1996-1998 E-Z-GO TXT Electric and DCS Golf Cart Service & Repair Manual

• • TECHNICIAN'S REPAIR AND SERVICE MANUAL TXT ELECTRIC AND DCS VEHICLES VEHICLES TXT FLEET TXT FLEET DCS TXT FREEDOM TXT FREEDOM DCS TXT 4 CADDY CUSTOMER SERVICE DEPARTMENT PHONE 1-800-241-5855 FAX 1·800-448-8124 E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA 30903-0388, 1-800-241-5855 E~GDii:t:ti,~·HI Repair and Service Manual

J l . .. LIMITED WARRANTY I ~¥'-?-1;:%-~~%%%#:4,%tx~"'$~'1tfZ&0i~f.t20J.Jt@-f:.+ >if ""»\}~'t4'&t:-4 .• g/\')~W1}1#ff&.SW%f .i§:;iirf'}t::&¥'~ w-: i£1__,¥R"'"t:- &ft'¥'*~$-WH:i$:%1~'$ JA~J»rd<:U~ffl'"'%~';¢"'=:>~~ TO OBTAIN A COPY OF THE LIMITED WARRANTY APPLICABLE TO THE VEHICLE, CALL OR WRITE A LOCAL DISTRIBUTOR, E-Z-GO BRANCH OR THE E-Z-GO WARRANTY DEPARTMENT WITH VEHICLE SERIAL NUMBER AND MANUFACTURER CODE. THE USE OF NON E-Z-GO PARTS MAY VOID THE WARRANTY. OVERFILLING 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. A FULLY CHARGED BATTERY WILL NOTFREEZE IN WINTER TEMPERATURES. • FOR WINTER STORAGE, THE BATTERIES MUST BE CLEAN, FULLY CHARGED AND • DISCONNECTED FROM ANY SOURCE OF ELECTRICAL DRAIN. THE BATTERY CHARGER AND THE CONTROLLER MODULE ARE BOTH SOURCES OF ELECTRICAL DRAIN. UNPLUG THE BATTERY CHARGER DC PLUG FROM THE VEHICLE RECEPTACLE. DISCONNECTTHE 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 AT 30 DAY INTERVALS. REFER TO THE PROLONGED STORAGE SECTION WITHIN THE BATTERIES AND CHARGING SECTION OFTHIS MANUAL. ii Repair and Service Manual

II TABLE OF CONTENTS ~i:iiZdE&:~:!'~{~~~:x;..:iii:_~~%~~.c,~::'.'v.~Ei«1~1"z..~Y&}::i\'J.j):%xY:$~,M-'0';;''~~~fu5JEi~~/,it:}<.;,'<LW.:i~~%~_~~S'St&tt&~M"-ii~~&"#!-<:f.~·:-•-,.'k."ik~·'t:wkf:~;::W.tft:;W)& • TITLE PAGE Safety ........................................................................................................................... Inside Covers Limited Warranty ...............................................................................................................................ii Safety Information ............................................................................................................................ v TITLE SECTION Generai .............................................................................................................................................A Safety .............. ;................................................................................................................................ B Body .................................................................................................................................................C Wheels and Tires ........................................................................................................................ , .... 0 Electronic Speed Control - DCS ....................................................................................................... E Front Suspension and Steering ........................................................................................................ F Electronic Speed Control. ................................................................................................................ G • Motor ................................................................................................................................................ J Batteries and Charging .................................................................................................................... K Battery Charger (Powerwise ™ and Powerwise ™ +) ........................................................................ L Brakes ............................................................................................................................................. M Horn and Accessory Wiring .............................................................................................................. N Rear Suspension .............................................................................................................................. P Rear Axle ..........................................................................................................................................R Paint ................................................................................................................................................. S Troubleshooting .............................. _ .................................................................................................. T Lightning Protection and Grounding ................................................................................................. U General Specifications ..................................................................................................................... V Repair and Service Manual Page iii

NOTES • Notes: ____________________________________________________________ __ • Pageiv Repair and Service Manual E.Z13Diiif:iit!•J:I

