Ezgo TXT 48V User manual

REPAIR AND SERVICE MANUAL
TXT 48V
ISSUED JANUARY 2010
ELECTRIC POWERED GOLF CAR
614279

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
SAFETY
For any questions on material contained in this manual, contact an authorized representative for clarification.
Read and understand all labels located on the vehicle. Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-
vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed
on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.
Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
Use extra caution when towing the vehicle(s). Do not tow a single vehicle at speeds in excess of 12 mph (19 kph). Do
not tow more than three vehicles at a time. Do not exceed 5 mph (8 kph) while towing multiple vehicles. Towing the
vehicle at above the recommended speed may result in personal injury and/or damage to the vehicle and other prop-
erty. Vehicles equipped with the AC Drive motor must be towed with the Run-Tow switch, located under the passenger
seat, in the ‘Tow’ position.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situations that could result in an unsafe condition
Observe these NOTICES, CAUTIONS and WARNINGS; be aware that servicing a vehicle requires mechanical skill
and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it
unsafe. NOTICES, CAUTIONS AND WARNINGS
WASH HANDS
AFTER HANDLING!
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
BATTERY WARNING
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
BATTERIES
CONTAIN LEAD
AND RELATED PARTS
!
<
14
˚
25
%
DO NOT
DRIVE ACROSS
SLOPES IN
EXCESS OF 14˚
Address practices not related to personal injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, will result in death or serious
injury.
Battery posts, terminals and related
accessories contain lead and lead compounds.
Wash hands after handling.
NOTICE
DANGER

Page i
Repair and Service Manual
TECHNICIAN’S
REPAIR AND SERVICE
MANUAL
ELECTRIC POWERED
PERSONAL VEHICLE
GOLF CARS
TXT 48V FLEET
TXT 48V FREEDOM
Starting Model Year 2010
E-Z-GO Division of TEXTRON, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the infor-
mation contained in this manual is subject to change without notice.
E-Z-GO Division of TEXTRON, Inc. 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.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]
INTERNATIONAL:
PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page ii Repair and Service Manual
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local
distributor, authorized Branch or the Warranty Department with vehicle serial number and
manufacturer code.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling battery 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 and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75 F (-60 C).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain. The battery charger and the controller are both sources of
electrical drain. Unplug the battery charger DC plug from the vehicle receptacle.
Disconnect the 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 or at a
minimum of 30 day intervals.
Refer to the ‘Prolonged Storage’ section within the BATTERIES AND CHARGING section of
this manual.
GENERAL INFORMATION

Page iii
Repair and Service Manual
TABLE OF CONTENTS
TITLE PAGE
Safety...........................................................................................................................Inside Covers
Model Notes...................................................................................................................................... i
Safety Information............................................................................................................................ v
TITLE SECTION
General Information & Routine Maintenance...................................................................................A
Safety...............................................................................................................................................B
Body.................................................................................................................................................C
Wheels and Tires .............................................................................................................................D
Electronic Speed Control - TCT........................................................................................................E
Front Suspension and Steering........................................................................................................F
Motor............................................................................................................................................... G
Batteries and Charging.....................................................................................................................H
Battery Charger ............................................................................................................................... J
Brakes..............................................................................................................................................K
Direction Selector.............................................................................................................................L
Electrical System............................................................................................................................. M
Rear Suspension..............................................................................................................................N
Rear Axle..........................................................................................................................................P
Weather Protection.......................................................................................................................... Q
Handheld Diagnostics ......................................................................................................................R
Troubleshooting................................................................................................................................S
Lightening Protection........................................................................................................................T
Paint.................................................................................................................................................U
General Specifications .....................................................................................................................V

Page iv Repair and Service Manual
TABLE OF CONTENTS
NOTES:

SAFETY INFORMATION
Page v
Repair and Service Manual
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings
This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with proce-
dures developed by the manufacturer. Adherence to these procedures and troubleshooting 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. The manufacturer strongly suggests that the owner-operator read this entire manual pay-
ing particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employ-
ees and other operators be encouraged to do the same.
If you have any questions, contact your closest representative or write to the address on the back cover of this publi-
cation, Attention: Customer Care Department.
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.
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.
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 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.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase 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. The manufacturer pro-
hibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the
safety of the vehicle.
Vehicles that are capable of higher speeds must limit their speed 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.
Always follow all safety rules established in the area where the vehicle is being operated.

