorized to operate the carrier. Operators shall be qualified as to visual, auditory, physical, and mental ability to safely operate the equip- ment according to Section 5 and all other applicable parts of this Standard, 5.2 Personnel and Burden Carrier Operators’ Training 5.2.1 The user shall conduct an operators’ training program. 5.2.2 Successful completion of the operators’ train- ing program shall be required by the user before opera- tion of the carrier. The program shall be presented in its entirety to all new operators and not condensed for those claiming previous experience. 5.2.3 The user should include in the operators’ train- ing program the following (@) instructional material provided by the manutac- turer (b) emphasis on safety of passengers, material loads, carrier operator, and other employees; (c) general safety rules contained within this Standard land the additional specific rules determined by the user in accordance with this Standard, and why they were for- mulated; (d)_ introduction of equipment, control locations and functions, and explanation of how they work when used properly and when used improperly, and surface condi- tions, grade, and other conditions of the environment in which the carrier is to be operated; (e) operational performance tests and evaluations during, and at completion of, the program. 5.3 Personnel and Burden Carrier Operator Responsibility 5.3.1 Operators shall abide by the following safety rules and practices in paras. 5.4, 5.5, 5.6, and 5.7. 5.4 General 5.4.1 Safeguard the pedestrians at all times. Do not drive camer in a manner that would endanger anyone. 5.4.2 _ Riding on the carrier by persons other than the ‘operator is authorized only on personnel seat(s) provided by the manufacturer. All parts of the body shall remain within the plan view outline of the carrier. 5.4.3 When a cartier is to be left unattended, stop cartier, apply the parking brake, stop the engine or turn ‘off power, tum off the control or ignition circuit, and remove the key if provided. Block the wheels if machine is on an incline 5.4.4 A cartier is considered unattended when the ‘operator is 25 ft. (7.6 m) or more from the carrier which remains in his view, or whenever the operator leaves the cartier and itis not within his view. When the operator is dismounted and within 25 tt. (7.6 m) of the carrer still in his view, he still must have controls neutralized, and the parking brake(s) set to prevent movement. 5.4.5 Maintain a safe distance from the edge of ramps and platforms. 5.4.6 Use only approved carriers in hazardous loca- tions, as defined in the appropriate safety standards. 5.4.7 Report all accidents involving personnel, building structures, and equipment. 5.4.8 Operators shall not add to, or modify, the car- rier. lezen) Repair and Service Manual Page B-5SAFETY Read all of Secon A and this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings 5.4.9 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles, access to stairways, or fire equipment. 5.5 Traveling 5.5.1 Observe all traffic regulations, including autho- rized speed limits. Under normal traffic conditions keep to the right. Maintain a safe distance, based on speed of travel, from a cartier or vehicle ahead; and keep the car- rier under control at all times. 5.5.2 Yield the right of way to pedestrians, ambu- lances, fire trucks, or other carriers or vehicles in emer- gency situations. 5.5.3 Do not pass another carrier or vehicle travel- ing in the same direction at intersections, blind spots, or at other dangerous locations. 5.5.4 Keep a clear view of the path of travel, observe other traffic and personnel, and maintain a safe clearance. 5.5.5 Slow down of stop, as conditions dictate, and activate the sound-producing warning device at cross aisles and when visibility is obstructed at other locations. 5.5.6 Ascend or descend grades slowly. 5.5.7 Avoid tuming, if possible, and use extreme caution on grades, ramps, or inclines; normally travel straight up and down. 5.5.8 Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop in a safe manner. 5.5.9 Make starts, stops, turns, or direction rever- sals in a smooth manner so as not to shift the load, endanger passengers, or overtum the carrier. 5.5.10 Do not indulge in dangerous activities, such as stunt driving or horseplay. 5.5.11 Slow down when approaching, or on, wet or slippery surfaces. 5.5.12 Do not drive cartier onto any elevator unless specifically authorized to do so. Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power, and set parking brakes. It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit. 5.5.13 Avoid running over loose objects, potholes, and bumps. 5.5.14 To negotiate turns, reduce speed to improve stability, then turn hand steering wheel or tiller in a smooth, sweeping motion. 5.6 Loading 5.6.1 Handle only stable and safely arranged loads. When handling off-center loads which cannot be cen- ‘ered, operate with extra caution. 5.6.2 Handle only loads within the capacity of the sarrier as specified on the nameplate. 5.6.3 Handle loads exceeding the dimensions used ‘9 establish carrier capacity with extra caution. Stability and maneuverability may be adversely affected. 5.7 Operator Care of Personnel and Burden Carriers 5.7.1 _Atthe beginning of each shift during which the zarrier will be used, the operator shall check the carrier zondition and inspect the tires, warning devices, lights, aattery(s), speed and directional controllers, brakes, and steering mechanism. If the cartier is found to be in need of repair, or in any way unsafe, the matter shall be ‘eported immediately to the designated authority and the zarrier shall not be operated until it has been restored to safe operating condition, 5.7.2 _ If during operation the carrier becomes unsafe 1 any way, the matter shall be reported immediately to the designated authority, and the carrier shall not be operated unti it has been restored to safe operating con- dition. 5.7.3 Do not make repairs or adjustments unless specifically authorized to do so. 5.7.4 The engine shall be stopped and the operator shall leave the carrier while refueling. 5.7.5 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap ‘eplaced before starting engine. 5.7.6 Do not operate a carrier with a leak in the fuel system or battery(s). 5.7.7 Do not use open flames for checking electro- yte level in storage battery(s) or liquid level in fuel tanks. 6 MAINTENANCE PRACTICES 3.1 Introduction 6.1.1 Carriers may become hazardous it mainte- nance is neglected. Therefore, maintenance facilities, ‘rained personnel, and procedures shall be provided. Such facilities may be on or off the premises. Page B-6 Repair and Service Manual Gass)SAFETY Fad ailof Section A and his secton beorealempting any procedure. Pay particular attention fal Notes, Cautions and Wangs 62 Maintenance Procedures 6.2.1 Maintenance and inspection of all carriers shall be performed in conformance with the manufac- turer's recommendations and the following practices. (a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed. (b) Only qualified and authorized personnel shall be permitted to maintain, repair, adjust, and inspect carriers. (¢) Before undertaking maintenance or repair, follow the manufacturer's recommendations for immobilizing the carrier. (@) Block chassis before working underneath it. (¢) Before disconnecting any part of the engine fuel system of a gasoline or diesel powered carrier with grav- ity feed fuel systems, be sure shutoff valve is closed, and run engine until fuel system is depleted and engine stops running. () Before disconnecting any part of the engine fuel system of LP gas powered carriers, close the LP gas cyl- inder valve and run the engine until fuel in the system is depleted and the engine stops running, (g) Operation to check pertormance ot the cartier shall be conducted in an authorized area where safe clear- ance exists. (h) Before commencing operation of the carrier, follow the manufacturer's instructions and recommended pro- cedures. (i). Avoid fire hazards and have fire protection equip- ‘ment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. () Properly ventilate the work area. (k) Handle LP gas cylinders with care. Physical dam: age, such as dents, scrapes, or gouges, may danger- ously weaken the tank and make it unsate for use. ()_ Brakes, steering mechanisms, speed and direc: tional control mechanisms, watning devices, lights, gov- ernors, guards, and safety devices shall be inspected regularly and maintained in a safe operating condition. (m) Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the orig- inal approved safe operating features. (n) Fuel systems shall be checked for leaks and condi- tion of parts. If a leak is found, action shall be taken to prevent the use of the carrier until the leak has been eliminated. (0) The cartier manufacturer's capacity, operation, ‘and maintenance instruction plates, tags, or decals shall 'be maintained in legible condition. {p) Batteries, motors, speed and directional control- lers, limit switches, protective devices, electrical conduc- tors, and connections shall be inspected and maintained in conformance with manufacturers recommended pro- cedures. (q) Carriers shall be kept in a clean condition to mi mize fire hazards and facilitate detection of loose or defective parts. (0) Modifications and additions which affect capacity and safe machine operation shall not be performed by the customer or user without manufacturer's prior written authorization; where authorized modifications have been made, the user shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are changed accordingly. (s) Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at loast equal to that provided in tho original equipment. End of ASME/ANSI B56.8-1988, Part I lezen) Repair and Service Manual Page B-7SAFETY NOTES, CAUTIONS AND WARNINGS Throughout this manual, the following NOTES, CAU- TIONS and WARNINGS are used. For the protection of all personnel and the vehicle, be aware of and observe the following: NOTE A NOTE indicates a condition that should be observed, ‘A CAUTION indicates a condition that pI iy result in damage to the vehicle or surrounding facilities. A WARNING indicates a FU ZNEISTEYW hazardous condition which could result in serious injury or death. IMPORTANT SAFETY WARNING In any product, components will eventually fal to perform properly as the result of normal use, age, wear or abuse. It is vitually impossible to anticipate all possible compo: nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there- fore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diag- nosing, removing or replacing any components that are not operating correctly, take the time to consider the safety of yourself and others around you if the compo- nent should move unexpectedly ‘Some components are heavy, spring loaded, highly cor- rosive, explosive or may produce high amperage or reach high temperatures. Battery acid and hydrogen gas ‘could result in serious bodily injury to the technician! mechanic and bystanders if not treated with utmost cau- tion, Be careful not to place hands, face, feet or body in a location that could expose them to injury should an unforeseen situation occur. ‘Always use the appropriate tools listed in the tool list and wear approved safety equipment. MODIFICATIONS TO VEHICLE Do not modify the vehicle in any manner that will change the weight distribution of the vehicle. ead all of Section A and this section before atempring any procede, Pay prtcular attention tall Notes, Cautions and Warrings Changes to the weight FUSES YW distribution or the center of gravity may make the vehicle unstable or prone to roll over which could result in injury or death to the operator or passen- ger(s). GENERAL MAINTENANCE When any maintenance procedure or inspection is per- ‘ormed, itis important that care be exercised to insure the safety of the technicianimechanic or bystanders and ‘0 prevent damage to the vehicle. Always read and understand the entire relevant manual section (chapter) before attempting any inspection or service, BEFORE SERVICING THE VEHICLE Before attempting to inspect or service a vehicle, be sure ‘0 read and understand the following warnings: To prevent personal inje FINUZACINISIEY Wry or death, observe the following: Before working on the vehicle, remove all jewelry (rings, watch, necklaces, etc.). Be sure that no loose clothing or hair can become caught in the moving parts of the powertrain. Use care not to contact hot objects. Before attempting to operate o adjust the power train, the rear of the vehicle must be raised and ‘supported on jack stands. Wear OSHA approved clothing and eye protection when working on anything that could expose the body or eyes to potential injury. n particular, use care when working with or around batteries, com- pressed air or solvents, Always turn the key switch to ‘OFF’ and remove the key before disconnecting a live circuit. When connecting battery cables, pay particular attention to the polarity of the battery terminals. Never confuse the positive and negative cables. Set the parking ‘PARK’ brake before performing any work on the vehicle. If repairs are to be made that will require welding or cutting, the batteries must be removed. Page B-8 Repair and Service Manual Gass)SAFETY ead allof Section A and this secton beer attempting any pocedure. Pay patcular attention foal Notes, Caution and Warnings Additional Warnings Before working on the electrical system, be sure to read and understand the following warnings that pertain to electrical system repair or maintenance: To provnt batery explo FINUZNGTINTEY'W sion that could result in ‘severe personal injury or death, keep all smoking materials, open flame or ‘sparks away from the batteries. Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it wil collect in the ceiling of buildings neces- sitating proper ventilation. Five air exchanges per hour is considered the minimum requirement. Be sure that the key switch is off and all electrical accessories are tured off before starting work on vehicle. The batteries should always be removed before any servicing or repairs that will generate sparks. Never disconnect a circuit under load at a battery terminal. Batteries are heavy. Use prop- er lifting techniques when moving them. Always lift the battery with @ commercially available battery lifting device. Use care not to tip batteries when removing or installing them; spilled electrolyte can cause burns and damage. The electrolyte in a storage battery Is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately. ‘Always wear a safety shield or approved safety goggles when adding water or charging batteries, Any electrolyte spills should be neutralized with a solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1 1/2 gallons (6 liters) of water and flushed with water. Overfiliing batteries may result in electrolyte being expelled from the battery during the charge aycle Expelled electrolyte may cause damage 0 the vehicle and storage facility. Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting ‘out’ a battery, which could result in an explosion and severe personal injury or death. Aerosol containers of battery terminal protectant ‘must be used with extreme care. Insulate metal container to prevent can from contacting battery terminals which could result in an explosion. BATTERY REMOVAL & INSTALLATION Too! List Qty. Required Insulated wrench, 9/16" 1 Socket, 1/2", 3/8" drive. a] Ratchet, 9/8" drive 1 Battery CArTi€r ..nnnnnnnnnnnene A Torque wrench, in. bs., 3/8" drive 1 In tho folowing text, there are references 10 Nee removing/installing bolts etc. Additional hard- ware (nuts, washers, etc.) that Is removed must always be installed in ts original position unless otherwise specified. Non- specified torques are as shown in table contained in Section ‘A. Before any electical service is per- CAUTION Be ke un-TowiMaintenance switch must be placed in the ‘Towiainte- nance’ positon ta power wire (battery, motor or controller) is disconnected for ‘any reason on the PDS model vehicle, the Run-Tow Maintenance ‘switch must be left in the ‘Tow/Maintenance’ position for atleast 30 seconds after the circutis restored, Turn vehicle key to ‘OFF’ and remove. Insure all optional electrical accessories are turned OFF. Using an insulated wrench, remove the main negative (-) cable (BL-) first, the main positive (+) cable (BL+) and then all other wires from the vehicle batteries. Remove the battery hold down by removing the hardware and lft- ing the retainer from the batteries. Remove the batteries using a commercial battery carrie. If the batteries have been cleaned and any acid in the battery rack area neutralized on a regular basis, no cor- rosion to the battery racks or surrounding area should be present. If any corrosion is found, it should be immedi- ately removed with a putty knife and a wire brush. The area should be washed with a solution of sodium bicar- bonate (baking soda) and water and thoroughly dried lezen) Repair and Service Manual Page B-9SAFETY Read all of Secon A and his section before attempting any procecue, Pay partcular attention to all Notes, Cautions and Warnings before priming and painting with a corrosion resistant paint. After the batteries have been replaced into the battery rack, replace the battery hold downs and tighten to 45 - 55 in. Ibs. (5 - 6 Nm) torque, to prevent movement, but Not tight enough to cause distortion of the battery cases. Inspect all wires and terminals and clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate (baking soda) and wire brush if required, Use care to connect the battery cables as shown in the following illustration (Ref Fig. 1 on page B-10), connect the main positive (+) battery cable (BL+) first, other battery connecting cables, and then connect the main negative (-) cable (BL-) last, tightening the battery post, hardware to 50 - 70 in. los. (6 - 8 Nm). Protect the battery terminals and battery cable terminals with a commer- cially available protective coating, Center of Front Axle Flat Portion of Frame iN BL+ tT Front of Vehicle 4) ng ss ‘Outside End View from Underside of Vehicle Fig. 1 Battery Connections LIFTING THE VEHICLE Tool List Qty. Required Floor jack. 7 sense Jack stands 4 COCKS enn 7 . 4 ‘Some servicing operations may require the front, rear or the entire vehicle to be raised. To prevent possible inju- 7 IWCCISINEY NW ry or death resulting from a vehicle falling from a jack, be sure the vehicle is on a firm and level surface. Never get under a vehicle while it is support- ed by a jack. Use jack stands and test the stability of the vehicle on the stands. Always place chocks in front and behind the wheels not being raised. Use extreme care since the vehicle is extremely unstable during the lifting process. Fig. 2 Lifting the Vehicle When lifting the vehicle, position jack Ba NT stends only in the areas inccated To raise the entire vehicle, install chocks in front and 2ehind each front wheel (Ref Fig. 2 on page B-10). Cen- ter the jack under the rear frame crossmember. Raise the vehicle and locate a jack stand under the outer ends of the rear axle. Lower the jack and test the stability of the vehicle on the ‘wo jack stands, Place the jack at the center of the front axle. Raise the vehicle and position jack stands under the frame cross- ‘member as indicated. Lower the jack and test the stability of the vehicle on all ‘our jack stands. If only the front or rear of the vehicle is to be raised, place the chocks in front and behind each wheel not being ‘aised in order to stabilize the vehicle. Lower the vehicle by reversing the lifting sequence. Page B-10 Repair and Service Manual Gass)BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. B00. ct Ganocal ot BODY COMPONENT REPLACEMENT. ct Insrument Panel Replacement os Cowl Replacement 5 Front Shield Replacement. os Focker Panel Replacement 6 Body Replacemen: o-6 Shute 2+2 Component Replacement 6 Fear Bumper Replacement or LIST OF ILLUSTRATIONS Fig, 1 Dri Out Metal Rivet ot Fig. 2 Body Components (Fron) ce Fig. 3 Body Components (ea o-3 Fig. 4 Shutlo 2 »2 Components cos ase) Repair and Service Manual Page CiBODY Notes: Page C:ii Repair and Service ManualBODY BODY PRIOTE]) "th folowing tox, there are referonces to AST removing/installing bolts etc. Additional hard- ware (outs, washers el) that are removed must always be installed in ther orginal positions unless otherwise specified. NNon-spectid torques ar0 as shown in the table in Section A General To prevent possible inju- 7 NUL GISINIEY NW ry or death from battery explosion, batteries should always be removed before any servicing that could generate sparks or repairs that require welding or cutting. Itis important to use a sharp drill bit when removing the rivets on the side of the vehicle, Extreme care ‘must be used when drilling out the rivets located in the front of the body and the bottom side of the body. Excessive pressure could result in the drill bit being forced through the body panel and penetrating a bat- tery. As extra protection, it is recommended that a protective piece of sheet metal be placed between the battery and the rivet. Use of a drill depth stop will pro- vide adaitional protection. In general, body component replacement can be accom- plished with a minimum of specialized tools. Most body ‘components are held in place with conventional remov- able hardware (nuts, bolts, washers and screws). Some components are mounted with ‘pop’ rivets which require that the rivet head be removed in order to push out the shank of the rivet. The rivet head is easily removed by drilling into the head with a sharp drill bit that is slightly ead all of Secon 8 and ths secon belore attempting any procedure. Pay partoua attention oa Noles, Cautions and Warnings larger than the shank of the rivet (Ref Fig. 1 on page C- 1). Care must be exercised when driling to prevent the drill from being forced through the plastic body compo- nents where it could damage components located imme- diately behind the rivet. The best way to prevent this from ‘occurring is to use a sharp drill bit that requires very tle pressure to cut successfully and to place a piece of pro- tective sheet metal between the surface being drilled and ‘components directly behind it. Dail Out Rivet Pop Rivet Head Only Fig. 1 Drill Out Metal Rivet BODY COMPONENT REPLACEMENT ‘The body components can be replaced by removing the securing hardware, replacing the component and secur- ing with hardware in the same orientation as removed. The illustrations on the following pages indicate the assembly methods for the various components. If the instrument panel is to be replaced, the NOTE) rai number pate and CE pate must be removed and reinstalled on the new instrument panel (Ref Fig 2 on page C-2). Repair and Service Manual Page C-1BODY Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings Fig. 2 Body Components (Front) Page 0-2 Repair and Service Manual ar)BODY ead ailof Section Band hs secton beorealempting any procedure. Pay particular attention fal Notes, Cautions and Wangs Fig. 3 Body Components (Rear) ay Repair and Service Manual Page 0-3BODY Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings SHUTTLE 2+2 COMPONENTS Fig. 4 Shuttle 2 + 2 Components Page 0-4 Repair and Service Manual ayBODY Instrument Panel Replacement If he instrument pane to be replace, the NOTE serial number plate must be removed from the ‘id insrument panel and reinstalled on the replacement pan (fet ig. 20n page C2). Tool List Qty. Reqd. Electrical dil 1 Drillbit, 732"... 1 Wrench, 516° 1 Philips screwdriver. 1 Rivet gun 1 The instrument panel may be removed without NOTE] roving ine cow! or may be removed a5 pat ofthe cow If the instrument panel (1) is to be replaced, the serial number plate (2) and capacity plate (3) must be removed from the old instrument panel and reinstalled on the replacement panel (Ref Fig. 2 on page C-2). When installing a replacement instrument panel, a new console safety label (4) MUST be ordered and placed on the new instrument panel. When ordering a replacement instru- ‘ment panel, provide vehicle serial number to the Service Parts Representative who will provide the correct part number for the safety label To prevent the possil 7 AZINE NW ty of injury due to lack of vehicle information, the correct safety label must be on the instrument panel atall times. Using an insulated wrench, disconnect the battery cable at the negative (-) battery terminal Pull the front of the floor mat (5) up to expose the rivets (6) that secure the instrument panel to the floor. Drill out the rivets attaching the bottom of the instrument panel to the floor and across the top of the instrument panel attaching it to the cow! (7) Remove the four screws (8) located within the instrument Panel pockets. ‘The instrument panel may now be pulled away from the cowl Remove the drive rivets (9) securing the ignition switch late (10) to the instrument panel. Rotate the ignition switch plate and push it through the instrument panel opening, freeing the panel for removal. Reassembly is the reverse order of disassembly and will require new rivets. Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Cowl Replacement Too! List Electric/air drill Diil bit, 7:32" Wrench, 5/16" Philips screwdriver. Rivet gun. Duct tape. Allen key, 3/16 sen Drill out the rivets (6) across the top of instrument panel (1) attaching it to the cowl (7) (Ref Fig. 2 on page C-2) Remove the rivet (11) at the front and back of each rocker panel (12) Remove the rocker panel sill plates (14) by removing the hardware (18) securing them to the frame. As the sill plate is removed, be sure to catch the three spacers (16) under each sill plate for reuse when sil plates are rein- stalled. Diill out the rivets (17) securing the sides of the cow! to the frame, Qty. Reqd. From underneath the cowl, remove the ratchet fastener (18) attaching the center of the splash panel (19) to the frame cross member. Remove the four screws (8) located within the instrument panel pockets. Remove the bolts and washers (20) from the sides of the cowl and lft the cowl assembly from the vehicle. Reassembly is the reverse order of disassembly and will require new rivets. The bolts and washers (20) rein- stalled into the cow! should be tightened to 8 - 12 ft. lbs. Front Shield Replacement Tool List ty. Read. Wrench, 7/16". se so at Pry bar. 1 ‘The front shield (22) need not to be removed to replace any other body components (Ref Fig. 2 on page C-2) If the front shield is damaged, remove hardware (23) securing the front shield to the frame. Remove the two rivets (24) securing the front shield to the brackets (25). lt a bracket is damaged, remove screw (26) securing it to the frame after removing the front shield, Install replacement shield in reverse order of disassem- by. lezen) Repair and Service Manual Page C-5BODY Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings Rocker Panel Replacement Too! List ty. Read. Phillips screwdriver. 1 Wrench, 7/16" 1 Electric/Air drill 1 Drill bit, 7/32" 1 Rivet gun... : renee Remove the rocker panel sill plates (14) by removing the hardware (15) securing them to the frame (Ref Fig. 2 on page C-2). As the sill plate is removed, be sure to catch the three spacers (16) under each sill plate for reuse when sil plates are reinstalled. To remove the rocker panel, remove the rivets (11) at the front anad rear of the rocker panel (12). Unsnap the rocker panel 12) from the vehicle frame. Replace rocker panel in reverse order of disassembly. Align the replacement sill plate with spacers in place and install hardware. Body Replacement Tool List Electrica dil an Dri bt, 7/82 Socket, 9/8 Socket, 7/16 Socket, 9/16 Ratchet, 3/8" Wrench, 3/8" Wrench, 7/16 Wrench, 9/16". Rivet gun Philips screwdriver... Pry bar. Prior to removing the rear body, the footrest or [NOTE] ro be. as appicable, must bo romoved. See the applicable paragraphs for instructions for replacement of those items. Remove the rocker panels as described above. Remove seat from body (27) (Ref Fig. 3 on page C-3). To prevent possible inju- Awarninca er death trom battery explosion, batteries should always be removed before any servicing that could generate sparks or repairs that require welding or cutting. Qty. Reqd. sel deepwell, 3/8" drive {tis important to use a sharp drill bit when removing the rivets on the side of the vehicle, Extreme care must be used when drilling out the rivets located in the front of the body and the bottom side of the body. Excessive pressure could result in the drill bit being forced through the body panel and penetrating a bat- tery. As extra protection, it is recommended that a protective piece of sheet metal be placed between the battery and the rivet. Use of a drill depth stop will pro- vide additional protection. Remove hardware (28) attaching seat back supports (29) to body. At the front of the rear body, remove the rivets (30) secur- ng the rear body to the frame and floorboard area. Drill out the heads of the large head rivets (31) that secure the bottom of the body panel to the side of the vehicle. Remove the rivets (32) that secure the floor of the bag- well area tothe frame underneath. Remove the body. Ifthe trunk lid (33) is to be reused, remove the hardware 4) securing the trunk lid to the body panel. Remove the srunk ld Installation of rear body is in the reverse order of disas- sembly using new rivets. Install the bolts (28) into the seat supports (29) and tighten to 21 - 25 ft. Ibs. Shuttle 2+2 Component Replacement Tool List Qty. Reqd. Electric/air drill Drill bit, 7/32" Socket, 9/16", 3/8" dFiV nn Ratchet, 3/8" drive Wrench, 9116". The foot rest is heavy 7 UZ and awkward to handle. To prevent possible per- sonal injury, itis strongly recommended that ade- quate help ora lifting device be used to remove the foot rest trom the vehicle, Remove rear valance panel (36) by prying out plastic fas- toners (37) (Ref Fig. 4 on page C4) Remove the hardware (38) attaching rear facing seat (39) to the seat back supports (40). Remove the screws (41) that secure seat back support to ‘ehicle frame, Remove the hardware 42) that secures seat back support to frame support (43). Remove each Page C-6 Repair and Service Manual Gass)BODY seat back support and spacer (44) from the rear body. Repeat procedure on other seat back support To avoid damage 10 the plastic body compo: LNQTES) pen romove or nsal eat support brackets by sling to the open end of the malded channel. Do not force the ‘seat support brackets into or out ofthe channels from above. Remove the hardware (45) securing the vertical foot rest bracket (46) to each frame support (43) (Ref Fig. 4 on page C-4). (Leave the bolt in place.) Remove the nut (47) securing the horizontal foot rest bracket to each frame support. (Leave the bolt in place.) While supporting the end of the foot rest, remove the bolt attaching the vertical bracket to the frame support Replacement of the foot rest is the reverse order of removal. Tighten bolts to 21 - 25 ft. Ibs. torque. Rear Bumper Replacement Tool List Qty. Reqd. Electric/Air drill 1 Dil bit, 7/3 Flat tip screwdriver 1 Allen wrench, 7/32" For Golf Cars, drill out rivets (48) located at each end of the rear bumper (49) (Ref Fig. 3 on page C-3). Carefully remove the plugs (53) with a screwdriver. Remove the shoulder bolts (52) underneath the plugs. Remove the rear bumper. To replace the bumper, place the rear bumper against the rear body panel and tighten the shoulder bolts (52) to 9 - 12 ft. Ibs. torque (Ret Fig. 3 on page C-3). Replace the plugs. Using the existing holes in the frame as a guide, drill holes in the bumper from underneath the vehi- cle and install new rivets. ead ailof Section Band hs secton beorealempting any procedure. Pay particular attention fal Notes, Cautions and Wangs For Shuttle 2+2, remove bolt (50) and J-nut (51) located at each end of the rear bumper (49) (Ref Fig. 3 on page C-3). Carefully remove the plugs (53) with a screwdriver. Remove the shoulder bolts (52) underneath the plugs. Remove the rear bumper. To install this type bumper, engage the top of the bumper with the underside of the fenders. Push bumper upward ‘as fender slides between the bumper clips and the bumper. Insert bolts through holes in the bumper into the frame and tighten to 9 - 12 ft. Ibs. torque. Tap a bumper cover plug into each hole. Secure each end of the bumper to the fender with bolt and J-nut. Repair and Service Manual Page C-7BODY Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings Notes: Page C-8 Repair and Service ManualWHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE Det Tie Repat. Dat Whe instalation Dat LIST OF ILLUSTRATIONS Fg. 1 Wheels and Tikes p-2 Ea Repair and Service Manual Page D:WHEELS AND TIRES Notes: Page Diii Repair and Service ManualWHEELS AND TIRES ead all of Secon 8 and ths secon belore attempting any procedure. Pay partoua attention oa Noles, Cautions and Warnings WHEEL AND TIRE SERVICE Tools List Qty. Required Lug wrench, 3/4” oe seve 1 Impact wrench, 1/2" drive. 1 Impact socket, 3/4", 1/2° drive. A Torque wrench, 1/2" drive, t. Ibs. 1 To prevent injury caused FWUZGISISEY NW by 2 broken socket, use only sockets designed for impact wrench use. Never use a conventional socket. Tire condition should be inspected per the Periodic Ser- vice Schedule. Inflation pressures should be checked when the tires are cool. When removing wheels with an impact wrench, use only impact sockets. Regular sock- ets are not designed for impact pressures exerted by power tools. A tire explosion can FT NUZNETINEY'W cause severe injury or death. Never exceed inflation pressure rating on tire sidewall. To prevent tire explosion, pressurize tire with small amount of air applied intermittently to seat beads. Never exceed the tire manufacturer's rec- ‘ommendation when seating a bead. Protect face and eyes from escaping air when removing valve core. Use caution when inflating tires. Due to the low volume of these small tires, overinflation can ‘occur in a matter of seconds. Overinflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause personal injury. Use caution when inflating tires. Due tothe low volume of these small tires, overiflation can occur in a matter of seconds. Overinflation could cause the tire to separate from the rim or cause the tire to explode, either of which could cause personal injury. Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section for recommended tre inflaion pressure, For outdoor appi- cations with major use on grassy areas, the following should be considered. On hard turf, it is desirable to have a slightly higher inflation pressure. On very soft turf, a lower pressure prevents tires from cutting into the tur. For vehicles being used on paved or hard surfaces, tite inflation pressure should be in the higher allowable range, but under no condition should inflation pressure be higher than recommended on tire sidewall. All four tires should have the same pressure for optimum han- dling characteristics. Be careful not to overinflate. Due to the low volume of these small tires, overinflation can ‘occur in a matter of seconds. Be sure to install the valve dust cap after checking or inflating, Tire Repair The vehicle is fited with low pressure tubeless tires mounted on one piece rims. Generally, the most cost effective way to repair a fat tre resulting from a puncture in the tread portion ofthe tire is to use a commercial tire plug Tire plug tools and plugs are available at most NOTE) siomoive parts outots and have the advan tage of not requiring the tre be removed from the wheel. If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire. Immerse the tire in water to locate the leak and mark with chalk. Insert tire plug in accordance with manufacturer's specifications. Ifthe tire is to be removed or mounted, the tire changing machine manufacturer's recommendations must be fol- lowed in order to minimize possibilty of personal injury, To prevent injury, be FINO ZNCISINEYW sure mounting/demount- jing machine is anchored to floor. Wear OSHA approved safety equipment when ‘mounting/demounting tres. Follow all instructions and safety warnings provided by the mounting/demounting machine manufacturer. Whee! Installation Do not tighten lug nuts to more than 85 CAUTION Baran It is important to folow the ‘crass sequence’ NOTE pattern when installing lug nuts. This will assure even seating othe wheel against the hub. With the valve stem to the outside, mount the whee! onto the hub with lug nuts. Finger tighten lug nuts in a ‘cross, sequence’ pattem (Ref Fig. 1 on page D-2). Then, tighten lug nuts to 50 - 85 ft Ibs. (70 - 115 Nm) torque in 20 ft. bs. (30 Nm) increments following the same ‘cross sequence’ pattern. lezen) Repair and Service Manual Page D-1WHEELS AND TIRES Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings Tite style may