ELK Golf GT LITHIUM V1 Instruction manual

GTLITHIUMV1Workshopmanual 1 
©2013ElkingtonGolfPtyLtd
GTLITHIUMV1
Workshopmanual



ForApprovedE•L•KGolfServiceCentres


GTLITHIUMV1Workshopmanual 2
©2013ElkingtonGolfPtyLtd
GTLITHIUMV1Workshopmanual

TABLEOFCONTENTS

1/REMOVINGTHETOPHANDLE………………………………………………………………….Page3
2/REPLACINGTHESPEEDCONTROLSWITCH……………………………………………….Page3–11
3/REPLACINGTHEPCBBOARD/DISPLAYINTHETOPHANDLE……………………Page11
4/REFITTINGTHETOPHANDLE……………………………………………………………………Page12
5/REPLACINGOFTHEMOTORCONTROLLER……………………………………………….Page13–16
6/REPLACINGTHEMOTOR…………………………………………………………………………..Page16–18
7/REPLACINGTHEAXLEDRIVEPINS…………………………………………………………….Page19
8/REPLACINGTHESTEMCABLE……………………………………………………………………Page20–26
9/REPLACINGTHEAXLEBEARINGS……………………………………………………………….Page26–28
10/REPLACING/REMOVALOFTHEBATTERYTRAY……………………………………….Page28–29
11/REPLACING/REMOVALOFTHEDRIVEAXLE……………………………………………Page29–33
12/REPLACINGTHEGEARBOX……………………………………………………………………….Page33–35
13/REPLACINGTHEUPPERBAGSUPPORT…………………………………………………….Page36–37
14/REPLACINGTHELOWERBAGSUPPORT……………………………………………………Page37–38
15/REPLACINGTHEFRONTWHEEL&HOUSINGASSEMBLY…………………………..Page39
16/ADJUSTINGFRONTWHEELTRACKING………………………………………………………Page39–40



GTLITHIUMV1Workshopmanual 3 
©2013ElkingtonGolfPtyLtd
1/REMOVINGTHETOPHANDLEASSEMBLY
Thereare6screwswhichsecuretheTopHandleassemblytotheMainFrameUpperTubeasshown
bythearrowsinfigure‐No1PLEASENOTE–Thereare3sleeves/busheswhichsitbetweenboth
sectionsofthehandleandUppermainframetube.Ensuretheyareinplacebeforerefittingthe
handle.RefertoFigureNo15A.

 FigureNo1
2/REPLACINGTHESPEEDCONTROLSWITCH
Withthetophandleassemblyremovedfromthemaintube,itwillnowseparateintotwohalves.
WhilesupportingtheuppersectionoftheTopHandleAssemblyastoavoiddamagingthestem
cablewiring,removethetwoPhillipsscrewsindicatedbyarrows,securingthecablesupportbracket
aspicturedinFigureNo2.

 FigureNo2

GTLITHIUMV1Workshopmanual 4 
©2013ElkingtonGolfPtyLtd

LoosenthescrewswhichsecuretheStemCableWiringtotheTerminalBlockandremovetheStem
CableWiringfromtheTerminalBlockaspicturedinFigureNo3.
PLEASENOTE–TheStemCableWiringiscolourcodedandthecolourofeachwiremustcorrespond
withthecoloursprintedontheTerminalBlockaspicturedinFigureNo3.

 FigureNo3

Unplug/DisconnecttheSpeedSwitchWiring,fromthePCBBoardaspicturedinFigureNo4.

 FigureNo4


GTLITHIUMV1Workshopmanual 5
©2013ElkingtonGolfPtyLtd

BeforeyoucanloosentheretainingnutwhichsecurestheSpeedSwitchtotheUpperHandle,you
mustfirstslidetheRedSpeedDialasfaraspossibletotheright,whichwillallowyoutoaccesstothe
securingnut.Tocarryoutthisprocess‐placeascrewdriverinthepositionaspicturedinFigureNo5
andgentlyshiftthespeeddialinthedirectionofthearrowsshown,asfarasyoucantotherightby
rotatingthescrewdriver.
PLEASENOTE–Beextremelycarefulwhilecarryingoutthispartoftheprocedure,astoavoid
damagingtheTopHandleAssembly.




