Ezgo MPT 1000 User manual

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A Textron Company
Ref Fcv 4 28812
ELECTRIC POWERED UTILITY VEHICLE
STARTING MODEL YEAR: 2004
SERVICE PARTS MANUAL
28812-G01

Page i
Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC
UTILITY VEHICLES
MPT®1000
INDUSTRIAL™ 1000
COMMANDER™ 2100
JACOBSEN HAULER™ 1000
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 information
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. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: [phone] FAX: [phone]
OUTSIDE USA PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA USA 30903-0388

Page ii
NOTES
Service Parts 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) parts may void the warranty.
Overfilling of 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 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).
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.

Page iii
TABLE OF CONTENTS
Service Parts Manual
SECTION Page No.
HOW TO USE THE SERVICE PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ILLUSTRATED PARTS BREAKDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
BATTERY CHARGER (LESTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
BRAKES - FRONT DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
ELECTRONIC SPEED CONTROL - PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
FRONT SUSPENSION / STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1
TRUCK BED, PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-1
SPECIALTY PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX A-1
OPTIONS/ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX B-1

Page iv
TABLE OF CONTENTS
Service Parts Manual
N
otes:

Page v
Service Parts Manual
This manual is divided into several sections:
GENERAL INFORMATION
•TABLE OF CONTENTS
•HOW TO USE THE SERVICE PARTS MANUAL
ILLUSTRATED PARTS BREAKDOWN
•Contains illustrations and parts lists for all systems of the vehicle
APPENDIX
•Contains a listing of specialty products and options/accessories
INDEX OF MAJOR COMPONENTS
•Contains a listing of parts (excluding hardware) grouped by part number and description and indicates on which
page(s) they can be found
USE OF THE MANUAL
To use this manual, consult the TABLE OF CONTENTS (page iii) or the INDEX OF MAJOR COMPONENTS (located at
rear of this manual) to locate the information or illustration required.
Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of
components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your
situation. Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual
for its location) and note the complete number shown on the plate. It is important that the serial number of your vehicle
and its model number be supplied to Service Parts when ordering any replacement components.
Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its loca-
tion) and note the complete number shown on the plate.
HOW TO USE THE SERVICE PARTS MANUAL

Page vi
HOW TO USE THE SERVICE PARTS MANUAL
Service Parts Manual
1. WHEN THE PART NUMBER IS NOT KNOWN
•Determine the function and application of the part required. Turn to the INDEX OF MAJOR COMPONENTS and
select the most appropriate component description.
•Turn to the page number indicated and locate the part description in the parts list. Read the full accompanying
description for specific information regarding the part that was not shown in the index.
•From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying
it with the pictorial representation on the illustrated page.
2. IF YOU KNOW THE PART NUMBER
•Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on.
•Turn to the page number indicated and locate the part number in the parts list. Refer to the accompanying descrip-
tion for specific information regarding the part.
•From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying
it with the pictorial representation on the illustrated page.
Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is
found. The part number is the lowest assembly sold by Service Parts. The asterisk (*) indicates that the part depicted is
not available for purchase.
NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the
assembly that it is used on. This process is repeated until the highest final assembly is reached.
To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is
available from the Service Parts Department.
Title Title
L
eft hand illustration page
(
continued on right hand page
i
f required) Parts list (continued on
rear of page if required)
Front of Vehicle
123
101
100
99
98
120
74 70
71
64
63
65
66
67
121
122
114
119
115
111
73
72
112
118
116
113
62
69
94
96
95
82,87
81,8684,89
83,88
102,104
105
79
91
92
107
106
62 - IncludesItems 63 - 66, 69 -74
70 - Includes Items 71 -74
81 - Includes Items 82 - 84
86 - Includes Items 87 - 89
94 - IncludesItems 95, 96
111 - Includes Items 112 - 114
118 - Includes Items 119 - 121
126 - Includes Items 127 - 131
103
*See Body Section for
decal information
127
128129
130
131
126

Page vii
Service Parts Manual
ILLUSTRATED PARTS BREAKDOWN
ILLUSTRATED PARTS BREAKDOWN

Page A-1 Service Parts Manual
5
4
12
14
15
16
17
18
19
20
3
31
30
4
29
29
13
2
1 - Includes Items 2 - 37
35
22
22 21
23
24
33
27
26
39
Part of
Frame
To Harness
from
Direction
Selector
9
11 10
36
37
34
BLK
WHT
6
7
GRN
RED
R
ef Acl 4-1
ACCELERATOR