vary Valve stem is always: to outside of whee! Always replace dust cap ‘CROSS SEQUENCE’ Fig. 1 Wheels and Tires Page D-2 Repair and Service Manual ar)ELECTRONIC SPEED CONTROL (NON-PDS) TABLE OF CONTENTS FOR SECTION ‘E” SECTION TITLE GENERAL Pedal Box Contraler GENERAL TROUBLESHOOTING. Symptoms, Testing Testing Batory Votage Continuity Chock Testing a Switch er Continuity. Testing a Solenoid for Continuity ‘TROUBLESHOOTING DIAGRAMS. INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT. CONTROLLER REPLACMENT. SOLENOID REPLACEMENT LIST OF ILLUSTRATIONS Fig. 1 Access to Pedal Box Fig, 2 Contoller and Solonci. Fig. 3 Batory Reference Voltage. Fig. 4 Continuity Check ot Switch Fig. Continutly Gneck et Solenois Fig, 6 Simplified Troubleshooting Diagram Fig, 7 Detailed Troublestaoting Diagram (Shot tof 8) Fig, 8 Detaled Troublestaoting Diagram (Shoot 2 of 8) Fig, 8 Detailed Troublestooting Diagram (Sheet 3 of 8) Fig. 10 Detaled Troubleshooting Diagram (Sheet 4 of 8) Fig, 11 Detaled Troubleshooting Diagram (Sheet 5 of 8) Fig, 12 Detaled Troubleshooting Diagram (Sheet 6 of 8) Fig, 19 Detaled Troubleshooting Diagram (Sheet 7 of 8). Fig. 14 Detaled Troubleshooting Diagram (Sheet 8 of 8). Fig, 18.Aocess to Pedal Box Fig, 16 ITS and Plunger Fig. 17 ITS Adjustment (Sheet of 2) Fig, 18 ITS Adjustment (Sheat 2 of 2). Fig, 9 Wing Diagram, PAGE NO. Repair and Service Manual Page E-iELECTRONIC SPEED CONTROL (NON-PDS) Notes: Page Es Repair and Service ManualELECTRONIC SPEED CONTROL (NON-PDS) ‘Read ll of Section B and this section before attempting any procedure. Pay particular atenton to al Notes, Cautions and Warnings GENERAL ‘The Electronic Speed Control system consists of two separate units, the pedal box and the controller. Pedal Box ‘The Pedal Box assembly is a modularized unit that con: tains the accelerator pedal, return spring and an enclosed box that contains the pedal position micro switch and a solid state Inductive Throttle Sensor (ITS) that is activated by a moving plunger attached to the accelerator pedal. To access the pedal box, remove the rocker panel, lft the floor mat, and remove the access cover from the floor (Ref Fig. 1 on page E-1). The ITS and plunger are accessed by removing the top cover from the enclosed pedal box, Rocker Panel “Access Cover Floor Mat, Fig. 1 Access to Pedal Box Controller ‘The Controller is a solid state unit activated by a sole- noid. Both are located under the seat on the passenger side of the vehicle. ‘A diode is positioned between the two coil terminals of the solenoid. Its orientation is critical. The cathode side of the diode, identified with a silver band, is oriented to ‘The pedal box and controller are connected by a four pin connector that is located under the seat within the black plastic environmental cover. ‘The controller is wired to the batteries and develops a regulated power supply for the ITS. The plunger position relative to the ITS varies the voltage which is fed back to the controller which interprets the change in voltage and supplies the appropriate power to the motor. ‘The ITS unit and the controller are both solid state units that contain no user serviceable parts. The testing pro- cedures are designed to test the basic functionality of the power and control wiring systems. Once the functionality of the wiring has been confirmed, the remaining tests are used to identify which of the compo- rents (controller or ITS) must be replaced. 1206 CONTROLLER ‘See Wiring Diagram at end of section for wire connections Resistor Fig. 2 Controller and Solenoid GENERAL TROUBLESHOOTING the solenoid terminal with the red wire attached (Ref Fig. Too! List Qty. Required 2.0n page E-1) Floor jack.. at Ie the diode is incorrectly oriented, the Ja0K stands e pedal box micro switch and the direc- Wheel chocks.. mae =I tion selector miro switch may be permanently damaged. Jumper wire (with alligator clips) 1 DVoM. a 2) Repair and Service Manual Page E-1ELECTRONIC SPEED CONTROL (NON-PDS) Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings Socket, 3/8", 3/8" drive. Ratchet, 3/8" drive Torque wrench, in. bs., 3/8" drive ‘Torque wrench, ft. Ibs., 3/8" drive Extension, 6", 3/8" drive Insulated wrench, 9/16"... Wrench, 1/2" Wrench, 7/16" Phillips screwdriver, large. Phillips screwdriver, small ‘Shop towel. Allen wrench, .050" ‘Symptoms Vehicle does not operate, operates poorly or intermit- tently, Testing Itis unlikely that the mechanical adjustment of the pedal box has changed, therefore the initial tests will be con- ducted with a digital volt ohm meter (OVOM) to identity the failed component. ‘A ypical DVOM is shown in illustrations. A recom- mended DVOM is available through the E-Z-GO Service Parts Department as P/N 27481-GO1. Any DVOM may be used; however, the accuracy, controls, displays and features may vary depending on the make and model. ‘Always follow the meter manufacturer's recommenda- tions and instructions for the use and care of the meter. To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage. To prevent injury result- yIWICUISINEY NW ing from unexpected movement of the vehicle, always raise the rear wheels before conducting any tests. To prevent possible motor damage, never operate vehicle at full throttle for more than 4-5 seconds while vehicle is in a “no-load” condition. Raise the rear wheels of the vehicle and support on jack stands (Refer to the Lifting Procedure in Section ‘B’ Safety). Test the vehicle stability before proceeding. Place the direction selector in ‘F’ and turn the key switch to ‘ON’. Depress the accelerator pedal until the micro ‘witch in the pedal box activates which should cause the solenoid to make an audible cick. Testing Battery Voltage itis important to determine the condition of the battery set before proceeding with any electrical troubleshooting. ‘An open voltage test is of litle use since a battery that ‘as deteriorated to the point of requiring replacement 2an still show six volts or higher in an open voltage test. If there is any doubt as to the adequacy of the battery set, sharge the batteries and perform a load test using a dis- sharge machine following manufacturers instructions. If aatteries are satisfactory, recharge battery set. With the adequacy of the batteries confirmed, use a DVOM connected directly to the battery terminal posts to determine the open voltage of the set (Ref Fig. 3 on page E-2). In the following tests, this voltage level will be used asa reference, Some loss due to resistance or wires and connectors may be indicated by readings that could be 4p to one volt less than the reference voltage. No reading nidicates an “open” condition and the battery wires should be inspected for a broken or disconnected wire or somponent. 3124 Battery Reference Voltage Positive Probe Negative Probe toBL- Fig. 3 Battery Reference Voltage Page E-2 Repair and Service Manual Gass)ELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Continuity Check To prevent possible inju- FI NIZNGISISEY Wry or death resulting from a battery explo- sion, use an insulated wrench and remove the BL- Lad a the battery to disconnect electrical power to vehicle. Before attempting to perform a continuity check, turn the key switch to ‘OFF’ and place the direction selec- tor in neutral. Ifthe solenoid does not function, the pedal micro switch, neutral micro switch (direction selector switch), solenoid, key switch and four pin connector should be checked for continuity Tum the key switch to ‘OFF" and place the direction selector in neutral before disconnecting power by remov- jing the B+ connection to the battery. Always use insu- lated wrenches when working on batteries. To check for continuity, set the DVOM to the KA setting and select ‘Continuity’. The meter will give an audible signal when it detects continuity. If the meter does not have a continuity setting, set it to KO, the meter will indicate “0" when it detects continuity. Testing a Switch for Continuity Place one probe on one contact of the switch, place the second probe on the second terminal of the switch (Ret Fig. 4 on page E-3). Actuating a normally open (NO) switch will cause the DVOM to show “0” or give an audible indication when the switch is operated, A normally closed (NC) switch will cause the meter to show *0" or give an audible indication when the probes are attached without activating switch: The audible indicator will stop and the meter display will indicate a value greater than “0” when the switch is acti- vated. ‘The change in display or audible indicator demonstrates thatthe switch is functioning Testing a Solenoid for Continuity Place one probe on one of the large terminals and the ther probe on the second large terminal (Ref Fig. 5 on page E-3). If the meter shows ‘0" or gives an audible indication, the solenoid terminals are “welded” closed and the solenoid must be replaced. If the continuity test indicates that contacts are not “welded” and the wiring to the solenoid coil is good, the coil has failed and the solenoid must be replaced. Press to » vais neice Fig. 5 Continuity Check of Solenoid ar) Repair and Service Manual Page E-3,ELECTRONIC SPEED CONTROL (NON-PDS) ead lof Secon B ad hs sctin befor attempting any procedue Pay prtculr attention ta Notes, Cautions and Warnings TROUBLESHOOTING DIAGRAMS ‘umbers to the information in the detailed troubleshoot- 1ng diagram. The simpiifed troubleshooting diagram is a quick ESC It is vital to the safety of the technician and assistants diagnosis (Ref Fig. 6 on page E-4). Use this diagram to that all wamings and safety procedures in this section be perform initial troubleshooting. Follow the indicated step _‘ollowed. oes Nat Run Electronic Speed Control Simplified Troubleshooting t 1206 Controller false eal eile very ews re ey Drea Sterne ett Dom Key OW Direction Selector nF eda fully depressed Seinite Siro i vor te soy Sun ‘Solenoid Click? Reference es, Veet te on “i we, canguoe eile Operates? Goto Step 37 Vehicle Opera Powe: Great (Steps 37 =) Vetice Operates? stop ‘Vette Operates cote Stop Fig. 6 Simplified Troubleshooting Diagram Page E-4 Repair and Service Manual ar)ELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Electronic Speed Control Diagnostic Procedure 1206 Controller oy OFF Direction Selector in W Bary 8-08 “Rolerence Vollage * Below 36 Vos Charge bateres befor prooeding ** Reference vottage changes wth bate laa (typical voage: 36-38 vos) — START Vote Between ator & Battery ‘Sie of Solenoid. Reterence Votage? conte ie tf Soro Lr | tat 8 Conrater 8 Correct Problem Between Baty Be ‘eSolenod i coe Sag | Catlett Replace if Welded pontroler Be rece (er) eplace Correct Wiring Py 259 iim oy Problem Between tess Than sotenoiConroter Be Retornce Vane No (era) Gore Wiring Problem Betunen fstien 8corrlere Fig. 7 Detailed Troubleshooting Diagram (Sheet 1 of 8) ay Repair and Service Manual Page E-5ELECTRONIC SPEED CONTROL (NON-PDS) Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings Key 0%, reson Selector inF Depress oro: prvcen sen Pot Orecton Sect Merositch Temoal oh Rea Wie very contruty- Ly lac Mose Key 0, iron elector in F Pedal dpresed fed Wie anf ne w Hi Soon ley Sra We Wire pele han co Baten 88 ‘atery 6 & Reterenc Vans? Ye} Wie (Sal Terminal hegaansta "et Microswitch Reassemte Goto| No zo) Fig. 8 Detailed Troubleshooting Diagram (Sheet 2 of 8) Page E-6 Repair and Service Manual ar)ELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings sare een tc cheb ter emer ican ypc, ates [men a Sn Wi ay 0, Dect Seet wri vanes “Pin ith Reo Wire) raga eae Gone > of Se, || Breer] see nen TD yo oat ara arora uuetass oa) ‘la tector 2 Eo Yl sn St reat cere) No Ze) ms Caen co to BB) nes Wie ene 1, rete Se ‘scan Haas “Cente cenit) ¥ yer gf cearenann ‘sont |] cage bien a ont Fig. 9 Detailed Troubleshooting Diagram (Sheet 3 of 8) ar) Repair and Service Manual Page E-7ELECTRONIC SPEED CONTROL (NON-PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings es EX van o0.96 oi comers — OW, een Steen re Kae =n Dvr a ortega a? — orn oer a rag5° Def veneer rtp erat oO scr Terie Pn? Sete tans _——— pane Ee ‘on oc Fag SO EL cis bree Seale a Sent 1 ses anager “ac ‘ek Beree eager > Paco at ie togu “ core eager sen ae) feos co Fig. 10 Detailed Troubleshooting Diagram (Sheet 4 of 8) Page E-8 Repair and Service Manual ar)ELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Key