• • SAFETY INFORMATION The Repair and Service Manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by E-Z-GO. Adherence to these procedures and trouble-shooting tips will ensure the best possible service from the product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the place of good common sense and prudent driving practices. Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. E-Z-GO strongly suggests that the owner-operator read this entire Owner's Guide and the Technician's Repair and Service Manual paying particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees and other operators be encouraged to do the same. If you have any questions, contact your closest E-Z-GO representative, call the E-Z-GO Customer Service Department at 1-800-241-5855 or write to the address on the back cover of this publication. • E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. • E-Z-GO Division of Textron reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. • This vehicle conforms to the current applicable standard for safety and performance requirements . • These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards or EPA regulations and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances. • With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery{-} post. NEVER USE THE CHASSIS OR BODY AS A GROUND CONNECTION. • Vehicle capacity is limited to a maximum of two persons per seat. • Never modify the vehicle in any way that will alter the weight distribution of the vehicle, its stability or increases the speed beyond the factory specification. Such modifications can cause serious personal injury or death. Modifications that increase the speed and or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle. Do not make any such modifications or changes. E-Z- GO prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle. Some vehicles may exceed the 15 mph maximum normally associated with golf course use. Higher speeds will result in increased stopping distances and less stability than similar slower vehicles. Vehicles that are capable of higher speeds must limit their speed substantially to no more than the speed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense. GENERAL OPERATION • Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition. • • Always read and observe all warnings and operation instruction labels affixed to the vehicle. Repair and Service Manual Pagev

SAFETY INFORMATION • Always follow all safety rules established in the area where the vehicle is being operated . • Always reduce speed to compensate for poor terrain or conditions. • Always apply service brake to control speed on steep grades. • Always maintain adequate distance between vehicles. • Always reduce speed in wet areas. • Always use extreme caution when approaching sharp or blind turns. • Always use extreme caution when driving over loose terrain. • Always use extreme caution in areas where pedestrians are present. MAINTENANCE • Always maintain your vehicle in accordance with the manufacturer's periodic service schedule. • Always ensure that mechanics performing repairs are trained and qualified to do so. • Always follow the manufacturer's directions if you do any maintenance on your vehicle. Be sure to disable the vehicle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire. • • Always insulate any tools used to remove the battery from its wiring in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the batteries or cover exposed terminals • with an insulating material. • Always check the polarity of each battery terminal and be sure to rewire the batteries correctly. • Always use specified replacement parts. Never use replacement parts of lesser quality. • Always use recommended tools. • Always determine that tools and procedures not specifically recommended by the manufacturer will not compro- mise the safety of personnel nor jeopardize the safe operation of the vehicle. • Never get under a vehicle that is supported by a jack. • Always support the vehicle using wheel chocks and safety stands. Lift the vehicle in accordance with the manufacturer's instructions. • Always empty the fuel tank or plug fuel hoses to prevent fuel leakage. • Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking. • Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated. • The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury, refer the repair or maintenance to a qualified mechanic. • Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic. Page vi Repair and Service Manual I

• • • SAFETY INFORMATION • Always replace damaged or missing warning, caution or information labels. • Always keep complete records of the maintenance history of the vehicle. VENTILATION • Hydrogen is explosive in concentrations as low as 4% and is generated in the charging cycle of electric vehicles. Because it is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Air exchanges of 5 changes per hour is considered the minimum requirement. • Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating. • Never charge or fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural or pro- pane water heaters and furnaces. • Always use a dedicated 15 amp circuit for each battery charger. Do not permit other appliances to be plugged into the receptacle when the charger is in operation . E.ZGDiiUitt•1:1 Repair and Service Manual Page vii

SAFETY INFORMATION • Notes: ____________________________________________________ ___ • • Page viii Repair and Service Manual E~liDiif:;id·l:l

