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SERVICE MANUAL - Custom Golf Carts by ACG, Inc.

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1. After lubricating work the slide back and forth to ensure that it slides smoothly and easily Reinstall rubber boot onto backing plate WARNING Apply grease carefully when performing the following steps Do not allow any grease to get onto the friction surfaces of the brake shoe pads Failure to heed this warning could cause diminished brake performance possibly resulting in property damage or severe personal injury 4 Use a small brush to carefully apply a light coat of white lithium grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on the brake backing plate Figure 6 9 5 Use a small brush to carefully apply a light coat of white lithium grease Dow Corning BR2 Plus or equivalent on each end of both brake shoes and into the slots in the brake shoe mounting block as show Figure 6 11 See preceding WARNING 6 Use a small brush to carefully apply a light coat of white lithium grease Dow Corning BR2 Plus or equivalent to the brake adjuster assembly adjust wheel shoe slots and the shaft of the adjuster wheel as shown Figure 6 11 See preceding WARNING 7 Install the adjust wheel 1 and two washers 2 and 3 into the adjuster assembly Figure 6 7 SiS Zo Jo a Soul Figure 6 8 Service Manual ACG Page 30 Service Manual ACG Page 31 BRAKE SHOE INSTALLATION Read Warning in previous section 1 Turn the adjusting wheel screw so that the shoe slot is vertical then posi
2. Remove E clip 4 from cable at the cable support bracket 5 Remove cable from bracket Note routing of cable through hanger for installation of new cable Pull cable from vehicle Brake Cable Installation Place end of the new cable into the equalizer 4 Figure 6 18 Secure the cable to the vehicle frame with new E clip Route cable through hanger in the same manner as before At the rear wheel brake connect the cable to the brake actuator arm using new clevis pin 2 and new cotter pin 1 Figure 6 19 Place the cable in the cable support bracket 5 and secure with new E clip 3 Adjust the brakes See Brake Adjustment Equalizer bracket may be _ inverted on some vehicles Figure 6 18 Service Manual ACG Page 37 SECTION 7 STEERING AND FRONT SUSPENSION WARNING Only trained technicians should repair or service the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in
3. gt TRN V BA LOUKS Figure 7 11 Secure Rack in Vise 2 Bend the edges of the tab washer 4 up against the ball joint 3 3 Apply a liberal amount of EP grease to the teeth of the rack 17 then slide the rack through the housing 6 Install the stop washer 18 and retaining ring 19 to the end of the rack Figure 7 12 CAUTION In Step 4 do not pass against the outer race of the bearing 4 f the bearing 9 was removed press on a new bearing exerting all pressure on the inner race grease the bearing before installing it Then install the external snap ring 10 Figure 7 12 5 If the needle bearing 7 is damaged the steering box assembly must be replaced Figure 7 12 6 Install pinion 8 and bearing 9 assembly into the housing 6 Figure 7 12 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly while lightly tapping on the pinion bearing assembly with a rubber mallet See following CAUTION CAUTION Do not force the pinion bearing assembly into the housing The gear teeth or the small bearing could be damaged 7 Install the internal snap ring 11 Figure 7 12 8 Using a socket to apply pressure evenly press in a new dust seal Figure 7 13 Service Manual ACG Page 47 Figure 7 13 Press in Dust Seal 9 Apply a small amount of grease to the rack guide 13 where it comes into contact with the rack 17 Figure 7 1
4. 12 See following Note DRON Note If the dust seal 12 is removed replace with a new one Figure 7 12 9 Using snap ring pliers remove the internal snap ring 11 Figure 7 12 10 Install the universal joint to the pinion and place a large open end wrench under the universal joint Figure 7 9 Use the wrench as a lever to pull the pinion from the housing 11 If the ball bearing 9 has been damaged remove the external snap ring 10 Figure 7 12 and press the bearing off Figure 7 10 12 Remove the retaining ring 19 and stop washer 18 then remove rack 17 from housing 6 Figure 7 12 13 If the inner ball joint 3 is excessively worn remove the ball joint and tab washer 4 from the rack by securing the rack in a vise Figure 7 11 Using wood blocks between the rack and the jaws of the vise to protect the rack from damage loosen and remove the inner ball joint with a wrench 14 Inspect the bushing inside the steering box assembly 6 for excessive wear If wear is excessive replace the steering assembly Figure 7 12 Service Manual ACG Page 46 RACK AND PINION ASSEMBLY 1 Install a new tab washer 4 and an inner ball joint 3 Figure 7 11 Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball joint to 60 ft lb 81 Nm A Pa 3 INNER 4 BALL TAB WASHER JOINT N VISE