 FigureNo5

OnceyouhavecarriedouttheprocedureaspicturedinFigureNo5,youwillbeabletoseeandhave
accesstotheSpeedSwitchsecuringnut,aspicturedinFigureNo6andindicatedbythearrow.

GTLITHIUMV1Workshopmanual 6
©2013ElkingtonGolfPtyLtd
FigureNo6

LoosentheSpeedSwitchsecuringnutbyusingthespeciallysuppliedSpannerwhichwassuppliedto
you,withyourServiceCentreStartUpKitaspicturedinFigureNo7.
PLEASENOTE–Whilelooseningthesecuringnut,youwillneedtoslidetheSpeedSwitchinthe
directionofthearrowinFigureNo7&7Aatthesametime,whichwillallowcompleteremovalof
theSpeedSwitch.


GTLITHIUMV1Workshopmanual 7
©2013ElkingtonGolfPtyLtd
 FigureNo7

OncetheSpeedSwitchsecuringnuthasbeencompletelyloosened,keepslidingtheSpeedSwitch,in
thedirectionofthearrowaspicturedinFigureNo7A,untilitiscompletelyfreefromtheTopHandle
AssemblyaspicturedinFigureNo8

 FigureNo7A

GTLITHIUMV1Workshopmanual 8
©2013ElkingtonGolfPtyLtd
 FigureNo8

BeforebeginningtofitthenewSpeedSwitch,itisimportanttonote‐ThattheshaftontheSpeed
Switch,hasa“flat”sectiontoallowtheSpeedDialtolocateontheshaftandalocating“lug”onthe
housingoftheswitchaspicturedinFigureNo9.Thelocating“lug”ontheswitchneedstobe
positionedcorrectlyintotheTopHandleAssemblyaspicturedanddefinedinthesectionoftheTop
HandleassemblyasindicatedbythearrowonFigureNo10.TofitthenewSpeedSwitch,beginby
slidingtheSpeedSwitchthroughthemountingholeintheTopHandleAssemblyandplacingthe
washerandnutontotheshaftaspicturedinFigureNo9.


FigureNo9

GTLITHIUMV1Workshopmanual 9 
©2013ElkingtonGolfPtyLtd
FigureNo10belowshowsthepositionthatthelocating“lug”ontheSpeedSwitchmustlocateinto
ontheTopHandleassemblydefinedbyanarrow. 
FigureNo10

OncetheSpeedSwitchisplacedintothetophandleaspreviouslyshowninFigureNo9,theSpeed
DialmustbeplacedontotheshaftoftheSpeedSwitch,aligningtheflatsectionontheSpeedSwitch
shaftwiththeflatsectionontheSpeedDialandthelocatingluginthecorrectpositionaspicturedin
FigureNo11.


 FigureNo11

.

GTLITHIUMV1Workshopmanual 10
©2013ElkingtonGolfPtyLtd
BeforeyoucantightenthesecuringnutontheSpeedSwitch,youwillhavetostartthenutonthe
threadoftheSpeedSwitchbyusingasmallscrewdrivertoturnthenutaspicturedinFigureNo12.
Thispartoftheprocesscanbealittletrickyandrequiresasteadyhandandalittlepatience.Be
verycarefulnottotryandforcethenutonwithaspannerandcrossthreadthenut.
PLEASENOTE–ItisextremelyimportanttoensuretheLocatingLugontheSpeedSwitchislocated
correctlyintotheslotontheTopHandleassembly.

 FigureNo12

OnceyouaresurethatthenuthasstartedcorrectlyonthethreadoftheSpeedSwitch,youarenow
abletotightenthesecuringnutwiththespecialspannerprovidedaspicturedinFigureNo13.Once
thenutistight,youwillneedtopushtheSpeedDialfurtherontotheshaftuntilitiscorrectly
centredintotheopeningoftheTopHandleassembly.