When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page A-2
Service Parts Manual
1 73333-G11 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2 - 37)........................................ 1
2 70116-G02 ACCELERATOR PEDAL BRACKET............................................................. 1
3 01050-G01 SCREW, #8 - 16 X 1/2" LG. .......................................................................... 4
4 25853-G01 PEDAL BOX AND COVER........................................................................... 1
5 00684-G6 SCREW, #8 - 32 X 3/4" LG. .......................................................................... 4
6 25861-G02 MICRO SWITCH........................................................................................... 1
7 01050-G01 SCREW, #4 - 20 X 5/8" LG........................................................................... 2
8
9 25854-G01 INDUCTIVE THROTTLE SENSOR .............................................................. 1
10 00983-G01 SELF THREADING NUT, 3/16" .................................................................... 2
11 26551-G01 PLUNGER..................................................................................................... 1
12 00486-G2 SETSCREW, #8 - 32 X 1/8" LG. ................................................................... 1
13 00550-G2 LOCK NUT, 1/4 - 28...................................................................................... 1
14 17677-G1 SPRING RETAINER, 1/2"............................................................................. 1
15 17979-G1 BUSHING...................................................................................................... 1
16 73046-G01 COMPRESSION SPRING............................................................................ 1
17 17677-G2 SPRING RETAINER, 3/8"............................................................................. 1
18 25799-G03 ACCELERATOR ROD .................................................................................. 1
19 00532-G4 LOCK NUT, 5/16 - 24.................................................................................... 1
20 10385-G4 CLEVIS YOKE (ADJUSTABLE).................................................................... 1
21 10386-G3 CLEVIS PIN, 5/16" X 1" LG .......................................................................... 1
22 17838-G1 NYLON BUSHING........................................................................................ 3
23 17255-G1 TEFLON WASHER, 5/16"............................................................................. 1
24 10387-G3 COTTER PIN, 3/32" X 3/4" LG ..................................................................... 1
25
26 74432-G01 PEDAL PIVOT PIN ....................................................................................... 1
27 12064-G6 PUSH NUT, 9/32".......................................................................................... 1
28
29 25879-G08 WIRING HARNESS (PEDAL BOX ASSEMBLY).......................................... 1
30 17313-G1 LOOM FLEX, 3/8" X 6" LG (BULK)............................................................... 1
ACCELERATOR

Page A-3 Service Parts Manual
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
31 17618-G1 WIRE TIE...................................................................................................... 2
32
33 25799-G01 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 34 - 37)............. 1
34 27844-G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 35 - 36)............ 1
35 15766-G1 OVAL RIVET, 3/16" X 3/8" LG.......................................................... 6
36 27512-G01 ACCELERATOR PEDAL PAD ......................................................... 1
37 * ACCELERATOR PEDAL........................................................................ 1
38
39 00715-G2 BOLT, 5/16 - 18 X 13/16" LG............................................................................... 4
ACCELERATOR

Page A-4
Service Parts Manual
ACCELERATOR

Page B-1 Service Parts Manual
1
R
ef Bcl 4-1
BATTERY CHARGER (LESTER)

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page B-2
Service Parts Manual
1 28435-G03 BATTERY CHARGER, LESTER, 36 VOLT, PORTABLE WITH POWERWISE
CONNECTOR, CE APPROVED (OPTIONAL)
For service or replacement parts, contact:
Lester Electrical
625 West “A” Street
Lincoln, NE 68522
Phone: [phone], FAX: [phone]
Always provide the following information when requesting information
or ordering replacement parts:
Model Number:
Serial Number: (stamped into housing)
BATTERY CHARGER (LESTER)

Page C-1 Service Parts Manual
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17 46
38
42
44
43
41
24
25
26
29
30
23
28
1
2
12
8
50
51
52
8 - Includes Items 9 - 12
32
33
35
36
34
11
9
10
13
14
27
18
21
20
6
4
15
47
5
18
40
BODY

Page C-2
Service Parts Manual
73
74
98
75
76
78
83
79
120
80
119
109
111
61
116
114
113
101
117
103
95
121
96
90
71
72
100
82
77
77
84
85
69
54
55
97
79 80
107
106
105
104
115
110
112
99
118
59
60
65
66
57
123
92
149
91
150
88
94
BODY

Page C-3 Service Parts Manual
159
164
158
162
163
161
160
165
166
BODY

Page C-4
Service Parts Manual
152 - Includes Items 153 - 156
133
129
Vehicle Rear
Bumper
Clevis Hitch
Angle Hitch
Heavy Duty
Hitch
137
132
136
134
139
142
147
141
140
146
144
145
125
130
131
126
127
128
HITCHES
143
ASH TRAY
156
155
154
153
R
ef Bod 21-3
BODY