5. 27 and steel sleeves 28 Replace any that are worn or damaged KINGPIN AND STEERING SPINDLE REMOVAL N gt NOOR S Remove the front hub See Front Wheel Bearings and Hubs Remove cotter pins 22 and nuts 20 and then remove ball joints from the spindles Figure 7 20 Remove drag link ball joint See also Tie Rod and Drag Link Removal Remove the nut 17 and lock washer if present from the top of the king pin 26 Figure 7 21 Raise the upper clevis 16 from the kingpin Figure 7 21 Remove the thrust washer 19 Slide the spindle off the king pin 26 Remove the wave washer 20 and inspect it If the washer is broken or has a wave bottom to wave crest height dimension of less than 040 inch 10 cm it must be replace Remove bolt 25 and nut 14 from bottom of king pin 26 and remove kingpin Inspect the kingpin and spindle If either is worn or damaged it must be replaced Inspect the bushings 3 and 4 If the bushings are worn or damaged remove them and press in new ones See following Note Note If the bushings are replaced ream new bushings to 750 752 3 4 inch 19 05 19 10 mm in diameter The reamer should be long enough to ream both bushings from one direction KINGPIN AND STEERING SPINDLE INSTALLATION _ Inspect all parts and replace them as necessary Install the king pin 26 over the leaf spring eye Insert the bolt 25 and install the nut 14 Figure 7 21 Tighten the b
6. 4 Y ed h EA i Qo 5 ELECTRIC 2Y VEHICLE 14 2 SEE SECTION 9 REAR SUSPENSION FOR MOUNTING Figure 6 1 Service Manual ACG Page 26 BRAKE SHOE REMOVAL READ PREVIOUS WARNING 1 2 Disconnect batteries as instructed See previous WARNING Place chocks at the front wheels Loosen but do not remove lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle Loosen the equalizer retaining nuts 2 and 3 on the equalizer rod 1 to loosen the brake cable Figure 6 2 Equalizer bracket may be inverted on some vehicles 1 Figure 6 2 Remove the rear wheels and then the brake drums If the brake drums were easily removed proceed to Step 6 Note When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal methods proceed to Step 5 to minimize damage to the brake cluster and brake components Remove brake drums and badly worn brake shoes 5 1 On the back of each brake cluster assembly locate the heads of two brake shoe retainer pins It may be necessary to remove sealant material around the head of each pin 5 2 Insert a 1 2 inch x 5 8 inch cold chisel under the head of each pin and shear them off as illustrated Figure 6 4 This will release the shoes from the backing plate allowing them to pivot away from the inside of the brake drum which
7. chain hoist or hydraulic floor jack with 1000 Ib 454kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 2 Place a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock absorbers without compressing them 3 Remove the tire and wheel assembly on the side from which the spring is to be removed 4 Remove the cotter pin 1 and the clevis pin 2 at the brake lever and brake cable connection and pull the clevis 3 away from the lever Figure 9 3 Detach the brake cable from the shock mount bracket 5 Remove the nut 5 cup washer 9 and rubber bushing 10 from the lower mounting stem of the shock absorber 6 Remove the nuts 14 and the U bolt 11 securing the spring to the transaxle Remove the shock mount bracket 16 and the U bolt 7 Remove the bolt 15 and nut 2 attaching the rear spring to the shackle 1 8 Remove the nut 2 and bolt 15 attaching the front of the spring to the vehicle frame and remove the spring 9 Inspect the bushings 4 and spacers 3 in the spring eyes and replace them if they are worn or damaged LEAF SPRING INSTALLATION 1 To install the spri