 FigureNo13

GTLITHIUMV1Workshopmanual 11
©2013ElkingtonGolfPtyLtd
BeforeyourefittheTopHandleassemblybackontothebuggy,itisadvisabletoplacethetwohalves
ofthehandletogetherandensurethattheSpeedDialinnotbindingontheTopHandleassembleas
picturedinFigureNo14
 FigureNo14
OnceyouarecertainthattheSpeedDialisturningcorrectlywithoutinterference,thenreconnect
theSpeedSwitchwiringtothePCBboardandreconnectthestemcablewiring,ensuringthateach
colouredwirecorrespondswiththecolourprintedontheterminalblock.FittheStemCablesecuring
bracketandrefitthehandletothebuggybyreferringtoparagraphNo4.Testtheoperationofthe
speedswitchandensurethatitisfunctioningcorrectlyandtheSpeedDialisnotfoulingontheTop
Handleassembly.
3/REPLACINGTHEPCBBOARD/DISPLAYINTHETOPHANDLE
Tocarryoutthisprocess,followthestepsasperFigures1to4thenremovethe3screwsindicated
byarrows,whichsecurethePCBboardasperFigureNo15andreplacethePCBboard.
Tocompletethisprocedure,reversethestepsofFigures1to4andtestthatthePCBboardis
operatingcorrectlyandallthreedistancesettingsarefunctioningcorrectlyalso.

 FigureNo15

GTLITHIUMV1Workshopmanual 12 
©2013ElkingtonGolfPtyLtd
4/REFITTINGTHETOPHANDLE
Beforerefittingthetophandle,pleaseensurethatthe3bushes/sleevesareinplace(onsome
modelsonly,asindicatedbyarrowsonFigureNo15A
Pleasebecarefulnottodropthesebushesintothemainupperframetubewhenrefittingthe
handle.
FigureNo15A

RefitandtightenthescrewsasindicatedbyarrowsonfigureNo15B

FigureNo15B


GTLITHIUMV1Workshopmanual 13
©2013ElkingtonGolfPtyLtd

5/REPLACINGOFTHEMOTORCONTROLLER
ToreplacetheMotorController,firstlyturnthebuggyupsidedown.
AftermanyyearsofextensiveresearchintofailedMotorControllers,itwasdiscoveredthatoneof
themaincausesforfailureisrepeatedshock.Forthisreason,theGTLithiumMotorControlleris
rubbermountedandtherubbermountingsthatarepositionedonthemountingscrewsofthe
MotorController,MUSTbeputbackinplacewhenreplacingtheunit.
ToremovethemotorController,firstlyyoumustremovethecableties,securingthewiringtothe
undersideoftheBatteryTrayanddisconnectthewiringfromtheMotorandStemCableindicatedby
arrowsaspicturedonFigureNo16Below.
 
Fffffffff
Loosenthe4screwsthatsecuretheMotorControllerasindicatedinFigureNo17
FigureNo17


GTLITHIUMV1Workshopmanual 14
©2013ElkingtonGolfPtyLtd
LoosenScrewsenoughtofreeMotorControllerformthebatterytray,butdonotremovethescrews
completelyastherubberbusheswillfallofftheretainingscrews.RefertoFiguresNo18,19&20
 FigureNo18
  
   FigureNo19

 FigureNo20

GTLITHIUMV1Workshopmanual 15
©2013ElkingtonGolfPtyLtd
NowdiconnecttheBatteryconnectionwiringwhichhousesthe2AndersonConnectors,byremoving
the2retaingscrews,indicatedbyarrowsonFigureno21.
TheMotorControllerisnowfreetoberemoved.Makesurethatyoudonotlooseanyrubber
bushesintheprocess.
 FigureNo21
TofitthenewMotorController,startbyrefitingtheBatteryConnectionwiring.Pleaseensurethat
locatinglugonthehousingofthisplugcorrespondswiththecutoutintheBatteryTrayasindicated
byarrowsonFiguresNo22&23.
 FigureNo22
 FigureNo23