Page vi
SAFETY INFORMATION
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
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 within the battery area in order to prevent sparks or battery explosion caused by short-
ing 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 compromise
the safety of personnel nor jeopardize the safe operation of the vehicle.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a
jack. Lift the vehicle in accordance with the manufacturer’s instructions.
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.
Always replace damaged or missing warning, caution or information labels.
Always keep complete records of the maintenance history of the vehicle.

SAFETY INFORMATION
Page vii
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
VENTILATION
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%.
Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five
air exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the recepta-
cle when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable
electrical code (whichever is more restrictive).

Page viii Repair and Service Manual
Notes:
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.

TABLE OF CONTENTS FOR SECTION ‘A’
SECTION TITLE PAGE NO.
GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-i
Repair and Service Manual
SERIAL NUMBER LOCATION .................................................................................A - 1
TRANSPORTING VEHICLE .....................................................................................A - 1
TOWING .......................................................................................................... A - 1
HAULING......................................................................................................... A - 1
SERVICING THE ELECTRIC VEHICLE....................................................................A - 1
ROUTINE MAINTENANCE...................................................................................... A - 2
REAR AXLE..............................................................................................................A - 2
BRAKES...................................................................................................................A - 2
TIRES........................................................................................................................A - 2
LIGHT BULB REPLACEMENT.................................................................................A - 2
VEHICLE CLEANING AND CARE............................................................................A - 2
VEHICLE CARE PRODUCTS...................................................................................A - 3
SUN TOP AND WINDSHIELD ..................................................................................A - 3
HARDWARE.............................................................................................................A - 4
TORQUE SPECIFICATIONS ....................................................................................A - 4
PERIODIC SERVICE SCHEDULE............................................................................A - 5
LIST OF ILLUSTRATIONS
Fig. 1 Initial Service Chart .....................................................................................A - 2
Fig. 2 Lubrication Point..........................................................................................A - 2
Fig. 3 Torque Specifications..................................................................................A - 4
Fig. 4 Periodic Service Schedule...........................................................................A - 5

Page A-ii Repair and Service Manual
Notes:
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-1
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
SERIAL NUMBER LABEL LOCA-
TION
Two serial number and manufacture date code label are
on the vehicle. One is placed on the body below the
front, driver side of the seat. The other is located on the
chassis under the seat.
Design changes take place on an ongoing basis. In
order to obtain correct components for the vehicle, the
manufacture date code, serial number and vehicle
model must be provided when ordering service parts.
TRANSPORTING VEHICLE
TOWING
This vehicle is not designed to be towed.
It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flatbed truck or other suit-
able transport.
HAULING
To reduce the possibility of severe injury or
death while transporting vehicle:
Secure the vehicle and contents.
Never ride on vehicle being transported.
Always remove windshield before trans-
porting.
Maximum speed with sun top installed is
50 mph (80 kph).
If the vehicle is to be transported at highway speeds,
the sun top must be removed and the seat bottom
secured. When transporting vehicle below highway
speeds, check for tightness of hardware and cracks in
sun top at mounting points. Always remove windshield
when transporting. Always check that the vehicle and
contents are adequately secured before transporting.
The rated capacity of the trailer or truck must exceed
the weight of the vehicle (see GENERAL SPECIFICA-
TIONS for vehicle weight) and load plus 1000 lbs. (454
kg). Lock the park brake and secure the vehicle using
ratchet tie downs.
SERVICING THE ELECTRIC
VEHICLE
To prevent severe injury or death, resulting
from improper servicing techniques, observe
the following Warnings:
Do not attempt any type of servicing opera-
tions before reading and understanding all
notes, cautions and warnings in this manu-
al.
Any servicing requiring adjustments to be
made to the powertrain while the motor is
running must be made with both drive
wheels raised.
Wear eye protection when work-
ing on the vehicle. In particular,
use care when working around
batteries, or using solvents or
compressed air.
To reduce the possibility of causing an
electrical arc, which could result in a bat-
tery explosion, turn off all electrical loads
from the batteries before removing any
heavy gauge battery wires.
To prevent the possibility of motor disinte-
gration, never operate vehicle at full throt-
tle for more than 4 - 5 seconds while
vehicle is in a “no load” condition.
It is in the best interest of both vehicle owner and ser-
vicing dealer to carefully follow the procedures recom-
mended in this manual. Adequate preventive
maintenance, applied at regular intervals, is the best
guarantee for keeping the vehicle both dependable and
economical.
Before a new vehicle is put into operation, it is recom-
mended that the items shown in the INITIAL SERVICE
CHART be performed (Ref. Fig. 1).
Vehicle batteries must be fully charged before initial
use.