8. 29 Figure 7 21 3 Loosen do not remove the hex nut 8 on the adjustment eccentric adjuster 7 Figure 7 17 in the center of the spring Use a 7mm deep well socket to rotate the eccentric Figure 7 17 After adjusting camber tighten the four spring retaining bolts 30 Figure 7 21 to 23 ft lb 31 Nm Then roll the vehicle forward one full tire revolution and recheck the camber 6 Tighten the hex nut 8 on the adjustment eccentric 7 to 10 ft lb 13 5 Nm Figure 7 21 as Toe in Adjustment 1 Ona level surface roll the vehicle forward and then stop Make sure the front wheels are pointed straight ahead Do not turn the steering wheel again during this procedure 2 One each front tire mark as closely as possible the center of the tread face that is oriented toward the rear of the vehicle The marks should be even with the bottom surfaces of the vehicle frame beams 3 Measure the distance between the marks on the rear facing surfaces of the tires and then roll the vehicle forward on and one half wheel revolutions until the marks appear on the forward facing surfaces of the tires at about the same height from the floor Figure 7 18 4 Measure the distance between the marks on the forward facing surfaces of the tires Figure 7 18 Note The front measurement must be less than the rear measurement Service Manual ACG Page 52 5 Subtract the measurement on the front of the tires from the measurement on t
9. 6 7 Slide the shaft out of the tube to expose the retaining ring Use pliers to twist the retaining ring until it breaks off then remove the wedge Remove the shaft from the bottom of the tube Use steering shaft to push bearing seat out from the opposite end of the steering tube Insert a flat blade screwdriver between the bottom of the outer race of the bearing and the bottom lip of the bearing seat and remove the bearing Service Manual ACG Page 41 STEERING COLUMN ASSEMBLY 1 Insert bearing seat into both ends of steering tube Place a block of wood on bearing seat and tap lightly on block until bearing seat is fully seated in steering tube 2 Press the bearing all the way into the bearing seat using a steering column bearing press tool or a metal tube approximately six inches 15 2 cm long with a maximum outer diameter of 1 3 16 inches 3 3 cm and a minimum inside diameter of 7 8 in 2 2 cm Be sure the bearing is installed in the bearing seat as shown Figure 7 5 so the wedge 16 will ride against the inner race of the bearing 3 Install the wedge 16 spring 15 washer 14 and snap ring 13 onto the bottom end of the steering shaft 19 Figure 7 5 4 Insert the shaft from the bottom of the steering tube 5 Turn the assembly over and place the shaft 19 on a bench Install the wedge 16 and retaining ring 22 onto the top of the shaft Be sure the prongs on the retaining ring face up and away from the wedge U
10. TIRE TIRE BEADS POSITIONED IN RIM WELL z RIM LOWER FLANGE IHE BEADS VALVE STEM SIDE UP V Km B c Figure 8 1 Figure 8 2 Service Manual ACG Page 59 SECTION 9 REAR SUSPENSION WARNING Only trained technicians should repair or service the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle owner s manual for proper location of al vehicle warning decals and make sure they are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot motor resistors engine o
11. amp Continuous Reduced Speed Reverse Self adjusting Rack and Pinion Aluminum I beam One piece fiberglass composite Marine type vinyl Marine type synthetic 21 25 mph 9 ft 2 Service Manual Page 9 SECTION 3 GENERAL INFORMATION Throughout this section important features unique to each model are highlighted We urge the owner operator to read and understand this section and to pay special attention to the features specific to the vehicle s Refer to the owner s manual provided with the vehicle for information on the following topics Controls and indicators Driving instructions Towing Transporting on a trailer Subsequent owner registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of each American Custom Golf Cars Inc vehicle is printed on a decal mounted in two places in the passenger side glove box and under the hood near the pop up hood latch Note Always have the vehicle identification number at hand when ordering parts or making inquiries SAFTEY COMMITTEE If the vehicle golf cart or NEV is to be rented or is part of a fleet we strongly recommend that a safety committee be appointed One of the main concerns of this committee should be the safe operation of the vehicles This should include at a minimum Where the vehicles should be driven Ensuring that proper warnings of driving hazards are displayed and visible See below for list of signs available from American C