GTLITHIUMV1Workshopmanual 16
©2013ElkingtonGolfPtyLtd
Fitthe2screwswhichsecurethisplugandensurethatthesescrewsarenotovertigtened,causing
damagetotheBatteryTray.
Pleaseensurethattherubberbushesareplacedon4screwsasperFigureNo20,beforeattempting
torefittheControllerandmakesurethatall4screwsarestartedcorrectlyandnotcrossthreaded
beforetighteningcompletely.Onceall4srewsaretight,reconnecttheStemCableWiringand
Motorwiring,thenfit3newcabletiesandsecurethewiring.
6/REPLACINGTHEMOTOR.
BeginbyremovingthecabletiessecuringtheMotorwiringtotheframe,thenunplugingtheMotor
Wiring,fromtheMotorControlleraspicturedinFigureNo24
 FigureNo24
Removethe3ScrewswhichsecuretheMotortotheGearBoxasindicatedbyarrows
onFigureNo25



 FigureNo25

GTLITHIUMV1Workshopmanual 17
©2013ElkingtonGolfPtyLtd
TheMotorcannowbeseperatedfromtheGearbox.Becarefulnottoloosetherubbersealthatsits
betweentheMotorandtheGearboxaspicturedinFigureNo26.Beawarethatthissealmaystay
stucktotheMotorwhentheMotorisremoved.



FigureNo26
BeforefittingthenewMotor,ensurethatthesealiscorrectlypositionedontheflangeofthe
Gearbox.Itisadviseabletouse,eithersiliconeorgreasetohelpkeepthissealinplacepriorto
fittingthenewMotorasperFigureNo27.
FigureNo27
Ensurethatthe3holesintherubberseal,lineupwihthe3holesintheGearboxflangeasindicated
byarrowsinFigureNo27
YoucannowbegintoinserttheMotorintothegearbox.Youmayneedtoturntheaxleslightly,to
allowthewormdrivegearstomatchcorrectlyandtheMotorbodytomatchupcorrectlywiththe
GearboxFlangeasperFigureNos28&29.

GTLITHIUMV1Workshopmanual 18
©2013ElkingtonGolfPtyLtd


FigureNo28
Fitthe3MotorretaingscrewsandensurethattheMotoriscorrectlyseatedagainsttheGearbox
flangebyholdinginwardpressureontheMotorandthentightenthe3screwsevenly.Referto
FigureNo29.




FigureNo29
ReconnecttheMotorwiringasperFigureNo24andrefitcableties,tosecurewiringtotheframe.



GTLITHIUMV1Workshopmanual 19
©2013ElkingtonGolfPtyLtd
7/REPLACINGTHEAXLEDRIVEPINS
Thisisaverysimpleprocessandallyouwillrequireisasmallhammeranda4mmpinpunch.Begin
byremovingthewheelbydepressingtheRedwheelreleasetabonthewheelasperfigureNo30.
ToremovetheoldDrivepinusea4mmpunchaspicturedinFigureNo31.ToinstallnewDrivepin,
useasmallhammerandgentlytapthepinintotheaxle,beingverycarefulnottobendtheaxle
duringthisprocessaspicturedonFigureNo32.Itisrecommendedthatyouusealittleloctiteon
theDrivePinwheninstalling.


 FigureNo30

 FigureNo31


 FigureNo32

GTLITHIUMV1Workshopmanual 20 
©2013ElkingtonGolfPtyLtd
8/REPLACINGTHESTEMCABLE
ToBeginthisprocess,firstlybeginbyremovingtheTopHandleassemblyasperFigureNos1to4.
OncetheTopHandlehasbeenremovedfromthebuggy,folddowntheframeandbegintopullout
theStemCableinthedirectionofthearrow,whichishousedwithinaflexibleprotectivetubeas
showninFigureNo33.
 FigureNo33
Keeppullingoutwardontheflexibletubeinthedirectionofthearrow,untiltheStemCableis
releasedfromtheuppersectionoftheMainFrame,asperFigureNo34.


 FigureNo34
OncetheStemcablehasbeenfullyreleasedfromtheUpperMainFrametube,slidetheflexible
protectivecoverfullyofftheStemCable,buttakespecialnotewhichwayyouhaveremovedthis
cover,asitwillneedtoberefittedthesamewayitwasoriginally,referFigureNo35.
