E-Z-GO TXT 48V Repair And Service Manual

192 pages

To Next Page

To Next Page

Page #1 background image

Loading...

Page #1 background image

REPAIR AND SERVICE MANUAL

TXT 48V

ISSUED JANUARY 2010

ELECTRIC POWERED GOLF CAR

614279

Table of Contents

Safety2
Notices, Cautions and Warnings2
General Information4
Battery Prolonged Storage4
Table of Contents5
Safety Information7
- General Operation7
- Maintenance8
- Ventilation9
General Information & Routine Maintenance11
- Hauling13
- Serial Number Label Location13
- Servicing the Electric Vehicle13
- Towing13
- Transporting Vehicle13
- Brakes14
- Light Bulb Replacement14
- Rear Axle14
- Routine Maintenance14
- Tires14
- Vehicle Cleaning and Care14
- Sun Top and Windshield15
- Vehicle Care Products15
- Hardware16
- Torque Specifications16
- Periodic Service Schedule17
- Before Servicing the Vehicle21
- General Maintenance21
- Important Safety Warning21
- Modifications to Vehicle21
- Notes, Cautions and Warnings21
- Additional Warnings22
- Battery Removal & Installation23
- Fig. 1 Battery Connections23
- Fig. 2 Lifting the Vehicle23
- Lifting the Vehicle24
Body27
- Body28
- Body Component Replacement29
- Drill out Metal Rivet29
- General29
- Instrument Panel Replacement29
- Front Shield Replacement32
- Rocker Panel Replacement32
- Body Replacement33
- Rear Bumper Replacement33
Wheels and Tires35
- Wheel and Tire Service37
- Tire Repair37
- Wheel Installation37
Electronic Speed Control - Tct39
- Changing Performance Options41
- General41
- Trucourse Technology (Tct) System41
- Trucourse Technology System™ Performance Options & Diagnostics41
- Run-Tow/Maintenance Switch42
- Trucourse Technology (Tct) System™ Operation42
- Access to Pedal Box43
- Controller43
- Pedal Box43
- Speed Sensor43
- Continuity Check44
- General Troubleshooting44
- Symptoms44
- Testing Battery Voltage44
  - Continuity Check of Solenoid45
  - Continuity Check of Switch45
- Testing a Solenoid for Continuity45
- Testing a Switch for Continuity45
- 1206HB-5201 Controller Faults and Troubleshooting46
- Troubleshooting Diagrams46
  - Controller Fault Responses47
  - Controller Faults and Troubleshooting47
- Inductive Throttle Sensor (Its) Testing and Replacement50
- ITS and Plunger50
- ITS Adjustment51
- Controller Replacement53
- Solenoid Replacement53
Front Suspension and Steering57
- Fig. 2 Lubrication Point57
- Axle Mounted Steering and Front Suspension59
- Lubrication60
- Maintenance60
- Wheel Bearing and King Pin Bushing Inspection60
- Wheel Bearing Packing60
- Wheel Alignment61
- Wheel Bearing Adjustment61
- Front Shock Absorber Replacement63
- Front Suspension63
- Front Suspension Components63
- Front Axle Replacement64
- Front Spring Replacement64
  - Front Axle Alignment65
  - Hub Replacement65
- Hub Replacement66
- Seal Installation66
- Wheel Bearing and Race Replacement66
- Rack Ball Joint Replacement67
- Steering67
  - Steering Components67
  - Rack Ball Joint Installation68
- Tie Rod Inspection/Replacement68
- Tie Rod Replacement68
- Bellows Replacement69
- Pinion Seal Replacement69
- Spindle Replacement70
- Rack and Pinion Unit Disassembly71
- Rack and Pinion Unit Replacement72
- Spindle Contact with Front Axle72
- Clipboard Removal73
- Steering Replacement73
- Checking Gap73
- Steering Wheel Replacement73
- Steering Shaft and Column Replacement74
- Small Retaining Ring Orientation74
- Steering Shaft and Column74
Motor77
- Motor Removal79
- Disconnect Battery Cable79
- Mark Axle and Motor79
- Motor Disassembly79
- Motor Components80
- Brush Wear81
- Brush Replacement81
- Bearing Replacement81
- Motor Tests82
- Motor Installation82
- Securing Brushes82
- Motor Assembly82
Batteries and Charging85
- Battery Maintenance87
- Safety87
- At each Charging Cycle88
- Correct Electrolyte Level88
- Electrolyte Level and Water88
- Monthly88
- Automatic Watering Gun89
- Battery Replacement89
- Cleaning Batteries89
- Preparing Acid Neutralizing Solution89
- Prolonged Storage90
- AC Voltage91
- Battery Charging91
- Freezing Point of Electrolyte91
- Troubleshooting91
- Hydrometer92
- Using a Hydrometer92