12. between dash and cowl brace Gently pry center dash out slightly from under edge of cowl brace 8 Pull center dash out approximately 1 inch 2 5cm from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down Note Bending the top right corner of the center dash inward during removal will prevent the contracts on the back of the key switch from touching the metal frame around the dash Disconnect the wires from the electrical components mounted on the dash panel Do not allow wires to touch Slide center dash panel up the steering column Remove the driver side dash pocket Remove cup holder hardware and cup holder Remove the flange lock screw from the top of the dash pocket Drill out the two pop rivets holding the dash pocket in place Slide dash pocket out of vehicle Remove the upper bolt and lock washer from the universal joint Remove the nuts bolts and washers from the steering column mount Remove the steering column from the vehicle STEERING COLUMN DISASSEMBLY 1 2 Remove screws and mount from steering column Remove boot While supporting steering column on a workbench remove snap ring from shaft Note Do not allow the steering shaft to slide out of the steering tube when removing the snap ring 3 Remove the washer spring and wedge Note Use a new seal retaining rings and new bearings for reassembly 4 5
13. is taken out of the brake cables Figure 5 25 Tighten the nut 2 on the equalizer rod 1 so that the brake pedal free play is to 1 2 inch 6 3 to 12 7mm Figure 5 26 Tighten the jam nut while holding 3 while holding the adjustment nut 2 in the correct position Figure 5 26 Adjust park brake ratchet pawl gap and pawl engagement pawl or ratchet is damaged both must be replaced Adjust retaining nut 7 on spring support rod until there is a 060 inch 1 5mm gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap The gap should be consistent through the range of pawl movement If the gap is not consistent loosen the four bolts 6 securing the accelerator pivot rod supports and adjust the supports If the gap becomes smaller as the park brake pedal is depressed move the pivot rod supports slightly rearward until the gap is consistent If the gap becomes larger as the park brake pedal is depressed move the pivot rod supports slightly forward until gap is consistent With the park brake unlocked measure and note the distance from the top of the accelerator pedal to the floorboard and then lock the park brake With the park brake locked make sure at least 75 of ratchet tooth length engages the pawl Tooth engagement should be between the two lines marked on the pawl With park brake still locked measure the distance from the top of accelerator pedal to floorboard If the measurement has c
14. severe personal injury or death Check the vehicle owner s manual for proper location of al vehicle warning decals and make sure they are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot motor resistors engine or exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Turn the key switch OFF and remove key place Forward Reverse handle or switch in the NEUTRAL position and chock the wheels prior to servicing the vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Fi
15. should then allow the brake drum to be pulled free After completing Step 6 skip step 7 Note Although Step 6 Removing the Axle allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes Remove the axle 6 1 Using 90 snap ring pliers remove the axle retaining ring 1 Figure 6 3 6 2 Pull the axle shaft 2 from the axle tube Figure 6 3 Service Manual ACG Page 27 6 Using needle nose pliers turn the clip retainer 1 90 to remove the shoe retainer clip 2 Figure 6 5 CAUTION The brake shoes are under and can release suddenly when brake shoe retainers are removed 7 Grasp both brake shoes and pull them together with the springs out of the brake assembly Figure 6 6 8 Remove adjuster wheel 1 with two washers 2 and 3 from the backing plate Figure 6 7 Figure 6 3 i TWO BRAKE SHOE RETAINER PIN ANY SL AXLE TUBE li 1 2 IN X 5 8 IN COLD CHISEL Figure 6 4 Service Manual ACG Page 28 A lt Ne 3 9 A SAO kS Figure 6 6 Figure 6 7 Service Manual ACG Page 29 BRAKE ASSEMBLY CLEANING Read WARNING 1 Carefully clean the brake backing plate and ball of its mechanical components 2 Remove the rubber boot from backing plate and wipe with a clean damp cloth 3 Lubricate the slide 1 and slide plate 2 with dry moly lubricant on both sides of the backing plate Figure 6 8
