EZGO TERRAIN 1000 Repair & Service Manual (72V ELECTRIC) – PDF DOWNLOAD
DESCRIPTION:
EZGO TERRAIN 1000 Repair & Service Manual (72V ELECTRIC) – PDF DOWNLOAD
72V ELECTRIC UTILITY VEHICLE TERRAIN 1000
- Many vehicles are used for a variety of tasks beyond their original intended use; therefore it is impossible to anticipate and wam against every possible combination of circumstances that may occur. Warnings cannot replace good common sense and prudent driving practices. Common sense and prudent driving practices do more to prevent accidents and injury than warnings and instructions can provide.
- The manufacturer strongly suggests anyone operating the vehicle read the entire owner’s guide provided with the pur- chase of the vehicle, paying particular attention to the CAUTIONS, WARNINGS and DANGERS within. For any questions or concerns, contact the closest representative. or write to the address on the back cover of this pub- lication. 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. This vehicle is designed and manufactured for off—road use. It does not conform to Federal Motor Vehicle Safety Stan- dards and is not equipped for operation on public streets. Some communities may permit these types of vehicles to be operated on their streets on a limited basis and in accordance with local ordinances.
- Ensure all electrical accessories are grounded to the DC to DC converter negative (—); not to the battery (—) post. Never use the chassis or body as a ground connection.
TABLE OF CONTENTS:
EZGO TERRAIN 1000 Repair & Service Manual (72V ELECTRIC) – PDF DOWNLOAD
SAFETY INFORMATION
GENERAL OPERATION
GENERAL INFORMATION AND ROUTINE MAINTENANCE
SERIAL NUMBER LABEL LOCATION
TRANSPORTING VEHICLE
Towing
Hauling
SERVICING THE ELECTRIC VEHICLE
ROUTINE MAINTENANCE
Recommended Tire Pressures
LIGHT BULB REPLACEMENT
VEHICLE CLEANING AND CARE
VEHICLE CARE PRODUCTS
SUN TOP AND WINDSHIELD
SAFETY
NOTICES, CAUTIONS, WARNINGS AND DANGERS
IMPORTANT SAFETY WARNING
MODIFICATIONS TO VEHICLE
GENERAL MAINTENANCE
BEFORE SERVICING THE VEHICLE
Additional Warnings Specific to Electrical System
BATTERY REMOVAL AND INSTALLATION
LIFTING THE VEHICLE
BODY
BODY COMPONENT REPLACEMENT
Instrument Panel Replacement
Center Compartment Replacement
Cowl Replacement
Brush Guard Replacement
Rocker Panel Replacement
Side Panel Replacement
Rear Fender Replacement
Rear Body Panel Replacement
Minor Scratches
Larger Scratches
Complete Panel Repair
NHEELS AND TIRES
WHEEL AND TIRE SERVICE
Tire Repair
Wheel Installation
FRONT SUSPENSION AND STEERING
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
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
ELECTRONIC SPEED CONTROL
CONTROLLER REPLACEMENT
SOLENOID REPLACEMENT
MOTOR
Motor Replacement
Motor Tests
BATTERIES AND CHARGING
BATTERY MAINTENANCE
At Each Charging Cycle
Monthly
Electrolyte Level and Water
Cleaning Batteries
Battery Replacement
Prolonged Storage
Battery Charging
AC Voltage
Hydrometer
Using A Hydrometer
ELECTRICAL SYSTEM
AWG TO METRIC CONVERSIONS
VOLTAGE TEST FOR BATTERIES
MAIN HARNESS
Power Supply
Accessory Wiring
Faulty VWre Replacement
Headlight Replacement
Taillight Replacement
General
Testing Battery Voltage
Continuity Check
Testing a Switch for Continuity
Testing a Solenoid for Continuity
BRAKES
BRAKE SYSTEM OVERVIEW
General Description
How the Service Brake Works
Equalizer Link
Automatic Adjuster Mechanism
How the Park Brake Works
Kick-Off Actuating Linkage
Compensator Assembly
FAULT DIAGNOSIS FLOWCHART
FAULT DIAGNOSIS TABLE
FAULT DIAGNOSIS AND INSPECTION
NewVehicIe
Fault Diagnosis and Inspection Procedures
Brake Pedal and Linkage Inspection
Periodic Brake Performance Test (PBPT)
Aggressive Stop Test
Wheel Brake Inspection
MAINTENANCE AND REPAIRS
Adjusting Brake Pedal Free Travel
Brake Drum Removal and Installation
Wheel Brake Service
Backing Plate/Entire Wheel Brake Assembly Removal and Installation
Brake Shoe Removal
Brake Shoe Installation
Brake Cable and Equalizer Assembly Removal and Installation
Compensator Assembly. Removal and Installation
Brake Pedal Removal and Installation
Park Brake Catch Bracket Removal and Installation
Park Brake Pedal Removal and Installation
Pedal BumperAdjustment
Park Brake Release Linkage Removal and Replacement
Park Brake Kick-Off Cam Removal, Replacement and Installation
BATTERY CHARGER
CHARGER DESCRIPTION
PORTABLE CHARGER OPTION
REAR SUSPENSION
General
Shock Absorber Removal
Shock Absorber Installation
Rear Spring Removal
Rear Spring Installation
Rear Axle Assembly Removal
RearAxIe Assembly Installation
REAR AXLE
REAR AXLE MAINTENANCE
Checking the Lubricant Level
REAR AXLE DISASSEMBLY
Axle Shaft Removal and Disassembly
Axle Shaft Seal Removal and Replacement
Axle Shaft Replacement
WEATHER PROTECTION
SUN TOP AND WINDSHIELD
Transporting Vehicle
Rear Support Installation
Front Struts
Sun Top
SPLIT WINDSHIELD
FULLWINDSHIELD
Transporting Vehicle
Canopy Top Removal
SPLIT WINDSHIELD
Split Windshield Removal
FULL WINDSHIELD
Full Windshield Removal
ROPS
Headrest Removal and Installation
Grab Handle Removal and Installation
Upper ROPS Frame Removal and Installation
Lower ROPS Weldment Removal and Installation
Front Seat Belt Removal and Installation
Front Seat Belt Buckle Latch Replacement
HANDHELD DIAGNOSTICS
HOW TO USE THE HANDHELD PROGRAMMER
Primary Connection: 4-Pin Tyco
Alternate Connection: 4-Pin Molex
Navigation
Changing Data Value
Bookmark
Main Menu Definitions
Summary of LED Display Formats
TROUBLESHOOTING
ELECTRICAL SYSTEM
Basic Electrical Power System Troubleshooting
Basic Electrical Troubleshooting for Accessories
SUSPENSION AND STEERING
GENERAL SPECIFICATIONS
VEHICLE DIMENSIONS
INCLINE AND TURNING CLEARANCE
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE
APPENDIX A
DELTA-Q USER’S GUIDE
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- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
Kye –
Still waiting for the seller to resolve the issue I already wrote about. That is why I gave a neutral 3 star rating until the issue is resolved