- Hydrometer Temperature Correction93
Battery Charger95
- Portable Charger Installation97
- Charger Description97
- Charger Installation97
- Understanding the Charger98
- LED Fault Code98
- Maintenance Instructions98
- Led Display Information98
- Mechanical Brakes101
- Brake System Overview103
- Mechanical Brake System103
- How the Parking Brake Works104
- Equalizer Link104
- Parking Brake and Kick-Off Mechanism104
- How the Service Brake Works104
- Compensator Assembly105
- Kick-Off Actuating Linkage105
- Troubleshooting Flowchart106
- Troubleshooting and Inspection Procedures110
- Brake Pedal Bumper Inspection110
- Brake Pedal Inspection110
- Brake Pedal and Linkage Inspection110
- Check for Excessive Free Travel111
- Equaliser and Compensator111
- Periodic Brake Performance Test (PBPT)112
- Kick-Off Cam Inspection112
- Parking Brake Pedal Hinge Inspection112
- Periodic Brake Performance Test113
- Aggressive Stop Test113
- Wheel Brake Inspection114
- Equally Loaded Vehicle114
- Adjuster Mechanism114
- Brake Shoe Wear115
- Orientation of Brake Shoe Springs115
- Free Travel Adjustment116
- Adjusting Brake Pedal Free Travel116
- Parts Replacement Vs. Repair116
- Maintenance and Repairs116
- Check Clevis Pins117
- Brake Assembly117
- Brake Drum Removal and Installation117
- Checking Parking Brake Latching Pressure117
- Wheel Brake Service118
- Wheel Brake Lubrication Points118
- Backing Plate Removal and Installation119
- Brake Shoe Installation119
- Brake Shoe Removal119
- Brake Cable, Equaliser and Compensator120
- Brake Shoes and Springs121
- Brake Pedal Removal and Installation121
- Catch Bracket and Latch Arm122
- Pedal Bumper Adjustment122
Direction Selector125
- Replacing the Reverse Warning Buzzer127
- Direction Selector Switch127
- Replacing the Direction Selector Switch127
- Direction Selection Switch Replacement128
- Direction Selector Switch Connections128
Electrical System131
- Electrical System133
- Digital Volt Ohm Meter133
- Electrical System134
- Accessory Wiring Diagram134
- Main Harness Wiring Diagram135
- Power Supply136
- Main & Accessory Wiring136
- Check for Loose or Bare Wires136
- Check Battery Condition136
- Electrical Accessories137
Rear Suspension141
- Shock Absorber Installation143
- Rear Spring Removal143
- Rear Spring Installation143
- Rear Axle Assembly Removal143
- Rear Axle Installation144
- Motor Wiring144
Rear Axle147
- Rear Axle Maintenance149
- Checking the Lubricant Level149
- Axle Shaft Removal and Disassembly149
- Rear Axle Disassembly149
- Removing/Installing Axle Shaft150
- Removing/Installing Inner Snap Ring150
- Axle Shaft Seal Removal and Replacement150
- Removing Seal150
- Cut Away of Outer Bearing and Brake Drum151
- Installing Seal151
- Axle Shaft Replacement151
Weather Protection153
- Top and Windshield155
- Front Strut155
- Trailering155
- Sun Top155
- Golf Car Sun Top156
- Split Windshield157
- One-Piece Front Windshield158
- Front Windshield158
- Rear Windshield159
- Navigation161
- How to Use the Handheld Programmer161
- Curtis Handheld Programmer161
Handheld Diagnostics161
- Main Menu Definitions162
- Changing Data Value162
- Bookmark162
Troubleshooting167
- Lightning Protection and Grounding173
- Grounding Requirements175
- Ground Systems175
- Lightning Protection Requirements175
- Equipment Fault and Personal Safety System175
- Lightning Protection System176
- Materials176
- Earth Electrode System176
- External Grounding Requirements176
Paint179
- Painting181
- Minor Scratches181
- Complete Panel Repair181
- Larger Scratches181
General Specifications183
- Product Specification185
- Configuration Highlights185
- Product Overview185

Other manuals for E-Z-GO TXT 48V

Owner's Guide72 pages

Questions and Answers:

Need help?

Do you have a question about the E-Z-GO TXT 48V and is the answer not in the manual?

E-Z-GO TXT 48V Specifications

General

Brand	E-Z-GO
Model	TXT 48V
Category	Offroad Vehicle
Language	English

Related product manuals

Preview: E-Z-GO TXT FLEET

E-Z-GO TXT FLEET

E-Z-GO TXT VALOR

E-Z-GO TERRAIN 1000

Preview: E-Z-GO ST 480

Preview: E-Z-GO 2Five Electric

E-Z-GO 2Five Electric