GENERAL • • • Emi3CiiUitt•1:1 Section TABLE OF CONTENTS FOR SECTION 'A' SECTION TITLE PAGE NO. SERIAL NUMBER PLATE LOCATION A - 1 CONTROLS A-1 Key/Headlight Switch .. ..... .......................... .. ........................................... .. ............................ A - 1 Direction Selector ..... .... ..... ................... .. ............... ................................................................A - 1 Accelerator Pedal .......................... ................................................... ....... .. ........................ .... A - 2 Combination Brake and Parking (PARK) Brake Pedai .. ............................................... .. ....... A- 2 Run- Tow/Maintenance Switch (on DCS vehicles only) .............. .. .... .......................... .........A-2 FEATURES A-2 All Vehicles ...................................................... .................................................... .. ... ............. A - 2 DCS Vehicles .............. .. ...... ... .. ... ... .... .. ... ......... .................. ....... ........ .. .................................. A- 3 BEFORE ENTERING VEHICLE BEFORE STARTING ADDITIONAL WARNINGS AND CAUTIONS (APPLY TO DCS MODELS) STARTING THE ELECTRIC VEHICLE COASTING TOWING SERVICING THE ELECTRIC VEHICLE SEATS A- 3 A- 3 A-4 A-4 A-5 A- 5 A- 5 A- 6 Preparation of Seats for Service ................................................................................ ...........A - 6 ROUTINE MAINTENANCE A- 6 REAR AXLE A- 6 Checking the Lubricant Level ......................... .. ....... .... .......... ........................................ .. ...... A - 6 GENERAL PREVENTATIVE MAINTENANCE A- 6 TIRES Daily Check List.. ............ ........... .. ........... •.•........... .. ..........................•.................................... A - 6 Owner/Operator ............. .............. ......... .. ......•....................... .. ............................................... A- 7 Mechanic .....•................. .. .......................... .... ...•............ ........................................................ A - 7 A-7 CARE AND CLEANING OF THE VEHICLE A-7 WINDSHIELD (IF EQUIPPED) . A- 8 Cleaning .. ... ... .. .. ............. ......... ....... .. .... .. .. .. ........... .. ..........................................................•. ..A - 8 Trailering ............... .. .................. ....... .... ... .....•........... ............................... .. ............................. A - 8 TORQUE SPECIFICATIONS FOR UNSPECIFIED HARDWARE A- 9 LIST OF ILLUSTRATIONS Fig. A-1 Serial No. Plate Location . .. .. .................. .. ................... .. .... .... .. ... ...........................•.. .... ...... A- 1 Fig. A-2 Key/Headlight Switch ...... . .. .. .. ... ........... .. .... .. .... .. ... .. ........... .. ..... .. ....................................... A- 1 Fi g. A-3 Direction Selector ........ .. ........................... ......... .. ............................................................ .. A - 1 Fig. A-4 Accelerator and Brake Controls ... ... ....... .. ........ .. ........... .. ............................ ..................... ..A - 2 Fig. A-5 Run-Tow/Maintenance Switch ... ..... ................................ .. .... .. ............... .. ........................ .. A-2 Fig. A-6 Rear Axle Lubricant Check/Fill ......... .. .. .............................................................. ... .. .......... A - 6 Fig. A-7 Torque Specifications ............ .. .. .................. .. ......................... ...... ... .... ... ................... ........ A- 9 Fig. A-8 Bolt Grades ................ .. ...... ..... ................................................. .. .. ........... ........................... A- 9 Fig. A-9 Lubrication Points ... .. ... ... ....... ..... ...... ............. .... .. ........................... .. .......... .. ......... .. .... .... A - 10 · Fig. A-10 Periodic Service Schedule .. .................... ...•..................... .. ..................... .. ........ ............. A- 11 Fig. A-11 Periodic Service Schedule (Continued) ........... .. .................................. ........•......•... .. ..... A - 12 Repair and Service Manual Page A-i

GENERAL Notes: ____________________________________________________________ __ ---------------------· • Page A-ii Repair and Service Manual

1996-1998 E-Z-GO TXT Electric and DCS Golf Cart Service & Repair Manual

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