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E-Z-GO MPT 1000 Service Manual

E-Z-GO MPT 1000
212 pages
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A Textron Company
ELECTRIC POWERED UTILITY VEHICLES
REVISED DATE: OCT 2006
TECHNICIAN’S
REPAIR AND SERVICE MANUAL
28838-G01

Table of Contents

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E-Z-GO MPT 1000 Specifications

General IconGeneral
BrandE-Z-GO
ModelMPT 1000
CategoryUtility Vehicle
LanguageEnglish

Summary

SAFETY

NOTES, CAUTIONS AND WARNINGS

Explains symbols used for warnings and precautions.

GENERAL OPERATION

Guidelines for responsible and safe vehicle operation.

MAINTENANCE

Safety precautions and procedures for vehicle maintenance.

GENERAL INFORMATION & ROUTINE MAINTENANCE

SERIAL NUMBER PLATE LOCATION

Identifies location of serial number and manufacture date code labels.

TRANSPORTING VEHICLE

Instructions for safely transporting the vehicle.

SERVICING THE ELECTRIC VEHICLE

Safety warnings for servicing electric vehicle components.

ROUTINE MAINTENANCE

General maintenance tasks and frequency for vehicle upkeep.

PERIODIC SERVICE SCHEDULE

Detailed schedule of maintenance tasks by time interval.

DAILY

Daily checks and maintenance tasks before operation.

WEEKLY

Weekly checks and maintenance tasks.

MONTHLY - 20 HOURS

Monthly maintenance tasks and checks.

QUARTERLY - 50 HOURS

Quarterly maintenance tasks and checks.

SEMI-ANNUAL - 125 HOURS

Semi-annual maintenance tasks and checks.

ANNUAL - 250-300 HOURS

Annual maintenance tasks and checks.

BODY

BODY COMPONENT REPLACEMENT

Procedures for replacing various body components.

WHEELS AND TIRES

WHEEL AND TIRE SERVICE

Guidelines for wheel and tire maintenance and service.

Tire Repair

Procedures for repairing flat tires on the vehicle.

Wheel Installation

Proper steps for installing wheels and tightening lug nuts.

FRONT SUSPENSION AND STEERING

MAINTENANCE

Routine maintenance for front suspension and steering systems.

Lubrication

Lubrication points and procedures for suspension components.

Wheel Bearing and King Pin Bushing Inspection

Inspecting wheel bearings and king pin bushings for wear.

Wheel Bearing Packing

Procedure for packing front wheel bearings with grease.

Wheel Bearing Adjustment

Steps for adjusting front wheel bearings.

Wheel Alignment

Procedure for checking and adjusting front wheel alignment.

FRONT SUSPENSION

Information on front suspension components and service.

Front Shock Absorber Replacement

Steps for replacing front shock absorbers.

Front Axle Replacement

Procedure for replacing the front axle assembly.

Axle Linkage Rod Replacement

Steps for replacing the axle linkage rod.

Front Spring Replacement

Procedure for replacing front leaf springs.

Hub Replacement

Steps for replacing the wheel hub.

Wheel Bearing and Race Replacement

Procedure for replacing wheel bearings and races.

STEERING

Information on steering system components and service.

Rack Ball Joint Replacement

Steps for replacing the rack ball joint.

Tie Rod Inspection/Replacement

Inspecting and replacing tie rod components.

Bellows Replacement

Procedure for replacing steering rack bellows.

Pinion Seal Replacement

Steps for replacing the pinion seal.

Spindle Replacement

Procedure for replacing the steering spindle.

Rack and Pinion Unit Disassembly and Inspection

Disassembling and inspecting the rack and pinion unit.

Rack and Pinion Unit Replacement

Steps for replacing the rack and pinion unit.

Checking/Adjusting Rack Extension-to Rack and Pinion Unit Clearance

Adjusting clearance in the steering rack system.

Steering Wheel Replacement

Steps for replacing the steering wheel.

Steering Shaft and Column Replacement

Procedure for replacing the steering shaft and column.

ELECTRONIC SPEED CONTROL (36V AND 48V)

36 VOLT SYSTEM VEHICLES GENERAL

Overview of the 36V electronic speed control system.

Pedal Box

Description of the pedal box assembly and its components.

Controller

Description of the electronic speed control controller.

GENERAL TROUBLESHOOTING

General troubleshooting steps for ESC system.