ON, Direction Selector in F Disconnect Battery Wie; Pedal Fully Depressed Disconnect 6 Pin Connector Yotage Between trom Controller Baten B83 (White Wire to TS Should "Tema With 9 Be Diseonne Black Wire EMD coninuiy deween White Wie at TS & Gontatee Connector coesns, bel on Ertoee ts oer tac eens) Find Return to Reconnect All” FB) rect Problem in 190-155 Vols? io (Ouse Range) Key ON, Direction Selector in F 7 Pedal Fully Depress Efoattry 8 o Back ie ‘Gant Harness “Pin Comnestor (Glack Wire Pn) Exeortinaty Setvean vai ‘Wir at ITS & Pata Boe “Pin Connect wnite Wire Pn) ‘ora Probie in “Pn Comactr, econodt ll Wires Sones Probe in Conmedtr, Reconnect al’ >>) Erect Comoctons Cacac Protlem we ac Control Hames We Reconnect ect Connections ed Box Hamas whe Wie Reconnect Al Wes Fig. 11. Detailed Troubleshooting Diagram (Sheet 5 of 8) ay Repair and Service Manual Page E-9ELECTRONIC SPEED CONTROL (NON-PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings own to 4 femaar Pat ‘het EX vay rung P| Comair comsepr ON, chan Stern F BD veceoen eyes Dieter srk Koy, cen electri F ee Gates reser sr caret Wee Paton on ote os Sencar ear e one ‘emzensoncer “eamesaes ‘come eas PT tase ‘use 1S me tn a cont po(o)od z Po (Outside Range A t. | eciuate Fig. 12 Detailed Troubleshooting Diagram (Sheet 6 of 8) Page E-10 Repair and Service ManualELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Key 0, DretionSoecor nF FA voz one Baller 8 Mat 82 Noo Votag) Carat ie Probl aboen Becton Koy 0, Direction Selector in F FD vera cerieen te] es 88 Matar St ro Key ON, Direction SeletorinF ves | ED vege teen ©2s var tes Tun ‘netr 8 Mor 52 — Koy ON, Direction Solecor nF otageBeveen ate Be sor 42 No Wo Vota) Corec Wire Prien ete Decion ‘sebtor Eioioe | oiay ee eeretoeVotage Deaton Stor No No Vota) Key ON, Diteton Selector in F $25 var tc Than Beterenoe Votoge? Faplace Motor Yes ‘Vota Baten =| aye Directon Sector No No Vora) Setoon Drecion ‘ier hier St oo Vorage) Cet Wire Problem ih Deon Steer otageBetueen ey Bk Matar oon donot EAE ul ezcoce | , ante oa Vonage) 6-25vah tees Than Reternoe Vatage, yes Popa Moto & Goto| ace) Cott Wire Problem Baoan ttn At ‘e Convaerb Fig. 13 Detailed Troubleshooting Diagram (Sheet 7 of 8) Repair and Service Manual Page E-11ELECTRONIC SPEED CONTROL (NON-PDS) Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings TD vote een ‘onal Bs & ‘onto t orn FED age oerveen i No (60% Ret Vo) Retrenoe Vatane? ves _ | verty wire switch > connatons/Opeatan Feplace as Necessary Replace Contra Reirstal Oange wire Key Direction Sector in F Pauly Depressed Lower vehicle eTest Dre Crick or Becta Sons ‘eaestancal Bostvtong eps Motor YS 5] cower venice eTest Ore No Goto Fig. 14 Detailed Troubleshooting Diagram (Sheet 8 of 8) Page E-12 Repair and Service Manual ayELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT Tool List Qty. Required Phillips screwdriver 1 Wrench, 7/16" Nut driver, 7/1 Drill bit, 17/64". sonnnnnnnnntnnnnnnnn DVOM 1 Raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to Lifting Procedure in Sec- tion ‘B’ Safety). Test the vehicle stability before proceed- ing. Remove the driver's side rocker panel insert and pull the floormat forward to expose the metal cover to the pedal box (Ref Fig. 15 on page E-13). Rocker Panel _—~Aogess Cover ay, Floor Mat Fig. 15 Access to Pedal Box Remove the cover and remove the four screws securing the plastic cover to the pedal box (Ret Fig. 16 on page E- 13), Set the parking ‘PARK’ brake. With the DVOM set to volts, probe the white wire at the ITS with the positive probe and attach the negative probe to the B- at battery. Place the direction selector in 'F’ and turn the key switch to ‘ON’. Depress the accelerator pedal. As the solenoid clicks the meter should read between 0.4 - 0.6 volts. The Lock Nut [Micro Switeh Micro Switch — Adjusting Cam Plunger Connector .16 ITS and Plunger meter should read 1.5 - 1.7 volts at full pedal (Ref Fig. 18 ‘on page E-15). If the reading is out of specification, the ITS sensor must be replaced. ‘The ‘TS’ attaches to the plastic pedal pa 5% using two plastic studs and two ‘speed nuts. Use oare not to overtighten the nuts which could strip the plastic studs while tightening the nuts enough to pre- vent movement of the ‘ITS’. Carefully remove the two wires that attach to the ITS and carefully remove the nuts securing the ITS to the plastic, pedal box studs. Install a new ITS being careful to align the ITS and not to ‘overtighten the retaining nuts. Attach the wiring, With the accelerator pedal in the full up position, insert a 17/64" drill bit between the plunger and the face of the ITS. The drill bit should be used to verify and adjust the distance between the face of the ITS and the face of the plunger (Ref Fig. 17 on page E-14). If the plunger needs adjustment, loosen the lock nut and rotate the plunger until the desired dimension is achieved. Firmly tighten the jam nut. Replace the plastic cover and press it firmly into place before tightening the cover screws. Replace the metal cover, floormat and rocker panel insert Repair and Service Manual Page E-13,ELECTRONIC SPEED CONTROL (NON-PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings @ PEDAL PRE-TRAVEL Pedal bracket rest against front of pedal frame opening Lock Nut Use 17/64" anit to measure gap between plunger Micro switch ands Piunger disengaged ms Micro switch ‘disengaged | Piungerhas not entered Ts! To adjust plunger: Loosen lock nut + Rotate plunger until ‘dosires dimension Is achieved Tighten Lock Nut Fig. 17 ITS Adjustment (Sheet 1 of 2) Page E-14 Repair and Service ManualELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings @ @ SOLENOID ACTIVATED PEDAL ALL THE WAY DOWN 0.40.6 volts 15-17 volts -- Heel ° 2 LG Puy Pedal bracket (of pedal frame ‘opening cam—_| Micro switch Plunger enters TS Plunger fuly “L_ activated With pedal all tne way down: Plunger should be fush with lor extend beyond rear of TTS Fig. 18 ITS Adjustment (Sheet 2 of 2) ay Repair and Service Manual Page E-15ELECTRONIC SPEED CONTROL (NON-PDS) Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings CONTROLLER REPLACEMENT Too! List Qty. Required Socket, 3/8", 3/8" drive. oo renee Socket, 7/16", 31 1 Socket, 1/ 1 Ratchet, 3/8” 1 Extension, 6", 9/8" drive 1 Insulated wrench, 9/16* 1 'ShOP OWE ree sev sel Torque wrench, 3/8" drive, in. Ibs. 1 Torque wrench, 3/8" drive, ft. bs. a Large screwdriver. 1 Remove the seat. To prevent electrical 7 INZNGISISTEY shock, the BL- wire must be removed before dis- charging the controller by shorting the B+ and B- ter- minals of the controller with a large screwdriver. Be sure to hold screwdriver by the insulated portion. Using an insulated wrench, romovo tho BL wire from the battery and cover the direction selector switch with a shop towel. Remove the environmental cover. ‘Note the location ofthe wiring on the controler before removing wiring from controller (Ref Fig. 2 on page E-1) Remove the controller mounting bolts and remove the controller. Mount new controller and reconnect wiring. Tighten the Controller mounting bolts to 108 - 132 in. Ibs. (12 - 15 Nm) torque and the terminal bolts to 11 - 14 ft. Ibs. (15 - 19 Nm) torque. Replace the environmental cover and tighten the mount- ing bolts to 108 - 132 in. lbs. (12 - 15 Nm) torque. Reconnect the BL- battery cable and replace the seat. NOTE SOLENOID REPLACEMENT Tool List Qty. Required Socket, 3/8", 9/8" drive oo oe 1 Socket, 7/16", 3/8" drive Socket, 1/2", 3/8" JFIVE svn Ratchet, 3/8" drive . Extension, 6", 3/8° drive Insulated wrench, 9/16" Shop towel... seve Torque wrench, 3/8" drive, in. Ibs. Torque wrench, 3/8" drive, ft. Ibs... Large screwdriver Remove the seat, To prevent electrical 7 NUTINI shock, the BL- wire must be removed before dis- charging the controller by shorting the B+ and B- ter- mminals of the controller with a large screwdriver. Be sure to hold screwdriver by the insulated portion. Using an insulated wrench, remove the BL- wie from the battery and cover the direction selector switch with a shop towel Remove the environmental cover NOTE "Note the location ofthe wiing on the solenoid before removing witing from solenoid (Ret Fig. 20n page E-1) Remove the solenoid mounting bolts and remove the solenoid. Mount new solenoid and reconnect wiring. Tighten the solenoid mounting nuts to 68 - 82 in. Ibs. (8 - 9 Nm) torque, the #10 terminal nuts to 15 - 20 in. Ibs. (2 Nm) and the 5/16" terminal nuts to 50 - 55 in. Ibs (6 Nm) torque. Replace the environmental cover and tighten the mount- ng bolts to 108 - 132 in. Ibs. (12 - 15 Nm) torque. Reconnect the BL- battery cable and replace the seat, Page E-16 Repair and Service ManualELECTRONIC SPEED CONTROL (NON-PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Ignition itrioce Chager Roscbtece Direction Selector ‘Switch w Contraler Wires indicated are contained in power hamess Al other wires are control wiring M82 is closed when direction selector switch is in forward or reverse MS3 is activated by accelerator pedal MS4 is closed by direction salector switch in reverse only Fig. 19 Wiring Diagram ar) Repair and Service Manual Page E17ELECTRONIC SPEED CONTROL (NON-PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings Notes: Page E-18 Repair and Service ManualELECTRONIC SPEED CONTROL (PDS) TABLE OF CONTENTS FOR SECTION ‘F” SECTION TITLE PAGE NO. PRECISION DRIVE SYSTEM™ GENERAL Ft PRECISION DRIVE SYSTEM™ PERFORMANCE OPTIONS & DIAGNOSTICS Fo ‘Changing Perormance Opions Fat PRECISION DRIVE SYSTEM™ OPERATION F-2 Pedal Bor F-8 Speed Sensor F8 Contr F-8 GENERAL TROUBLESHOOTING: fea Symptoms Fa Testing Fea Tesing Bator Volage Fs Contnuty Chock Fs Teanga Switch ir Cony rs Testng a Solon Conny. Fs “TROUBLESHOOTING DAGRAMS F-6 INDUCTIVE THROTTLE SENSOR (TS) TESTING AND REPLACEMENT. F-20 CONTROLLER REPLACEMENT F-2 SOLENOID REPLACEMENT F-2 LIST OF ILLUSTRATIONS Fig. 1 Run-TowMahnance Switch, F-2 Fig 2 Accoss to Pedal Bx F-8 Fig. 8 Controle and Sono F3 Fg 4 Battery Fearon Volage F-8 Fig, 8 Conny Chek ct Swe, F8 Fg 6 Gontnuly Chock! Solano F8 Fig. POS Diagnose Made Faut Codes F7 Fg. 8 Contr Comecors and Connecions Fa Fig. 9 Weng Diagram F-8 Fi 10 Dettd roublochoatng Diagram (Shooto 10) #10 Fig 11 Detaled Troubleshooting Diagram (Sheet 2o 1) Fn Fo. 12 Detaled Troubleshooting Diagram (Shooto! 1) Foe Fig 18 Detaled Trevbeshotng Diagram (Shee ot 1) F183 Fo 14 Detaled Troubleshooting Diagram (Shee Sol 1) Fite Fig 15 Detaled Troubleshooting Diagram (Short 6 ot 1) an Fp 16 Detaled Trosblechotng Diagram (Sheet 7 of 10) Ft Fig. 1? Detaled Troubleshooting Diagram (Sheet ot 1) Fa? Fg 18 Detaled Troubleshooting Diagram (Sheet 9c! 1) Foe Fig 19 Detaled Troblesroang Diagram (Shoo! 100! 10) F19 Fg. 20 11S and Pungor F-20 Fig. 21 11S Agusimont Shot #02) Fat Fg 22 17S Adustnent (Sheet 202) Foe Fig. 28 Contolor Wing. Fa Fig 24 Solon Wing. Fiat ar) Repair and Service Manual Page FiELECTRONIC SPEED CONTROL (PDS) Notes: Page Fi Repair and Service ManualELECTRONIC SPEED CONTROL (PDS) ‘Read ll of Section B and this section before attempting any procedure. Pay particular atenton to al Notes, Cautions and Warnings PRECISION DRIVE SYSTEM™ GENERAL Precision Drive System (PDS) vehicles are operated in ‘one of four modes or “performance options”. The option of the vehicle is determined by which “option plug” is installed in the Electronic Speed Control Assembly. The options are defined as follows: 4. The All-Terrain performance option: The motor's speed is sensed and regulated to 13.2 mph (21 kph) directly by the controller, the vehicle's flat ground speed will not change with different ground surfaces. The speed sensor also allows for precise control of the downhill vehicle speed during compression brak ing. As the vehicle crests a hill and begins to descend, the speed will be smoothly regulated to 13.2 mph (21 kph). This option is enabled when there is a blank plug installed. 2, The Steep Hill performance option: This option includes all of the driving features of the All-Terrain option plus compression braking. Compression brak ing occurs when the throttle is released while the vehicle is moving. The motor will electrically retard the motion of the vehicle until the throttle is depressed aaain or the vehicle stops. This is the strongest of the two compression braking options. This is also a 13.2 mph (21 koh) option. This option is enabled when the biue plug is installed. 