EZGO GOLF CART FLEET FREEDOM & PDS REPAIR SERVICE MANUAL


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EZGO FLEET FREEDOM SHUTTLE ELECTRIC PDS GOLF CART SERVICE REPAIR PDF MANUAL 2001-2008

TECHNICIAN'S REPAIR AND SERVICE MANUAL

ELECTRIC & PRECISION DRIVE SYSTEM (PDS) PERSONAL VEHICLES
& FLEET GOLF CARS

VEHICLES Covered:

FREEDOM PDS
FREEDOM FLEET GOLF CAR
PDS FLEET GOLF CAR
SHUTTLE 2+2


General Information & Routine Maintenance
Safety
Body
Wheels and Tires
Electronic Speed Control (Non-PDS)
Electronic Speed Control (PDS)
Front Suspension and Axle Mounted Steering
Front Suspension and Frame Mounted Steering
Motor
Batteries and Charging
Battery Charger
Brakes
Direction Selector
Electrical Wiring
Rear Suspension
Rear Axle
Weather Protection
Paint
Troubleshooting
Lightning Protection and Grounding
General Specifications

TABLE OF CONTENTS FOR SECTION 'A'
SECTION TITLE
SERIAL NUMBER PLATE LOCATION
TOWING
SERVICING THE VEHICLE
ROUTINE MAINTENANCE
REAR AXLE
BRAKES
PDS MODEL VEHICLES
TIRES
CARE AND CLEANING OF THE VEHICLE
VEHICLE CARE PRODUCTS
TOP AND WINDSHIELD
TRAILERlNG
HARDWARE
TORQUE SPECIFICATIONS
PERIODIC
SERVICE SCHEDULE
TABLE OF CONTENTS FOR SECTION 'B'

SECTION TITLE

GENERAL (Part II of ANSI I NGCMA Z130 1 - 1993)
GENERAL (Part II of ASME I ANSI B56 8- 1988)
NOTES, CAUTIONS AND WARNINGS
IMPORTANT SAFETY WARNING
MODIFICATIONS TO VEHICLE
GENERAL MAINTENANCE
BEFORE SERVICING THE VEHICLE
Additional Warnings
BATTERY REMOVAL & INSTALLATION
LIFTING THE VEHICLE

TABLE OF CONTENTS FOR SECTION 'C'
SECTION TITLE
BODY
General
BODY COMPONENT REPLACEMENT
Instrument Panel Replacement
Cowl Replacement
Front Shield Replacement
Rocker Panel Replacement
Body Replacement
Shuttle 2+2 Component Replacement
Rear Bumper Replacement

TABLE OF CONTENTS FOR SECTION 'D'
SECTION TITLE
WHEEL AND TIRE SERVICE
Tire Repair
Wheel Installation

TABLE OF CONTENTS FOR SECTION 'E'
SECTION TITLE
GENERAL
Pedal Box
Controller
GENERAL TROUBLESHOOTING
Symptoms
Testing
Testing Battery Voltage
Continuity Check
Testing a Switch for Continuity
Testing a Solenoid for Continuity

TROUBLESHOOTING DIAGRAMS
INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT
CONTROLLER REPLACEMENT
SOLENOID REPLACEMENT

TABLE OF CONTENTS FOR SECTION 'F'
SECTION TITLE
PRECISION DRIVE SYSTEMfM GENERAL
PRECISION DRIVE SYSTEM PERFORMANCE OPTIONS & DIAGNOSTICS
Changing Performance Options
PRECISION DRIVE SYSTEM OPERATION
Pedal Box
Speed Sensor
Controller
GENERAL TROUBLESHOOTING
Symptoms
Testing
Testing Battery Voltage
Continuity Check
Testing a Switch for Continuity
Testing a Solenoid for Continuity
TROUBLESHOOTING DIAGRAMS
INDUCTIVE THROTTLE SENSOR (ITS) TESTING AND REPLACEMENT
CONTROLLER REPLACEMENT
SOLENOID REPLACEMENT

TABLE OF CONTENTS FOR SECTION 'G'
SECTION TITLE
FRONT SUSPENSION AND AXLE MOUNTED STEERING
MAINTENANCE
Lubrication
Wheel Bearing and King Pin Bushing Inspection
Wheel Bearing Packing
Wheel Bearing Adjustment
Wheel Alignment
FRONT SUSPENSION
Front Shock Absorber Replacement
Front Axle Replacement
Front Spring Replacement
Hub Replacement
Wheel Bearing and Race Replacement
STEERING
Rack Ball Joint Replacement
Tie Rod Inspection/Replacement
Bellows Replacement
Pinion Seal Replacement
Spindle Replacement
Rack and Pinion Unit Disassembly and Inspection
Rack and Pinion Unit Replacement
Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance
Steering Wheel Replacement
Steering Shaft and Column Replacement

TABLE OF CONTENTS FOR SECTION 'H'
SECTION TITLE
GENERAL
Motor Removal
Motor Disassembly
Bearing Replacement
Field Coil Replacement
Brush Replacement
Motor Assembly
Motor Tests
Motor Installation