Page A-2
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
ROUTINE MAINTENANCE
Some maintenance items must be serviced more frequently on
vehicles used under severe driving conditions.
This vehicle will give years of satisfactory service provid-
ing it receives regular maintenance. Refer to the Peri-
odic Service Schedule for appropriate service intervals
(Ref. Fig. 4). Refer to Lubrication Point for appropriate
lubrication location (Ref. Fig. 2).
Do not use more than three (3) pumps of grease for
each grease fitting at any one time- Excess grease
may cause grease seals to fail or grease migration into
areas that could damage components.
Putting more than three pumps of grease in a grease fit-
ting could damage grease seals and cause premature
bearing failure.
REAR AXLE
The only maintenance required for the first five years is
the periodic inspection of the lubricant level. The rear
axle is provided with a lubricant level check/fill plug
located on the bottom of the differential. Unless leakage
is evident, the lubricant need only be replaced after five
years. The procedure to follow for checking the rear axle
lubricant level is in the REAR AXLE section.
BRAKES
After the vehicle has been put into service, it is recom-
mended that the brakes be checked daily by performing
a brake test.
To prevent severe injury or death resulting
from operating a vehicle with improperly oper-
ating brake system, the braking system must
be properly maintained. All driving brake tests
must be done in a safe location with regard for
the safety of all personnel.
For information on conducting a brake test, refer to
BRAKES section.
TIRES
Tire condition should be inspected per the Periodic Ser-
vice Schedule. Inflation pressures should be checked
when the tires are cool. Be sure to reinstall valve dust
cap after checking or inflating. For additional informa-
tion, refer to WHEELS AND TIRES section.
LIGHT BULB REPLACEMENT
Refer to ELECTRICAL SYSTEM for information regard-
ing light bulb replacement.
VEHICLE CLEANING AND CARE
When pressure washing vehicle, do not use pressure in
excess of 700 psi (4825 kPa). To prevent cosmetic
damage, do not use any abrasive or reactive solvents
to clean plastic parts.
Fig. 1 Initial Service Chart
Fig. 2 Lubrication Point
ITEM SERVICE OPERATION
Batteries Charge batteries
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Establish acceptable stopping distance
Check hydraulic brake fluid level
Tires Check air pressure (see SPECIFICATIONS)
Portable
Charger Remove from vehicle and properly mount
NOTICE
View From Underside Of Vehicle
Rack Ball Joint
Ref Lub 1

