28646-G01 0 EERE Company TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC & PRECISION DRIVE SYSTEM™ PERSONAL VEHICLES & FLEET GOLF CAR STARTING MODEL YEAR: 2001SAFETY 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 iNOTES 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 iiTABLE 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-tGENERAL 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 (al