Page C-5 Service Parts Manual
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
1 70662-G01 UPPER FLOORPAN (AXLE MOUNTED STEERING) ........................................ 1
2 14601-G11 RIVET, 3/16" X 9/16" LG ..................................................................................... 9
3
4 70451-G01 LOWER FLOORPAN........................................................................................... 1
5 14601-G11 RIVET, 3/16" X 9/16" LG ..................................................................................... 7
6 70452-G01 ACCESS COVER................................................................................................ 1
7
8 71151-G01 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 9 - 12) ........................ 1
9 71153-G01 DEFLECTOR (PASSENGER SIDE) ............................................................. 1
10 71154-G01 DEFLECTOR (DRIVER SIDE)...................................................................... 1
11 00614-G5 SCREW, #8 - 18 X 5/8" LG........................................................................... 6
12 71158-G01 INSTRUMENT PANEL INSERT (FOUR CUP).............................................. 1
13 71179-G02 LABEL (SAFETY) (TEXT)................................................................................... 1
14 74409-G01 LABEL (SAFETY) (PICTOGRAPH)..................................................................... 1
15 74443-G01 LABEL (ANTI-ROLLBACK) ................................................................................. 1
16
17 71413-G01 SPLASH PANEL.................................................................................................. 1
18 16816-G2 RATCHET FASTENER, 1/4" X 3/4" LG............................................................... 5
19
20 71115-G01 VINYL TRIM ........................................................................................................ 2
21 71055-G01 RIVET, 3/16" X 1" LG .......................................................................................... 10
22
23 71468-G** COWL.................................................................................................................. 1
24 71289-G01 NAMEPLATE (E-Z-GO) (OVAL).......................................................................... 1
25 28907-G01 NAMEPLATE (JACOBSEN) (OVAL) ................................................................... 1
26 74401-G01 NAMEPLATE (CUSHMAN) (OVAL)..................................................................... 1
27 71055-G01 RIVET, 3/16" X 1" LG .......................................................................................... 9
28 71055-G01 RIVET, 3/16" X 1" LG .......................................................................................... 6
29 71338-G01 FENDER FLARE (DRIVER SIDE)....................................................................... 1
30 71338-G02 FENDER FLARE (PASSENGER SIDE).............................................................. 1
BODY

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page C-6
Service Parts Manual
31
32 27166-G04 FRONT SHIELD.................................................................................................. 1
33 70725-G02 FRONT SHIELD BRACE..................................................................................... 2
34 01038-G01 SCREW, 1/4 - 20 X 1/2" LG................................................................................. 4
35 16469-G1 WASHER, 1/4" .................................................................................................... 2
36 01057-G01 RIVET, KTR, 1/4" X 1" LG ................................................................................... 2
37
38 74265-G02 BUMPER............................................................................................................. 1
39
40 00570-G2 WASHER, 5/16" .................................................................................................. 2
41 75048-G04 SPACER, 1"......................................................................................................... 2
42 75048-G01 SPACER, 1/2"...................................................................................................... 2
43 00905-G8 LOCK WASHER, 5/16"........................................................................................ 4
44 01035-G02 BOLT, 5/16 - 18 X 2 1/2" LG................................................................................ 4
45
46 71101-G02 COWL SUPPORT BRACKET ............................................................................. 1
47 71102-G02 SELF TAPPING SCREW, 1/4 - 20 X 1/2" LG...................................................... 3
48 71055-G01 RIVET, 3/16" X 1 1/8" LG .................................................................................... 1
49
50 75459-G01 GLOVE BOX DOORS (BOTH SIDES)................................................................ 1
51 75459-G02 GLOVE BOX DOOR (DRIVER SIDE) ................................................................. 1
52 75459-G03 GLOVE BOX DOOR (PASSENGER SIDE)......................................................... 1
53
54 74801-G01 LABEL (MPT™)................................................................................................... 2
55 74805-G01 LABEL (1000)...................................................................................................... 2
56
57 74099-G01 LABEL, TILT WARNING PICTOGRAPH............................................................. 2
58
59 28915-G01 LABEL (JACOBSEN HAULER™) (DRIVER SIDE)............................................. 1
60 28915-G02 LABEL (JACOBSEN HAULER™) (PASSENGER SIDE) .................................... 1
BODY