TROUBLESHOOTING DIAGRAMS

Flowcharts for diagnosing ESC system issues.

INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT

Testing and replacing the Inductive Throttle Sensor.

CONTROLLER REPLACEMENT

Procedure for replacing the ESC controller.

SOLENOID REPLACEMENT

Procedure for replacing the solenoid.

48 VOLT SYSTEM VEHICLES GENERAL

Overview of the 48V electronic speed control system.

PERFORMANCE OPTIONS & DIAGNOSTICS

Information on performance options and diagnostics.

Changing Performance Options

Steps to change vehicle performance options.

OPERATION

How the 48V system operates.

MOTOR

GENERAL

General information about the vehicle motor.

Motor Removal

Procedure for removing the motor from the vehicle.

Motor Disassembly

Steps for disassembling the motor.

Bearing Replacement

Procedure for replacing motor bearings.

Field Coil Replacement

Steps for replacing field coils.

Brush Replacement

Procedure for replacing motor brushes.

Motor Assembly

Steps for assembling the motor.

Motor Tests

Diagnostic tests for the motor.

Motor Installation

Procedure for installing the motor.

BATTERIES AND CHARGING

SAFETY

Critical safety precautions when working with batteries.

BATTERY

General information about vehicle batteries.

BATTERY MAINTENANCE

Routine maintenance for vehicle batteries.

At Each Charging Cycle

Battery checks performed after each charge.

Monthly

Monthly battery maintenance tasks.

Electrolyte Level and Water

Maintaining correct electrolyte levels.

Cleaning Batteries

Procedures for cleaning battery exteriors.

Battery Replacement

Steps for replacing vehicle batteries.

Prolonged Storage

Recommendations for storing batteries long-term.

Battery Charging

Procedures for charging vehicle batteries.

TROUBLESHOOTING

Troubleshooting common battery and charging issues.

Hydrometer

Description and use of a hydrometer for battery testing.

Using A Hydrometer

Step-by-step guide for using a hydrometer.

BATTERY CHARGER

Information on the vehicle's battery charger.

Description

Details about the battery charger's specifications.

Portable Charger Installation

Instructions for installing the portable battery charger.

BRAKES - REAR MECHANICAL

BRAKE SYSTEM OVERVIEW

Overview of the rear mechanical brake system.

General Description

General description of the brake system components.

How the Service Brake Works

Explanation of the service brake's operation.

Automatic Adjuster Mechanism

How the automatic brake adjuster functions.

How the Parking Brake Works

Explanation of the parking brake's operation.

TROUBLESHOOTING FLOWCHART

Visual guide for diagnosing brake issues.

TROUBLESHOOTING TABLE

Table listing brake problems, causes, and corrections.

TROUBLESHOOTING AND INSPECTION

Procedures for inspecting and troubleshooting brakes.

Brake Pedal and Linkage Inspection

Inspecting the brake pedal and linkage for issues.

Check the brake pedal free travel

How to check and adjust brake pedal free travel.

Periodic Brake Performance Test (PBPT)

Test to evaluate brake system performance.

Aggressive Stop Test

Test to ensure brake adjuster function.

Wheel Brake Inspection

Steps for inspecting wheel brake components.

Brake Shoe and Adjuster Replacement

Procedure for replacing brake shoes and adjusters.

Brake Cable and Equalizer Assembly Removal and Installation

Steps for replacing brake cables and equalizer.

Brake Pedal Removal and Installation

Procedure for removing and installing the brake pedal.

Parking Brake Catch Bracket Removal and Installation

Steps for removing and installing the parking brake catch bracket.

Parking Brake Kick-Off Cam Removal, Replacement and Installation

Procedure for servicing the parking brake kick-off cam.

BRAKES - FRONT DISC

SYSTEM DESCRIPTION

Overview of the front disc brake system.

MASTER CYLINDER REPLACEMENT

Procedure for replacing the master cylinder.

BRAKE MASTER CYLINDER FLUID

Information on brake fluid and checks.

Check Brake Fluid

How to check the brake fluid level.

ROUTINE MAINTENANCE

Routine maintenance for front disc brakes.

REPLACEMENT OF WEAR ITEMS

Replacing common wear items in the brake system.

Brake Pad Replacement

Steps for replacing brake pads.

Rotor Replacement

Procedure for replacing brake rotors.