16. the grooved end onto the inner ball joint 3 CAUTION The ball joint 23 Figure 7 12 has left hand threads The tie rod and drag link have right hand threads on one end and left hand threads on the other end Right hand threads are indentified by a groove in the tie rod or drag link 17 Install the ball joint 23 See preceding CAUTION 18 Adjust the steering See Steering Adjustment Service Manual ACG Page 49 RACK AND PINION INSTALLATION 1 Position the steering gear box assembly on the shock and gear support and install the bolts 30 washers 31 and nuts 32 Do not tighten the mounting bolts Figure 7 12 2 For ease of assembly and to prevent corrosion apply a light coat of anti seize and lubricating compound to the splined end of the steering column shaft 3 Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft into the upper universal joint Install the bolt and lock washer on the upper universal joint and tighten to 15 ft lb 20 Nm 4 Tighten the steering rack mounting bolts 30 to 22 ft lb 29 8 Nm Figure 7 12 5 Adjust the steering See Steering Adjustment Service Manual ACG Page 50 TIE ROD AND DRAG LINK Read WARNING at beginning of section TIE ROD AND DRAG LINK REMOVAL gt AGN Using locking pliers to hold tie rod and drag link loosen jam nuts 7 and 12 on the tie rod ball joints Figure 7 20 and loosen jam nut
17. water dampened cloth to remove any remaining bleach concentration CAUTION To prevent damage to the vehicle when removing difficult stains or heavy soiling remove the seat bottom from the vehicle first FRONT AND REAR BODY REPAIR CAUTION Holding the heat gun too close to the body could melt the body or damage the finish SMALL SCRATCHES THAT CANNOT BE BUFFED OUT 1 Thoroughly clean the affected area with alcohol and then dry thoroughly 2 Using 240 grit or finer paper to remove gloss from the surface Sand as little body surface as possible beyond scratch Service Manual ACG Page 13 SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP WARNING Only trained technicians should repair or service the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle owner s manual for proper location of al vehicle warning decals and make sure the
18. 2 10 Place a few drops of Loctite 222 on the threads of the screw 16 Figure 7 12 11 Install the rack guide 13 pressure spring 14 and screw 16 The screw should be threaded in until a rotational torque of 10 in lb 1 13 Nm is achieved Figure 7 12 Reposition the rack and pinion in a vise Insert a 3 8 inch deep well socket into the steering column end of the universal joint 2 and tighten the bolt 1 to 15 ft lb 20 3 Nm Figure 7 15 Use a torque wrench connected to the 3 8 inch deep well socket to measure the resistance of the rack and pinion Rotational resistance should measure 7 to 15 in lb 8 to 1 7 Nm If measured resistance does not equal 7 to 15 in lb loosen the lock nut 15 and tighten the screw 16 until it bottoms out then back the screw off one quarter turn Tighten the lock nut to 28 ft lb 38 Nm Figure 7 14 Note When tightening the lock nut 15 make sure the screw 16 does not change adjustment Figure 7 14 3 8 INCH 1 4 DRIVE DEEP WELL SOCKET Figure 7 14 Rack and Pinion Adjustment Figure 7 15 Rack and Pinion Resistance 12 Install the dust seal bellows 20 and retaining ring 21 Figure 7 12 13 Install the dust seal bellows 1 and hex nut 29 Service Manual ACG Page 48 14 Install the universal joint on the pinion Tighten the bolt to 15 ft lb 20 Nm 15 Install new bellows clamps wire ties 2 16 Install the drag link 28 by fully threading
19. ACG Page 44 _ PRESS RAM __PINION GEAR _ BEARING Figure 7 10 Remove Bearing from Pinion Figure 7 12 Steering Gear Service Manual ACG Page 45 RACK AND PINION Read WARNING at beginning of this section RACK AND PINION REMOVAL gt Remove the front body as instructed in Section 4 2 Remove the cotter pin 22 and ball joint retaining nut 25 Figure 7 12 3 Using a ball joint removal tool remove the ball joint 23 Figure 7 12 from the spindle assembly See Figure 7 8 4 Remove the bolts 30 washers 31 and lock nuts 32 from the steering rack assembly mounting bracket Figure 7 12 5 Remove the bolt and washer on the upper universal joint and then remove the rack assembly and universal joint from the vehicle RACK AND PINION DISASSEMBLY CAUTION The ball joint 23 Figure 7 12 has left hand threads Remove ball joint 23 and inspect it for excessive wear Figure 7 8 Remove the drag link 28 Figure 7 12 Remove both bellows clamps 2 plastic wire ties Remove the hex nut 29 and slide off the dust seal bellows 20 Remove the retaining ring 21 and then slide off dust seal bellows 20 Remove the rack screw lock nut 15 rack guide screw 16 rack guide pressure spring 14 and the rack universal joint 7 Remove the universal joint assembly from the pinion 8 by fully removing the bolt and then sliding off the universal joint 8 If necessary remove the dust seal
