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E-Z-GO MPT 800 Technician's Repair And Service Manual
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ELECTRONIC SPEED CO
NTROL (48V)
Page F-2
8
Repair and Service Manual
Read all of
Section B and this section
bef
ore attempti
ng any procedure. P
ay
par
tic
ular attention to all
Notes, Cautions and W
ar
nings
Fig
. 10 J-
1 Pin Co
nnec
tor Di
agno
stics
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
J1
ITS
MS3
Pedal Box
WHT / YEL
WHT
ORN
ORN
GRN
GRN
GRN / WHT
BLK / WHT
BLU / WHT
GRN / BLK
VIO
YEL
YEL
REV
N
FWD
RED
RED / WHT
RED / WHT
RED / WHT
WHT / BLK
WHT
BLK
BLU
BLK
WHT
SPARE
SPARE
SPARE
SPARE
SPARE
Key
Switch
Direction
Selector
Switch
1264 Controller
F2
B+
M-
B-
F1
Reverse
Buzzer
RED
RED
RED
RED
YEL
RED / YEL
ORN / RED
ORN / RED
Aux
WHT
WHT
Logic
Tow Switch
1
2
3
5
Performance
Plug
Solenoid
Reed
Switch
Charging
Connector
J3
J2
+
4
5
6
1
2
3
BRN
GRY
93
95
Table of Contents
Table of Contents
5
General Information
4
Notes
6
Safety Information
7
General Operation
7
General Information & Routine Maintenance
11
List of Illustrations
13
Section Title
13
Fig. 1 Initial Service Chart
13
Routine Maintenance
13
Serial Number Plate Location
13
Servicing the Electric Vehicle
13
Transporting Vehicle
13
Care and Cleaning of the Vehicle
14
Fig. 2 Lubrication Point
14
Light Bulb Replacement
14
Vehicle Care Products
15
Fig. 3 Torque Specifications
16
Hardware
16
Torque Specifications
16
Periodic Service Schedule
17
Fig. 4 Periodic Service Schedule
18
Safety
19
General (Asme/Ansi B56.8-1988 Part II)
21
Section Title
21
Wheels and Tires
41
General Maintenance
25
Important Safety Warning
25
Modifications to Vehicle
25
Notes, Cautions and Warnings
25
Additional Warnings
26
Before Servicing the Vehicle
26
Battery Removal & Installation
27
Lifting the Vehicle
28
Front Suspension and Steering
45
Maintenance
48
Lubrication
48
Wheel Bearing and King Pin Bushing Inspection
48
Wheel Bearing Packing
48
Wheel Bearing Adjustment
49
Wheel Alignment
49
Section Title
48
Electronic Speed Control (36V
67
Electronic Speed Control (48V
85
Motor
103
Front Suspension
51
Front Shock Absorber Replacement
51
Front Axle Replacement
52
Axle Linkage Rod Replacement
52
Front Spring Replacement
52
Hub Replacement
54
Wheel Bearing and Race Replacement
54
Steering
56
Rack Ball Joint Replacement
56
Tie Rod Inspection/Replacement
57
Bellows Replacement
58
Pinion Seal Replacement
58
Spindle Replacement
59
Rack and Pinion Unit Disassembly and Inspection
60
Rack and Pinion Unit Replacement
60
Checking/Adjusting Rack Extension-To-Rack and Pinion Unit Clearance
61
Steering Wheel Replacement
62
Steering Shaft and Column Replacement
63
Batteries and Charging
111
Battery
113
Battery Maintenance
113
At each Charging Cycle
113
Electrolyte Level and Water
114
Cleaning Batteries
115
Battery Replacement
115
Prolonged Storage
116
Battery Charging
117
AC Voltage
117
Safety
113
Section Title
113
Electrical System
121
Troubleshooting
117
Hydrometer
118
Using a Hydrometer
118
Battery Charger
119
Description
119
Portable Charger Installation
119
Charger Maintenance
120
Brakes
131
Section Title
132
Brakes - Rear Mechanical
133
Brake System Overview
133
General Description
133
Equalizer Link
133
Automatic Adjuster Mechanism
134
How the Parking Brake Works
134
Compensator Assembly
135
Kick-Off Actuating Linkage
135
Troubleshooting Flowchart
136
Troubleshooting Table
138
Troubleshooting and Inspection
140
New Vehicles
140
Troubleshooting and Inspection Procedures
140
Brake Pedal and Linkage Inspection
140
Periodic Brake Performance Test (PBPT)
142
Aggressive Stop Test
143
Wheel Brake Inspection
144
Maintenance and Repairs
146
Parts Replacement Vs. Repair
146
Adjusting Brake Pedal Free Travel
146
Brake Drum Removal and Installation
147
Brakes - Front Disc
153
Battery Charger
157
Battery Charger
159
Description
159
Portable Charger Installation
159
Section Title
159
Rear Suspension
165
Rear Axle
167
Rear Axle
169
Weather Protection
175
Top and Windshield
177
Paint
181
On-Board Charger
160
Opening the Charger
160
Understanding the Charger
160
Component Replacement
161
Troubleshooting
161
Continuity Checks
161
Diode Test Procedure
161
Portable Charger
164
Troubleshooting
185
Section Title
187
Electrical System
187
Basic Electrical Power System Troubleshooting
188
Basic Electrical Troubleshooting for Accessories
188
Suspension and Steering
189
Lightning Protection and Grounding
191
General Specifications
197
Industrial
197
Brakes
199
Tires
199
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E-Z-GO MPT 800 Specifications
General
Brand
E-Z-GO
Model
MPT 800
Category
Utility Vehicle
Language
English
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