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-3
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
It is important that proper techniques and cleaning mate-
rials be used. Using excessive water pressure may
cause damage to seals, plastics, the electrical system,
body finish or seat material. Do not use pressure in
excess of 700 psi (4825 kPa) to wash vehicle.
Normal cleaning of vinyl seats and plastic or rubber trim
require the use of a mild soap solution applied with a
sponge or soft brush and wipe with a damp cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require
the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive
appearance and durable protection. Frequent washing
with lukewarm or cold water is the best method of pre-
serving those painted surfaces.
Do not use hot water, strong soap or harsh chemical
detergents.
Rubber parts should be cleaned with non-abrasive
household cleaner.
Occasional cleaning and waxing with non-abrasive prod-
ucts designed for ‘clear coat’ automotive finishes will
enhance the appearance and durability of the painted
surfaces.
Corrosive materials used as fertilizers or for dust control
can collect on the underbody of the vehicle. These
materials will accelerate corrosion of underbody parts. It
is recommended that the underbody be flushed occa-
sionally with plain water. Thoroughly clean any areas
where mud or other debris can collect. Sediment packed
in closed areas should be loosened to ease its removal,
taking care not to chip or otherwise damage paint.
VEHICLE CARE PRODUCTS
To help maintain the vehicle, there are several products
available through local Distributors, authorized
Branches, or the Service Parts Department.
• Touch-up paint specially formulated to match
vehicle colors for use on TPE (plastic) bodies (P/
N 28140-G** and 28432-G**).
• Multi-purpose Battery Protectant formulated to
form a long-term, flexible, non-tacky, dry coating
that will not crack, peel or flake over a wide tem-
perature range (P/N 75500-G01).
• White Lithium Grease designed to provide lubri-
cation protection in areas where staining or dis-
coloring is a problem, or in areas of extreme
temperature ranges (P/N 75502-G01).
• Penetrant/Lubricant, a 4-in-1 product that pene-
trates the most stubborn of frozen parts, lubri-
cates leaving a light lubricating film, prevents
corrosion by adhering to wet or dry surfaces and
displaces moisture, sealing against future mois-
ture return (P/N 75503-G01).
• Multi-purpose Cleaner and Degreaser that con-
tains natural, environmentally safe solvents (P/N
75504-G01).
• Multi-purpose Hand Cleaner is an industrial
strength cleaner containing no harsh solvents, yet
gently lifts grease off hands. May be used with or
without water (P/N 75505-G01).
• Battery Cleaner that promotes easy, non-violent
neutralization of battery acids and battery acid
crystals. The resulting sodium salts are water sol-
uble and easily washed away (P/N 75506-G01).
• Battery Maintenance Kit for complete battery
cleaning and watering, with battery maintenance
instructions (P/N 25587-G01).
• Biodegradable Cleaner that cleans the toughest
dirt and heavy soils by breaking down grease to
be easily wiped or rinsed away (P/N 75507-G01).
• Multi-purpose Value Pack sampler package
including 4 ounce (118 ml) aerosol cans of Bat-
tery Protector, Penetrant/Lubricant, White Lithium
Grease, and Carburetor and Choke Cleaner (P/N
75508-G01).
• Plexus plastic cleaner and polish removes minor
scratches from windshield (P/N 28433-G**).
SUN TOP AND WINDSHIELD
The sun top does not provide protection from
roll over or falling objects.
The windshield does not provide protection
from tree limbs or flying objects.
The sun top and windshield are designed for weather
protection only.
Clean with lots of water and a clean cloth. Minor
scratches may be removed using a commercial plastic
polish or Plexus plastic cleaner available from Service
Parts Department.

Page A-4
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
HARDWARE
Periodically the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref. Fig. 3).
Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
torque values.
Generally, two grades of hardware are used in the vehi-
cle. Grade 5 hardware can be identified by the three
marks on the hexagonal head. Unmarked hardware is
Grade 2.
TORQUE SPECIFICATIONS
Fig. 3 Torque Specifications
ALLTORQUE FIGURES ARE IN FT. LBS. (Nm)
BOLT SIZE
Grade 2
1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
4
(5) 8 (11) 15 (20) 24 (33) 35 (47) 55 (75) 75 (102) 130 (176) 125 (169) 190 (258)
Grade 5
Grade 8
6
(8) 13 (18) 23 (31) 35 (47) 55 (75) 80 (108) 110 (149) 200 (271) 320 (434) 480 (651)
6
(8) 18 (24) 35 (47) 55 (75) 80 (108) 110 (149) 170 (230) 280 (380) 460 (624) 680 (922)
BOLT SIZE
Class 5.8
(Grade 2)
M4 M5 M6 M8 M10 M12 M14
1
(2) 2 (3) 4 (6) 10 (14) 20 (27) 35 (47) 55 (76.4)
Class 8.8
(Grade 5) 2
(3) 4 (6) 7 (10) 18 (24) 35 (47) 61 (83) 97 (131)
Class 10.9
(Grade 8) 3
(4) 6 (8) 10 (14) 25 (34) 49 (66) 86 (117) 136
(184)
5.8
8.8
10.9
Ref Tsp 1