20. Do not attempt to service vehicle while it is running Hot Do not attempt to service hot motor resistors engine or exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Turn key switch OFF and remove key place Forward Reverse handle or switch in the NEUTRAL position and chock the wheels prior to servicing the vehicle To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 After disconnecting the batteries discharge the controller capacitors as follows Turn the key switch to ON and place the Forward Reverse handle in the REVERSE position Slowly depress the accelerator pedal and keep depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged CAUTION Do not use detergents or cleaning solvents that contain ammonia aromatic solvents or alkali materials on body panels or seats Do not allow battery acid to drip on body panels Battery acid will cause permanent damage Wash spilled battery acid from body panels immediately Service Manual ACG Page 12 CLEANING THE VEHICLE Read DANGER and WARNING in SECTION 1 SAFTEY American Custom Golf Cars Inc vehicles are equipped with composite front and rear bodies Use only commercially available aut
21. Figure 6 17 Remove the screwdriver 7 Install the axle shaft 2 into the axle tube and install the retaining ring 1 Figure 6 3 See following WARNING and CAUTION WARNING Be sure retaining ring is properly seated in groove If ring is not properly installed the axle assembly will separate form the transaxle and damage the axle assembly and other components Loss of control of the vehicle could result in severe personal injury or death CAUTION Before installing axle shaft clean any residual oil from the exposed end of the axle tube and from the oil seal area 8 Install the brake drum and make sure that it is properly seated See following NOTE Note If drum installation is difficult the brake shoes may need to be adjusted vertically in the mounting slots 9 After the drum is installed make sure the axle and drum turn freely and then install the wheel See Wheel Installation Section 8 Service Manual ACG Page 32 Figure 6 12 Figure 6 13 BRONZE SPRING SPRING COILS SILVER SPRING Note that the silver spring is mounted with the coils to the side of the adjustment lever spring A Figure 6 14 Service Manual ACG Page 33 Figure 6 15 Figure 6 16 ADJUSTING ADJUSTING WHEEL Figure 6 17 Service Manual ACG Page 34 BRAKE ADJUSTMENT Read WARNING at beginning of section 1 When cleaning or repair on both wheels is complete and with the brake
22. Forward Reverse handle in the REVERSE position Slowly depress the accelerator pedal and keep depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged Service Manual ACG Page 14 GENERAL INFORMATION To properly service and adjust the pedal group the accelerator type must be identified before the work begins All American Custom Golf Cars Inc vehicles use a 2 wire or 3 wire potentiometer Service and adjustment procedures differ significantly so it is important to make sure that the correct procedure is used BRAKE PEDAL AND PARK BRAKE 1 Disconnect batteries as instructed See WARNING on page 14 2 Place chocks under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands for proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Remove the brake pedal assembly Disconnect the equalizer rod 13 from the pedal shaft by removing the bolt 14 and nut 15 Figure 5 5 Remove the nuts 5 fla
23. ICAL Ws 4PLACES _ o gt RY O 22 lt e AN K 7 26 P i o G Figure 5 8 Service Manual ACG Page 21 PEDAL GROUP ADJUSTMENT Disconnect the batteries as instructed See WARNING on page 14 Adjust brake pedal height 3 Chock wheels and release park brake Lift rear of vehicle and place jack stands under the axle tubes to support the vehicle 4 To provide slack in the brake cables loosen the equalizer retaining nuts 2 and 3 on the equalizer rods 1 Figure 5 23 5 Loosen the brake stop am nut 31 and then relieve pedal pressure on the stop by pushing down slightly on the pedal Next adjust the brake stop bumper 22 up or down Figure 5 24 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases the distances between pedal and floorboard Proper brake pedal height is 6 inches 15 2 cm Figure 5 25 6 Tighten the jam nut 31 to 8 ft lb 9 5 Nm Page 5 18 7 Adjust brake pedal free play Note Brake pedal free play is the distance the brake pedal can be depressed before the brake actuator arm at the brake cluster moves 8 10 11 Inspect the park brake pawl and ratchet for excessive wear grooves cracks or chips If either the 13 14 15 16 17 22 Measuring perpendicular from the floorboard to the back of the brake pedal depress the brake pedal and measure the distance that the pedal moves before all of the slack