3, The Mild Hill performance option: This option includes all of the driving features of the Steep Hill option, except that the compression braking feel is milder, and the flat ground compression braking speeds are 14.25 mph (23 kph) instead of 13.2 mph (21 kph). This option is enabled when the yellow plug is installed. 4, The Freedom performance option: This option includes all of the driving features of the All-Terrain option except that the flat ground and downhill com- pression braking speeds are 18 mph (29 kph) instead of 13.2 mph (21 kph). This option is enabled when the red plug is installed. THIS OPTION IS NOT OFFERED ON FLEET VEHICLES. The vehicle performance option can be determined with- out removing the ESC cover by placing the vehicle in diagnostic mode (See diagnostic mode instructions). The number of beeps heard immediately after entering diag- nostic mode corresponds to the option per the above option numbers. Performance options of the Precision Drive System include: + Anti-Roll back to limit backward motion of the vehicle down an inctine to less than 2 mph (3 kph) © Walk-Away to limit vehicle movement without driver input, slowing the vehicle to 2 mph (3 kph) and sounding an audible alarm (reverse beeper) © Anti-Stall protection to prevent commutator dam- age from stalling the vehicle against an object or on a hill * High pedal disable to prevent undesired accelera- tion if the direction selector lever is changed, or the key is turned on while the accelerator is depressed * Diagnostic mode to ease troubleshooting PRECISION DRIVE SYSTEM™ PERFORMANCE OPTIONS & DIAGNOSTICS Performance] Top Speed [Compression] Anti-Stall Option Braking | Protection Strength ‘Aitewan [13-135 mph [None Yes (21-22 kph) Steep Hl [13-135 mph | Heavy Yes (21-22 koh) Mid Hil [14-145 mph [Mild Yes (22.5 -23 kh) Freedom [17-1amph [None Yes (27 -30.5 kph) Changing Performance Options ‘The performance option may be changed i the existing cption is not compatible with the terrain that the vehicle willbe operated 1. Raise the seat and move the Run-Tow/Maintenance ‘switch to the ‘TOW/MAINTENANCE ' position. 2. Remove the four bolts securing the black plastic Elec- tronic Speed Controller (ESC) environmental cover. 3. Remove the ESC environmental cover and locate the S:pin performance option plug at the top of the con- teller. 4, Replace the existing performance option plug withthe desired new plug. (This wil require the removal of the tamper proof label.) 5. Replace the ESC environmental cover. Move the Run-TowiMaintenance switch to “RUN. lezen) Repair and Service Manual Page F-1ELECTRONIC SPEED CONTROL (PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings 7. Place a new performance option label (colored dot) fon the outside of the ESC environmental cover to indicate the new option. ‘At monthly intervals, test the PDS system by allowing the vehicle to roll down an incline with the accelerator pedal released. Braking force should be felt at approximately 2 mph (3 kph) indicating that the PDS system is function- ing. If vehicle speed continues to rise, apply the service brake to control speed and proceed with diagnostic check. The PDS vehicle has the ability to diagnose and report several common golf car fault modes. These faults are reported through the reverse waming beeper with a sequence of beeps. The faults are reported with the vehi- le in ‘diagnostic mode’ Diagnostic mode can only be entered through five con- secutive neutral-reverse selections with the key switch tured off and the vehicle stopped. Approximately two seconds after the fith selection, the controller will report the performance option that itis equipped with a single series of beeps. One purpose in this function is to verity that diagnostic mode has been successfully initiated. The other purpose is to allow verification of which perfor- mance option the vehicle is equipped with without remov- ing the ESC environmental cover. ‘Once in diagnostic mode, the vehicle will continue to ‘operate as it did before, only now it will audibly report any faults detected. The faults are reported as a series of short beeps followed by a pause and then another series of short beeps. The number of beeps in each series con- stitute the fault code. For example: three short beeps fol- lowed by a pause, and then two more short beeps would indicate fault code 3-2. To exit diagnostic mode, turn the Run-Tow/Maintenance switch from ‘RUN’ to ‘TOW/MAIN- TENANCE” and back to ‘RUN’ again. Charing the vehicle wil also deactivate the [NOTE] prose moc, ‘The two-position ‘Run-Tow/Maintenance’ switch is located under the passenger side of the seat on the ESC ‘environmental cover (Ref Fig. 1 on page F-2). PRECISION DRIVE SYSTEM™ OPERATION With the switch in TOW/MAINTENANCE: position: * the controller is deactivated * the electronic braking system is deactivated which allows the vehicle to be towed or roll freely © the warning beeper is deactivated Run-Tow/Maintenance Switch Controller Environmental Cover Fig. 1 Run-Tow/Maintenance Switch With the switch in ‘RUN’ position: * the controller is activated ‘the electronic braking system and warning beeper features are activated NOTE] 725 vehicles operate only in the ‘RUN’ posi tion, It all of the following events occur with the switch in RUN’ position ') the vehicle has been stopped for more than one second ») the accelerator pedal has been released for more than one second ©) the vehicle begins to roll above 2 mph (3 kph) the electronic braking will limit speed to approximately 2 ‘nph (3 kph) and the warning beeper will sound. When the accelerator pedal is depressed, the electronic brak- ‘ng and warning beeper will be overridden and normal vehicle operation resumes. Any unusual situation sensed ay the PDS system will cause a similar response. The system functions in all key switch positions The PDS system is not a PNUENEININE WY substitute for the ser- vice brake which should be used to control speed and reduce possibility of injury. If all of the following events occur with the switch in RUN’ position 2) the vehicle is being driven down a slope ») the vehicle speed exceeds the designed speed with the accelerator pedal depressed or released (except options equipped with compression brak- ing) Page F-2 Repair and Service Manual Gass)ELECTRONIC SPEED CONTROL (PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings the electronic braking will limit the speed of the vehicle to the designed speed range (the warning beeper will not sound). When the electronic braking system is activated by this sequence of events, the motor generates power which is returned to the batteries. PDS models are equipped with a regenerative motor control system. The motor's speed is sensed and regulated directly by the controller. As a vehicle begins to accelerate while descending a hil, the speed sensor will cause the motor to electrically retard the speed of the vehicle through regenerative braking. Ifthe operator attempts to override the electronic braking feature by moving the direction selector or key switch to another position, the warning beeper will sound and the vehicle will brake rapidly until it reaches the speed of approximately 2 mph (3 kph). The PDS system also incorporates an anti-stall protec- tion feature that prevents commutator damage from stall ing the vehicle against an obstacle or ascending a hil. The electrical power to the motor willbe interrupted inter- mittently allowing the vehicle to roll a short distance, thereby allowing the internal components of the motor to move before damage can be done. ‘The Steep and Mild Hill option (See chart on page 1) fea~ tures different degrees of compression breaking that takes place any time that accelerator pedal is released. The Steep Hill option will rapidly slow the vehicle to a stop unless the accelerator pedal is depressed. The Mild Hill option will slow the vehicle to a stop at a slower rate unless the accelerator pedal is depressed. ‘The PDS is a low power consumption unit butit will drain the vehicle batteries over a period of time. If the vehicle is to be stored for a prolonged period of time, the PDS should be disconnected from the batteries by selecting the ‘TOWIMAINTENANCE® position on the Run-Tow/ Maintenance switch located under the passenger seat The Electronic Speed Control system consists of three separate units, a pedal box, speed sensor and controller. Pedal Box ‘The pedal box assembly is a modularized unit that con: tains the accelerator pedal, return spring and an enclosed box that contains the pedal position micro switch and a solid state Inductive Throttle Sensor (ITS) that is activated by a moving plunger attached to the accelerator pedal. To access the pedal box, remove the rocker panel, lft the floor mat, and remove the access cover from the floor (Ref Fig. 2 on page F-3). The ITS and plunger are accessed by removing the four screws and top cover from the enclosed pedal box. Rocker Panel “Access Cover Floor Mat, 2 Access to Pedal Box Speed Sensor ‘The speed sensor uses a sealed sensor to read the impulses of a ring magnet attached to the armature shaft of the motor. Magnetic pulses are converted into electri- cal signals which the controller uses to determine the motor speed. Controller ‘The controller is a solid state unit that activates a sole- Noid and controls the function of the vehicle by respond- ing to inputs from the ITS and motor speed sensor. The controller and solenoid are located within an environ- mental cover/heatsink under the seat on the passenger side of the vehicle (Ref Fig. 3 on page F-3). 1206MX Controller ‘See Wiring Diagram at end of section for wire connections Fig. 3 Controller and Solenoid lezen) Repair and Service Manual Page F-3ELECTRONIC SPEED CONTROL (PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings ‘The pedal box is connected to the controller through a four pin plug at J4 on the controller. The speed sensor is ‘connected to the controller through a three pin plug at J5 (Ref Fig. 8 on page F-8) ‘The controller is wired to the batteries and develops a regulated power supply for the ITS. The plunger position relative to the ITS varies the voltage which is fed back to the controller which interprets the change in voltage and. supplies the appropriate power to the motor. ‘The ITS unit and the controller are both solid state units that contain no user serviceable parts. The testing pro- cedures are designed to test the basic functionality of the power and control wiring systems. Once the functionality of the wiring has been confirmed, the remaining tests are used to identify which of the compo- nents (controller or ITS) must be replaced. GENERAL TROUBLESHOOTING Tool List Qty. Required FlOOT jaCK.nnnninnnnnsnnnnnnnnnnsnnsnnn Jack stands Wheel Chocks on . Jumper wire (with alligator clips) DVOM.... ‘Socket, 3 Torque wrench, in. Ibs., 38" drive Torque wrench, t. lbs, 9/8 drive Extension, 6", 3/8" drive Insulated wrench, 9/16" Wrench, 1/2" Wrench, 7/16" Philips screwdriver, large Phillips screwaliver, small ‘Shop towel... Z Allen wrench, .050" Dl bit, 7/32 ‘Symptoms Vehicle does not operate, operates poorly or intermit- tently, Testing ‘Amaintenance feature of the PDS controller is the ability to diagnose electrical faults preventing the vehicle to operate at its fullest potential. When the controller is alaced in the diagnostic mode, the reverse warning auzzer will emit a series of beeps informing the techni- sian to the cause of the vehicle malfunction. To place the vehicle in the diagnostic mode, with the key 1 the ‘OFF" position, move the ‘Run-Tow/Maintenance’ Switch to the 'RUN' position, move the Direction Selector ‘rom ‘Neutral’ to ‘Reverse’ five times. The first series of beeps (one, two, three or four) will indi- zate the performance option with which the vehicle is aquipped. The second series of beeps will indicate the ‘ault code (one, two, three or four followed by a pause and one, two, three or four more beeps). By reading the decal attached to the controller cover, or by reading the PDS Diagnostic Mode Fault Code chart (Ref Fig. 7 on gage F-7), the fault, its symptom(s) and corrective action ‘0 be taken can be found. itis, therefore, critical to the diagnostic procedure that tne buzzer be operational and can be verified