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-5
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
PERIODIC SERVICE SCHEDULE
3Check Clean, Adjust, etc. SReplace
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions
DAILY
BEFORE USE:
3Check service brake general operation
3Check park brake function
3Check warning device function in reverse
3Check tire condition
3Check overall vehicle condition
BATTERIES Recharge to full charge state after each day’s use
CHARGER / RECEPTACLE 3Inspect connector system at each charge
WEEKLY
TIRES 3Examine for cuts, excessive wear and pressure (See GENERAL
SPECIFICATIONS)
WHEELS 3Check for bent rims, loose or missing lug nuts
MONTHLY - 20 HOURS (includes items listed in previous table & the following)
BATTERIES Clean battery & terminals
3Check charge condition and all connections
WIRING 3Check all wiring for loose connections and broken/missing insulation
SERVICE BRAKE 3Conduct brake performance test
BRAKE FLUID (IF EQUIPPED) 3Check for leakage
ACCELERATOR 3Check for smooth movement
CHARGER / RECEPTACLE Clean connections, keep receptacles free of dirt and foreign matter
DIRECTION SELECTOR 3Check attachment, adjust as required
STEERING ASSEMBLY 3Check for abnormal play, tightness of all hardware
TIE ROD/LINKAGES 3Check for excessive play, bent components or loose connections
REAR AXLE 3Check for leakage, add SAE 30 oil as required
QUARTERLY - 50 HOURS (includes items listed in previous tables & the following)
FRONT AXLE 3Check for damage to axle and loose or missing hardware
FRONT SHOCK ABSORBERS 3Check for oil leakage and loose fasteners
FRONT SPRINGS 3Check for loose hardware, cracks at attachments
FRONT WHEEL ALIGNMENT 3Check for unusual tire wear, align if required
Fig. 4 Periodic Service Schedule

Page A-6
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
PARK BRAKE
3Check for bent/binding linkage rod
3Check for damage or wear to latch arm or catch bracket
Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE
LATCH
REAR SHOCK ABSORBERS 3Check for oil leakage, loose mounting hardware
HARDWARE AND FASTENERS 3Check for loose or missing hardware and components
Tighten or replace missing hardware
SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)
BATTERIES Clean batteries & terminals
DIRECTION SELECTOR 3Check for wear and smooth movement (lubricate shaft with light oil if required)
KING PINS 3Check for excessive play and tightness of retaining nuts
STEERING ASSEMBLY 3Check bellows and pinion seal for damage or grease leakage
RACK END BALL JOINT Lubricate, use wheel bearing grease
REAR AXLE 3Check for unusual noise and loose or missing mounting hardware
ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)
FRONT WHEEL BEARINGS Check and adjust if required (see FRONT SUSPENSION AND STEERING)
REAR AXLE 3Check lubricant, add lubricant (SAE 30 oil) as required
SERVICE BRAKES
(HYDRAULIC BRAKES)
Clean and adjust, see Technician’s Repair and Service Manual
3Check brake shoe linings, see Technician’s Repair and Service Manual
3Check brake fluid
Fig. 4 Periodic Service Schedule

TABLE OF CONTENTS FOR SECTION ‘B’
SECTION TITLE PAGE NO.
SAFETY
Page B-i
Repair and Service Manual
NOTES, CAUTIONS AND WARNINGS ....................................................................B - 1
IMPORTANT SAFETY WARNING............................................................................B - 1
MODIFICATIONS TO VEHICLE................................................................................B - 1
GENERAL MAINTENANCE......................................................................................B - 1
BEFORE SERVICING THE VEHICLE.......................................................................B - 1
Additional Warnings.........................................................................................B - 2
BATTERY REMOVAL & INSTALLATION ................................................................B - 3
LIFTING THE VEHICLE............................................................................................B - 4
LIST OF ILLUSTRATIONS
Fig. 1 Battery Connections ...................................................................................B - 4
Fig. 2 Lifting the Vehicle.......................................................................................B - 4

Page B-ii Repair and Service Manual
Notes:
SAFETY
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.