TABLE OF CONTENTS FOR SECTION 'J'
SECTION TITLE
SAFETY
BATTERY
BATTERY MAJNTENANCE
At Each Charging Cycle
Monthly
Electrolyte Level and Water
Cleaning Batteries
Battery Replacement
Prolonged Storage
Battery Charging :
AC Voltage
TROUBLESHOOTING
Hydrometer
Using A Hydrometer

TABLE OF CONTENTS FOR SECTION 'K'
SECTION TITLE
DESCRIPTION
PORTABLE CHARGER INSTALLATION
UNDERSTANDING THE CHARGER
BATTERY CHARGER MAINTENANCE
TROUBLESHOOTING
Continuity Checks
Diode Test Procedure

TABLE OF CONTENTS FOR SECTION 'L'
SECTION TITLE
BRAKE SYSTEM OVERVIEW
General Descrip1ion How the Service Brake Works Equalizer Link Automatic Adjuster Mechanism How the Parking Brake Works Compensator Assembly Kick-Off Actuating Linkage
TROUBLESHOOTING FLOWCHART TROUBLESHOOTING TABLE TROUBLESHOOTING AND INSPECTION
New Vehicles
Troubleshooting and Inspection Procedures Brake Pedal and Linkage Inspection Periodic Brake Performance Test (PBPT) Aggressive Stop Test Wheel Brake Inspection
MAINTENANCE AND REPAIRS
Parts Replacement vs Repair
Adjusting Brake Pedal Free Travel
Brake Drum Removal and Installation
Wheel Brake Service
Backing Plate/Entire Wheel Brake Assembly Removal and Installation
Brake Shoe and Adjuster Replacement
Brake Cable and Equalizer Assembly Removal and Installation
Compensator Assembly, Removal and Installation
Brake Pedal Removal and Installation
Parking Brake Catch Bracket Removal and Installation
Parking Brake Pedal, Removal and Installation
Pedal Bumper Adjustment
Parking Brake Release Linkage Removal and Replacement
Parking Brake Kick-Off Cam Removal, Replacement and Installation


TABLE OF CONTENTS FOR SECTION 'M'
SECTION TITLE
DIRECTION SELECTOR (SEAT SUPPORT PANEL)
Removing Direction Selector
Replacing the Reverse Warning Buzzer
Replacing a Micro Switch
DIRECTION SELECTOR (DASH- PDS)
Removing Direction Selector
Replacing the Reverse Warning Buzzer
Replacing the Direction Selector Switch

TABLE OF CONTENTS FOR SECTION 'N'
SECTION TITLE
DIGITAL VOLT OHM METER
TROUBLESHOOTING
POWER SUPPLY
ACCESSORY WIRING

TABLE OF CONTENTS FOR SECTION 'P'
SECTION TITLE
REAR SUSPENSION
GENERAL
Shock Absorber Removal
Shock Absorber Installation
Rear Spring Removai
Rear Spring Installation
Rear Axle Assembly Removai
Rear Axle lnstallation

TABLE OF CONTENTS FOR SECTION 'Q'
SECTION TITLE
REAR AXLE MAINTENANCE
Checking the Lubricant Level
REAR AXLE DISASSEMBLY
Axle Shaft Removal and Disassembly
Axle Shaft Seal Removal and Replacement
Axle Shaft Replacement


TABLE OF CONTENTS FOR SECTION 'R'
SECTION TITLE
TOP AND WINDSHIELD
Trailering
GOLF CAR SUN TOP
Rear Support Installation
Front Strut
SunTop
SHUTTLE 2+2 SUN TOP
Rear Support Installation
Front Support Installation
Sun Top Installation
SPLIT WINDSHIELD
ONE-PIECE FRONT WINDSHIELD
REAR WINDSHIELD

TABLE OF CONTENTS FOR SECTION 'S'
SECTION TITLE
PAINTING
Minor Scratches
Larger Scratches
Complete Panel Repair


TABLE OF CONTENTS FOR SECTION 'T'
SECTION TITLE
ELECTRICAL SYSTEM
Basic Electrical Power System
Troubleshooting
Basic Electrical Troubleshooting for Accessories
SUSPENSION AND STEERING

TABLE OF CONTENTS FOR SECTION 'U'
SECTION TITLE
Grounding Requirements
Ground Systems
Lightning Protection Requirements
Equipment Fault and Personal Safety System
Ground Network Requirements
External Grounding Requirements
Materials
Earth Electrode System
Lightning Protection System
Equipment Fault and Personal Safety System

TABLE OF CONTENTS FOR SECTION 'V'
SECTION TITLE
TXT ELECTRIC- FREEDOM
TXT PDS ELECTRIC- FREEDOM
TXT ELECTRIC- FLEET
TXT PDS ELECTRIC- FLEET
TXT ELECTRIC - SHUTTLE 2+2




Keywords: service;pds;ez-go fleet;shuttle
File Size: 43.7 MBytes

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