by placing the vehicle in reverse. To check, repair or replace the auzzer, see the PDS Diagnostic Mode Fault Codes chart. itis unlikely that the mechanical adjustment of the pedal 2ox has changed, therefore the initial tests will be con- ‘ducted with a digital volt ohm meter (DVOM) to identity the failed component. ‘ typical DVOM jis shown in illustrations. A recom- mended DVOM is available through the E-Z-GO Service Parts Department as P/N 27481-G01. Any DVOM may pe used; however, the accuracy, controls, displays and ‘eatures may vary depending on the make and model. Always follow the meter manufacturer's recommenda- ‘ions and instructions for the use and care of the meter. To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage. To prevent injury result- WINUZAININEY NW ing from unexpected movement ofthe vehicle, always raise the rear wheels before conducting any tests. To prevent possible motor damage, never operate Vehicle at full throttle for more than 4-5 seconds while vehicle is in a “no-load” condition. For static tests, raise the rear wheels of the vehicle and support the vehicle on jack stands (Refer to the Lifting Procedure in Section ‘B’ Safety). Test the vehicle stability defore proceeding. Place the direction selector in ‘F' and turn the key switch to ‘ON’. Depress the accelerator pedal until the micro switch in the pedal box activates which should cause the Page F-4 Repair and Service Manual Gass)ELECTRONIC SPEED CONTROL (PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings solenoid mounted to the controller to make an audible click. If the solenoid does not click, test the batteries. Testing Battery Voltage It is important to determine the condition of the battery set before proceeding with any electrical troubleshooting. ‘An open voltage test is of litle use since a battery that has deteriorated to the point of requiring replacement can still show six volts or higher in an open voltage test. It there is any doubt as to the adequacy of the battery set, charge the batteries and perform a load test using a dis- charge machine following manufacturer's instructions. If batteries ate satisfactory, recharge battery set. 3124 Patorenco Voltage Positive Probe toBL+ Fig. 4 Battery Reference Voltage With the adequacy of the batteries confirmed, use a DVOM connected directly to the battery terminal posts to determine the open voltage of the set (Ref Fig. 4 on page F-5). In the following tests, this voltage level will be used as a reference. Some loss due to resistance of wires and connectors may be indicated by readings that could be up to one volt less than the reference voltage. No reading indicates an “open” condition and the battery wires should be inspected for a broken or disconnected wire or ‘component. Continuity Check To prevent possible inju- FINENESS ry or death resulting from a battery explo- sion, use an insulated wrench and remove the BL- ite rom the batery to disconnect electrical power to vehicle. Before attempting to perform a continuity check, turn the key switch to ‘OFF and place the direction selec- tor in neutral. Before any electrical service is per- CAUTION ea ko Run-TowiMaintenance switch must be placed in the ‘Tow/Mainte- nance’ position. a power wire (battery, motor or controller) is disconnected for ‘any reason on the PDS model vehicle, the Run-Tow Maintenance ‘switch must be left in the ‘Tow/Maintenance’ position for atleast 30 seconds after the circuit is restored. Tur the key switch to ‘OFF’ and place the direction selector in neutral before disconnecting power by remov- ing the BL- connection to the battery. Always use insu- lated wrenches when working on batteries. To check for continuity, set the DVOM to the KQ setting and select, ‘Continuity’. The meter will give an audible signal when it detects continuity. If the meter does not have a continuity setting, set it to KO, the meter will indicate "0" when it detects continuity Testing a Switch for Continuity Place one probe on one contact of the switch, place the ‘second probe on the second terminal of the switch (Ref Fig. 5 on page F-6) ‘Actuating a normally open (NO) switch will cause the DVOM to show '0” or give an audible indication when the switch is operated. A normally closed (NC) switch will cause the meter to show *0" or give an audible indication when the probes are attached without activating switch. The audible indicator will stop and the meter display will indicate a value greater than “0" when the switch is acti vated. The change in display or audible indicator demonstrates that the switch is functioning. Testing a Solenoid for Continuity Place one probe on one of the large terminals and the ‘other probe on the second large terminal (Ref Fig. 6 on page F-6). If the meter shows “0” or gives an audible indi lezen) Repair and Service Manual Page F-5ELECTRONIC SPEED CONTROL (PDS) Read all of Secon Band his section before attempting any procecue, Pay particular ateton tal Notes, Cautions and Warnings Fig. 5 Continuity Check of Switch cation, the solenoid terminals are “welded” closed and the solenoid must be replaced. It the continuity test indicates that contacts are not “welded” and the wiring to the solenoid coil is good, the coil has failed and the solenoid must be replaced. Fig. 6 Continuity Check of Solenoid TROUBLESHOOTING DIAGRAMS The following diagrams will assist in servicing the vehi sle. By utilizing the diagnostic mode Fault Codes, consi arable time will be saved in determining the probable vehicle operating malfunction. The vehicle power and control wiring diagram is included for your convenience 1 tracing the electrical wiring. The following 10 flow sharts will assist in diagnosing and correcting problems ‘ot diagnosed through the Fault Code Diagnostic Mode. Page F-6 Repair and Service ManualELECTRONIC SPEED CONTROL (PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Fault Code Fault Vehicle Operation Corrective Action Change Direction Selector Fault Vehicle Operates in [+ At Drection Selector check wiring (Cia Diracsion Or Bed - Replaceltepair wiring: Good - Replace selector switch No Buzzer ‘Buzzer Inoperative [+ Verify Run-TowiMaintenance Switch isin RUN’ position; * Verity 36 volts at J1 Pin 10; Repairireplace Pin 10 wire: * Verity 36 volts at J1 Pin 1; Repaicreplace Logic Power; * (In Reverse) Verity 36 volts at J1 Pin 2; Repairireplace wire or micro Switch in Direction Selector switch (0-0 [No Fault Codes: Vehicle inoperative + Open Pedal Box, verify micro switch wiring is Connected & is not dam with Key ON agec; Repair/repiace as necessary; * Direction Selector Forward micro switch OPEN, verify switch is opera: tional and wiring is connected & not damaged: Repairireplace as neces- say: * Verity Key Switch is operational; Repairreplace as necessary “The following codes require the rear wheels be raised before performing tests: 1-1 | Controller Failure Vehicle will not run * Very Power wiring (steps & ~ 15); Check for motor shorts, carbon dust build up; Replace controller 1-2 | Throttle Fault Solenoid sticks, Vehicle will not run ‘+ Readjust (steps 41 - 45) or Replace pedal box or pedal box harness @ | High Pedal Disable ‘Vehicle wil not run ~ Release pedal Inspect linkage, J4 Pin 2 (36v with Key ON & Direction Selector in Forward), J4 Pin (6 volts with key ON, Direction Selector in Ferward, Pedal Down), Verify micro switch in Pedal Box: 2-4 | Solenoid Coil Failure or Gail Disconnected Vehicle will not run * Very small solenoid terminal with YELLOW wire has 36 volts; No - continue to next step; Yes - go to BLUE wire test at Jt pin 6 + Verity Jt Pin 7 has 36 volts; No = continue to next step: Yes - repair YELLOW wire, return to start ofthis test sequence * Disconnect J1 connector, check for damaged pins: [None - continue to next step; Yes - repair and return to start of this test sequence * Verity small solenoid terminal with BLUE wire has 36 votts; [No - continue to next step; Yes - go to BLUE wire test at Jt pin 6 + Replace solenoid and return to start of this test sequence: + Verity J1 Pin 6 BLUE wire has 36 volts; No - repair BLUE wire and return to start ofthis test sequence; Yes continue + With Pedal depressed, zero voltage? Yes - replace solenoid 3-1 | Solenoid Driver Failure Vehicle will not run * Check wiring for damage; Replace controler 3-3 | Solenoid Did Not Giose| Vehicle will not un * Verify all solenoid connections for proper connections and tightness; Replace solenoid if necessary Fig. 7 PDS Diagnostic Mode Fault Codes Repair and Service Manual Page F-7ELECTRONIC SPEED CONTROL (PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings 3-4 ] Field Open ‘Solenoid clicks, Vehicle will not run = Verily motor and controller field connections; Replace power harness or motor if necessary 4-1 | Armature Open Solenoid clicks, Vehicle will nt run + Verily motor and controlar armature connections; Replace power har- ness or motor itnecessary 4-3 | Solenoid Drop Out Vehicle stops * Verily all solenoid connections for proper connections and tightness; Replace solenoid if necessary The following codes require the vehicle be operated under load while performing tests: 1-3 | Speed Sensor Fault Vehicle runs slowly * Check speed sensor magnet, wire, sensor & connector connections; Replace speed sensor if necessary 2-1 [Low Battery Voltage Vehicle performance reduced * Perform discharge test, Charge batteries/replace bad batteries 2-2 | High Battery Voltage Vehicle performance reduced * Verily that battery system is less than 48 volts, 2-3 | Thermal Cutback Vehicle performance reduced * Allow cont oller to cool and verily heat sink bolt tightness 3-2 | Solenoid Welded Vehicle runs slowly + Replace solenoid ‘4-2 | Motor Stalled Vehicle performance reduced ‘+ Remove mechanical blockage Fig. 7 PDS Diagnostic Mode Fault Codes Fig. 8 Controller Connectors and Connections Page F-8 Repair and Service Manual ar)ELECTRONIC SPEED CONTROL (PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings 1206MX Controller 4 5 Direction Selector Pedal Box Logic Supply ction Se »BWWip S| BBN GRN | ea Rev! gyal o,nanonn Cheraing Conrsctee OANRED F gamo-] wit ce sewer ' Troed | reverse |. oe . Beoper RED gp GANELK Rayan WHTIVELs WHTVEL go, VEL, WHT, Solenoid 2 Buu = + | vet ' 1206MX Controller Fig. 9 Wiring Diagram Repair and Service Manual Page F-9ELECTRONIC SPEED CONTROL (PDS) Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings * Below 96 Vols: Charge ttre tor pocesing ** Reference voltage changes ‘i atey loa Atypical voape 36 = 38 vot) Rernve Resistor {tom Aeros Lage Solenoid Terminals Re-chek Vorage veron eyo, Taree HO saearnn “SE Riunvnca tar Shik ec hes tare pe ® rs ‘to Reverse, (*) " aes es To So fal Ae -AllTerain, ea seein aoe Baa ete sugesnas nue str Kero, BE sce a eae cues aoe T ree ima P| ve] Bee a | ace, ae 7 co aaa {6-550 vom sem Between Battery B+ ‘Less Than Reference | Battery B- & Fa ae meee 19-50) Coss than Reerened Votage? Electronic Speed Control Diagnostic Procedure 1206MX Controller Yotage Betveen Contoter B-& Contoter B es {| oc Yes 10-500 \ Yes ro Volta Replace Resistor Bearoan Controler ess Than Reference 30 tol Controller Bs Voltage i Between Baty 8- ‘ conalet 10 Detailed Troubleshooting Diagram (Sheet 1 of 10) Page F-10, Repair and Service ManualELECTRONIC SPEED CONTROL (PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings — Move Run-Tow Maint Switeh to RUN EX Votege Between Batter 8 ontoler side ‘of Solero Y 4-08 vai Less Than Reference Votase? yes No (15 Vor Lass} Replace Conrater —— Votage aetween ye] Baten 84 Contra AY ¥ 04-08 vals Less Than Reference Votage? Yes, No (ero) cob —— Key on, Direction Selector in F, aise ear of Vehicle Pedal Fully Depress Votage Beteen Conater F& Carta F2 rayon, Wo ze) Direction Selector in F, Pedal Fully Depressed (3 Vote Between Gontaer #1 & Hato F2 (8 4 seconds) 6010 seconds) VotageBeteen Battery 8 Mork repace Wire Bowen contol LY ‘otf? ple wire Between Conta A ‘voto At toyon, Wo a0) Direction Selector in, No Zero) PealDepressed Volage Between Votags Between tater Bf anoterr2 & Mtr A oto Ft apace Wie Between Replace Motor antoler Ft ey Eto No Zea) No eo) ont van contra apace Motor Motor a2 oe ig. 11 Detailed Troubleshooting Diagram (Sheet 2 of 10) ase) Repair and Service Manual Page F-11ELECTRONIC SPEED CONTROL (PDS) Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings kyon, Direction Selector in F ern | lace Slenoid 7 ‘een Slenad” Voltage’ Voltage’ ‘& Controller: pts ae ese eek Pin 8 Terminal Reference Reference eplace Controller key on, No (ro No (Zao) Reterence Replace Blue Wire Reference No (ero) No (Zero) 0 to Fig. 12 Detailed Troubleshooting Diagram (Sheet 3 of 10) Page F-12 Repair and Service Manual ayELECTRONIC SPEED CONTROL (PDS) Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Remove Key witch Pate, Key ON, Direction elector nF, Votane Between Batty 8 8 Ky Sovteh ferina wt ‘Whieretow Wire reyon, Wo zero) Direction Selector nF ER Voraoe Between | Batleny B= & Key sont Yerina wt Wiite Wire No (era) Replace nie Wie Betueen Key Sate ‘Conta, enlace Sh Bate BD cae Pa sina Vota detren Battery 8 & ing Terminal Reterence Votage? Is Diteton Selector "RRocko St orate Dash? Vio oof) ‘Move Run-Tow/Maint Switch {to TOWMANT, Disconnect Packard Connector 1a Forward Miero-Suith, Move Run-Tow/Maiat Switch AUN Volage Between Bate Goto args ie BT aPtimnetor ¥ Peplae Whitaretow Wie Batwoen Key site & Controle Continuity Across Reorence Forvaré Mer-Suen Vatage? Ne (era) ples Oranges vs WireFom pn To reson Setar v Go toll No (era) Ware Fan-Torriean Swvtch te TOWAMANT, Replace Miro Wve fun Towa Sotho RUN Replace Key Sith Pentel Sth Pe Remove Key Switeh Plat Key ON, Direction Salector in F Votage Between Bat Bf Rocker ‘Sue Terminal With Gray Wire Key on, Direction Selector in F Volage Between say 8-& Rocker Swteh Terminal With Green We Reference volage? Goto Replace Cotroter [a No (2a) Replace Gray Wee Between Gotrater DiasionSolator oes Satoh v oof Reference Votase? No (22) Replace Directo Selector Rocker Sich Hive For Town Swich 0 TOW MAINT, Replace Green Wire an Pi 80 Conector Move RunsTownain Swit to RUN Goto Aoplace Green Wie eatween Conor | ‘recon Selector Rocka Swe Fig. 13 Detailed Troubleshooting Diagram (Sheet 4 of 10) lezen) Repair and Service Manual Page F-13,ELECTRONIC SPEED CONTROL (PDS) Read all of Secon Band his section before attempting any procecue, Pay partcularateton to all Notes, Cautions and Warnings key 0, Direction Selector nF, Pedal depressed Until Micro-Switchis Closed EW aca Pn ine, ] Valiente atey fe at Tera BW oawry2n | tage Ben ‘aie 8 fia eral No Zora) Feplae Contrler v ED ae resins Vatage Betueen ey 8 & fn ermal Disconnect Run-owint v “Fin connector Fram Coutoters3 ‘Lozate Pin tin J, Reference Vatagedeteen Votaae? PP] eatery 88 Yes Goto int Tena ‘in Connector To No (ero) ContalerJ3 ED Vonage Seren] Replace Red Wire a Votage Baten seen Pn rence Bally 8 & ‘tSero Votan? PP ruta St ‘with Red Wie No (ra) alee Floormat, i ee oe Remove rack and pinion unit from vehicle. See ‘Rack and Pinion Unit Replacement’ on page G-14. Anchor in vice by clamping on the mounting ears of the unit. Disassemble rack and pinion unit (1) by first removing screw (13) and tensioner (2) to relieve pressure on rack (8) and pinion (4) (Ref Fig. 17 on page G-13). Loosen jam nut (5) and remove rack ball joint (6) from rack extension (7). Cut wire ties (8, 14) securing bellows (9) and slide bellows off rack extension. Pull rack (3) from unit (1). Remove pinion seal (10). See ‘Pinion Seal Replacement’ on page G-11. Remove internal retaining ring (11) from rack and pinion unit and pull out pinion (4) and ball bearing (12) as an assembly. Clean rack, pinion and housing. Inspect gear teeth, bear- ing surfaces and grease seal surfaces of rack and pinion for excessive wear or damage. If any is found, the rack and pinion unit must be replaced as an assembly. See “Rack and Pinion Unit Replacement’ on page G-14. Fig. 17 Rack and Pinion Unit Disassembly If rack and pinion pass inspection, clean them, tensioner and housing thoroughly and lubricate for assembly. Use ‘grease specified in tool list ‘Assemble rack and pinion unit by first installing pinion in. reverse order of removal making sure to lubricate pinion ‘eal lip prior to installing seal. See ‘Pinion Seal Replace- ment’ on page G-11. Insert rack into rack and pinion unit. Turn pinion clockwise to help pull rack in if necessary. Install bellows and secure to rack extension with wire tie (8). Do not secure large end of bellows to rack and pin- ion unit until instructed to do so after setting proper rack ‘extension-to-rack and pinion unit clearance. Install ten- sioner and tighten bolts (13) to 100 - 120 in. Ibs. (115 - 138 kg cm) torque. Thread jam nut and rack ball joint to original location on rack extension and set jam nut hand tight. Install rack and pinion unit on vehicle. See ‘Rack and Pinion Unit Replacement’ on page G-14. CEVA TTET NT Miter replacing or servicing steering ‘components, always verity that an 1/8" {gap exists between large hex of rack extension and rack and pin- {on unit when steering is turned fully to the right forcing passen- ger spindle arm against front axle. Set proper rack extension-to-rack and pinion unit clear- ance. See ‘Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance’ on page G-14. lezen) Repair and Service Manual Page G-13FRONT SUSPENSION AND AXLE MOUNTED STEERING Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings Rack and Pinion Unit Replacement Too! List Qty. Required Socket, 13 mm, 3/8" drive Ratchet, 3/8" drive Needle nose pliers. Wrench, 11/16" Ball joint separator... Plastic faced hammer. Wrench, 5/8” Torque wrench, 1/2" drive, ft. bs. Socket, 11/16", 1/2" dtVE wrens Torque wrench, 3/8" drive, in. Ibs. 1 ‘To remove rack and pinion unit (12) (Ref Fig. 11 on page G-9), loosen front wheels and lift and support front of vehicle per SAFETY section, Remove front wheels. Remove bolt (13) and washer (14) securing intermediate shaft (15) to rack and pinion unit (12) Remove cotter pin (2) and loosen castellated nut (3) until rack ball joint (1) threads are protected. Using a ball joint separator as a lever, apply pressure to ball joint and tap nut with plastic faced hammer to release ball joint from passenger side spindle arm. Remove nut from ball joint and ball joint from spindle arm. Remove the three lock nuts (18) securing rack and pinion unit to front axle and discard nuts. The rack and pinion unit can now be removed from vehicle. Retain washers (19), spacers (20) and the two bolts (16) for assembly. Replace rack and pinion unit in reverse order of removal. Use new lock nuts (18) and tighten them to 35 - 0 f. Ibs, (60 - 70 Nm) torque. Tighten castellated nut (3) to 36 ft. Ibs. (50 Nm) torque and continue to tighten as needed to insert new cotter pin. Maximum torque is 50 tt. Ibs. (70 Nm). Tighten bolt (13) securing intermediate shatt to pinion to 155 - 215 in. lbs. (180 - 250 kg em) torque. EET 81%: 222g & servicing steering components, always verity that an 1/8” ‘gap exists between large hex of rack extension and rack and pin- ‘on unit when steering is turned fully tothe right forcing passen- ger spindle arm against front axle, ‘Set proper rack extension-to-rack and pinion unit clear- ance. See ‘Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance’ on page G-14. Install front wheels per WHEELS AND TIRES section and lower vehicle per SAFETY section, Check front wheel alignment and adjust it necessary. See ‘Wheel Alignment’ on page G-3. Checking/Adjusting Rack Extension-to- Rack and Pinion Unit Clearance Tool List ty. Required Wrench, 11/16" 1 Wrench, 31 Wrench, 1/ Wire cutter Washer, 1/8" thick. Srowtoot socket, 3/4", 1/2" drive Torque wrench, 1/2" drive, ft. Ibs. Wire tie, 10° long ‘Check for proper rack extension-to-rack and pinion unit slearance by first turing steering wheel fully to the right. The rear spindle arm on the passenger side must rest against the front axle (Ref Fig. 18 on page G-14). If it does not, all adjustment is made at the rack ball joint (6) (Ref Fig. 17 on page G-13). Loosen jam nut (5) at rack Dall joint and use wrench to thread shaft of rack exten- sion (7) further into rack ball joint. This will provide more ‘ravel for the steering wheel to be turned to the right. Passenger Side ‘Spindle Arm Resting Against Front Axle Fig. 18 Spindle Contact with Front Axle With spindle arm resting against front axle, cut wire tie (14) securing bellows (9) to rack and pinion unit (1) and slide bellows away from rack and pinion unit to see large ‘ex of rack extension. An 1/8" gap should exist between the large hex and the end of the rack and pinion unit, Page G-14 Repair and Service Manual Gass)FRONT SUSPENSION AND AXLE MOUNTED STEERING Fea allof Section Band his secton beer attempting any pocedure. Pay pateularatenton foal Notes, Caution and Warnings Approximately 118" Thick Washer 19 Checking Gap ‘Adjust, using an 1/8" thick washer as a gauge, by turning shaft of rack extension with wrench to create the 1/8” gap. Tighten jam nut (5) to 35 - 45 ft. Ibs. (47 - 61 Nm) torque. Secure bellows to rack and pinion unit with new wire tie (14) Steering Wheel Replacement Tool List, Socket, 15/16", 1/2" drive Ratchet, 1/2" drive... Plastic faced hammer Ball peen hammer... Aanti-seize compound Torque wrench, 1/2" drive, tls. To maintain correct orientation when replacing STE steering wheel, first turn wheels straight ahead. EERE © 210 samase 10 tne ction, perform the following removal proce- dure. Do not use a screwdriver to push or ry the retaining tabs. From the front side of the steering wheel (4), remove the clipboard (5) by first pulling straight up on the bottom of the clipboard to release the two bottom retaining tabs. Then, using thumb for leverage as shown, reach from behind steering wheel with fingertips to first pull down, and then push up to release the two top clipboard retain- ing tabs (Ref Fig. 20 on page G-15). Loosen the steering wheel retaining nut (6) two to three turns (Ref Fig. 21 on page G-15). DO NOT REMOVE NUT AT THIS TIME. Apply upward pressure to the steer- ing wheel. Place a plastic faced hammer against the steering wheel nut and strike plastic faced hammer sharply with a ball peen hammer. Qty. Required steering Shaft Fig. 21 Steering Wheel Replacement Do not strike steering nut or end of CAUTION Pee a hammer. Internal damage to rack and pinion unit can result When steering wheel is loosened, remove retaining nut and remove steering wheel. Prior to replacement, assemble the replacement steering wheel by aligning the retaining tabs on the rear collar hub (7) with slots in back of steering wheel. Squeeze tabs to allow insertion of hub. Do not force. Squeeze hub on top and bottom to fully seat. Replace steering wheel by first lightly coating the splines of the steering shaft with a commercially available anti- seize compound. With the vehicle wheels in the straight ahead position, align the steering wheel on the steering shaft and slide wheel on shaft. Tighten the steering wheel nut (6) to 15 - 20 ft. Ibs. (20 - 27 Nm) torque. Inspect the four retaining tabs on the clipboard (5) for white stress lines (Ref Fig. 20 on page G-15). If stress lines are present, replace clipboard. install by carefully pressing, first the top two, then the bottom two retaining tabs into the matching slots in steering wheel. lezen) Repair and Service Manual Page G-15FRONT SUSPENSION AND AXLE MOUNTED STEERING Read lof Section Band this section before attempting any procecue, Pay partculratenton to al Notes, Cautions and Warnings Steering Shaft and Column Replacement Tool List Qty. Required Ratchet, 1/2" drive. Socket, 3/4", 1/2" drive. ‘Socket, 13 mm, 3/8" drive . Ratchet, 3/8" drive. Socket, 9/16", 1/2" drive. ‘Snap ring pliers Bearing separator. Gear puller... Arbor press... Bearing driver set. Torque wrench, 1/2" drive, ft. Ibs. Torque wrench, 3/8" drive, in. Ibs. Wheel bearing gr@a8@ ..nnnnnnnnnnnmnnnnnns AR To remove steering shaft (4) (Ref Fig. 22 on page G-16), remove the steering wheel. See ‘Steering Wheel Replacement’ on page G-15. Loosen front wheels. Lift and support front of vehicle per ‘SAFETY section and remove tront wheels. Remove the bolt (1) and washer (2) that secures the intermediate shatt (3) to the steering shaft (4). Fig. 22 Steering Shaft and Column Remove the four bolts (5) and washers (6) that secure the steering column (7) to the chassis and remove the column. Remove large retaining ring (8) on bottom end of column and pull shaft and bearing (9) out as an assembly. Slide wave washer (10) out bottom end of steering column and

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