BLEEDING BRAKES

Procedure for bleeding the hydraulic brake system.

REAR SUSPENSION

REAR SUSPENSION (GENERAL)

General information on the rear suspension system.

Shock Absorber Removal

Procedure for removing rear shock absorbers.

Shock Absorber Installation

Steps for installing rear shock absorbers.

Rear Spring Removal

Procedure for removing rear springs.

Rear Spring Installation

Steps for installing rear springs.

REAR AXLE

Rear Axle Removal

Procedure for removing the rear axle assembly.

Rear Axle Installation

Steps for installing the rear axle assembly.

REAR AXLE DISASSEMBLY

General procedures for disassembling the rear axle.

Axle Shaft Removal and Disassembly

Steps for removing and disassembling axle shafts.

Axle Shaft Seal Removal and Replacement

Procedure for servicing axle shaft seals.

Axle Shaft Replacement

Steps for replacing an axle shaft.

WEATHER PROTECTION

TOP AND WINDSHIELD

Information on tops and windshields.

SUN TOP

Installation of the sun top.

Rear Support Installation

Steps for installing rear sun top supports.

Front Strut

Installation of front struts for the sun top.

Sun Top

Final installation of the sun top.

SPLIT WINDSHIELD

Installation of a split windshield.

ONE-PIECE WINDSHIELD

Installation of a one-piece windshield.

PAINT

PAINTING

Procedures for painting vehicle surfaces.

Minor Scratches

Steps for repairing minor paint scratches.

Larger Scratches

Procedures for repairing larger paint scratches.

Complete Panel Repair

Guidelines for painting entire body panels.

TROUBLESHOOTING

ELECTRICAL SYSTEM

Troubleshooting electrical system issues.

VEHICLE WILL NOT MOVE (36VOLT VEHICLES)

Diagnosing why the vehicle won't move (36V).

VEHICLE SPEED ERRATIC

Troubleshooting erratic vehicle speed.

NO REDUCED SPEED IN REVERSE

Diagnosing lack of reduced speed in reverse.

MOTOR NOISY

Troubleshooting noisy motor conditions.

BATTERIES WILL NOT CHARGE

Troubleshooting battery charging issues.

Basic Electrical Power System Troubleshooting

Troubleshooting the basic electrical power system.

Basic Electrical Troubleshooting for Accessories

Troubleshooting accessory electrical issues.

SUSPENSION AND STEERING

Troubleshooting suspension and steering issues.

UNEVEN TIRE WEAR

Diagnosing and correcting uneven tire wear.

STIFF STEERING

Troubleshooting stiff steering conditions.

PLAY IN STEERING

Diagnosing and correcting steering play.

VIBRATION

Troubleshooting sources of vehicle vibration.

STEERING PULLS TO ONE SIDE

Diagnosing steering pull to one side.

LIGHTNING PROTECTION AND GROUNDING

1. Grounding Requirements

Requirements for building ground systems.

2. Ground Systems

Overview of interconnected ground systems.

3. Lightning Protection Requirements

Requirements for external lightning protection.

4. Equipment Fault and Personal Safety System

Ensuring equipment and personnel safety.

5. Ground Network Requirements

Requirements for installing ground networks.

6. External Grounding Requirements

Requirements for external grounding installations.

7. Materials

Specifications for grounding materials.

8. Earth Electrode System

Description of the earth electrode system.

9. Lightning Protection System

Details of the lightning protection system design.

10. Equipment Fault and Personal Safety System

Ensuring safety through fault protection.

GENERAL SPECIFICATIONS

MPT™ 800

Specifications for the MPT™ 800 model.

MPT™ 1000

Specifications for the MPT™ 1000 model.

INDUSTRIAL™ 800

Specifications for the INDUSTRIAL™ 800 model.

INDUSTRIAL™ 1000

Specifications for the INDUSTRIAL™ 1000 model.

Commander™ 280

Specifications for the Commander™ 280 model.

Commander™ 2100

Specifications for the Commander™ 2100 model.

Jacobsen Hauler™ 800

Specifications for the Jacobsen Hauler™ 800 model.

Jacobsen Hauler™ 1000

Specifications for the Jacobsen Hauler™ 1000 model.

Vehicle Dimensions

Dimensional data for various vehicle models.

PowerWise™ Portable Battery Charger Dimensions

Dimensional data for the portable battery charger.

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