24. R WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle owner s manual for proper location of al vehicle warning decals and make sure they are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot motor resistors engine or exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support
25. Use new cotter pins when installing brake cables CAUTION Before installing axle shaft clean any residual oil from the exposed end of the axle tube and from the oil seal area 2 Be sure bolt 11 and new lock nuts 10 are used to mount the brake assembly Figure 6 1 3 Torque bolts to 30 ft lb 40 6 Nm WARNING Be sure retaining ring is properly seated in groove If ring is not properly installed the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of control of the vehicle could result in severe personal injury or death 4 Tighten lug nuts on rear wheels using crisscross pattern to 55 ft lb 74 6 Nm See Wheel Installation Section 8 5 Adjust the brakes See Brake Adjustment Service Manual ACG Page 36 BRAKE CABLE REMOVAL AND INSTALLATION Read WARNING at beginning of this section Brake Cable Removal Disconnect batteries as instructed See Warning at beginning of section Place chocks at the front wheels Release the park brake if latched and loosen equalizer retaining nuts 1 on equalizer rod 2 to loosen the brake cables 3 Figure 6 18 Rotate the brake cable upward and pull cable end through the hole in top of equalizer 4 Remove E clip from cable at vehicle frame 5 Figure 6 18 Remove cable from frame Remove cotter pin 1 and the clevis pin 2 from the brake lever on each wheel and pull the clevis 3 away from the lever Figure 6 19
26. ack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands for proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 4 O Disconnect the accelerator rod assembly 17 18 and 19 Figure 5 8 at the front and rear ball studs and remove it from the vehicle Using a 9 16 inch sock and 9 16 inch wrench remove the nut 23 two washers 25 and bolt 4 securing the accelerator pedal 1 to the pivot rod 6 Remove the nut 10 and ball stud 16 from the accelerator pivot rod assembly 6 Slide the spring retainer 11 off of the accelerator pivot rod Inspect the pivot support bearing 9 for wear and replace if necessary Use a marker to mark the position of the park brake ratchet 24 on the accelerator pivot rod 6 See following Note Note Failure to mark position of the ratchet could cause it to be reinstalled improperly resulting in improper adjustment and possible failure of the park brake 9 10 11 12 13 Inspect all parts for wear and
27. ble lifting device chain hoist or hydraulic floor jack with 1000 Ib 454kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Turn the key switch OFF and remove key place Forward Reverse handle or switch in the NEUTRAL position and chock the wheels prior to servicing the vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 After disconnecting the batteries discharge the controller capacitors as follows Turn the key switch to ON and place the Forward Reverse handle in the REVERSE position Slowly depress the accelerator pedal and keep depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged Service Manual ACG Page 25 GENERAL INFORMATION American Custom Golf Cars Inc vehicles are equipped with self adjusting mechanically expanding shoe drum brakes on each rear wheel Components are shown in Figure 6 1 TYPICAL 4 14 10 PLAcEs 11 10 r TYPICAL 4 j M PLACES M gt DETAI PLACES UE lt SN TYPICAL 2 pod 16 PLACES gt GASOLINE EN Ke VEHICLE s aa 4 Q 08 PD 29
28. cable still loose lower the vehicle to the floor 2 Depress and release the brake pedal repeatedly until an audible clicking can no longer be heard 3 Adjust brake pedal free play Service Manual ACG Page 35 BRAKE CLUSTER REMOVAL AND INSTALLATION Read WARNING at beginning of this section Brake Cluster Removal 1 Disconnect batteries as instructed See WARNING at beginning of section 2 Place chocks at the front wheels and loosen the lug nuts on the rear wheels Lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle 3 Loosen the equalizer retaining nuts 2 and 3 on the equalizer rod 1 to loosen the brake cable Figure 6 2 4 Remove lug nuts and rear wheels and then the brake drums Note When servicing vehicles with self adjusting brakes with badly worn brake shoes and when the drums cannot be removed by normal methods perform Step 5 of Brake Shoe Removal then continue this procedure 5 Remove the axle 5 1 Using 90 snap ring pliers remove the axle retaining ring 1 Figure 6 3 5 2 Pull the axle shaft 2 from the axle tube Figure 6 3 6 Remove cotter pin 13 and clevis pin 12 from brake cable Figure 6 1 7 Remove four bolts 11 and lock nuts 10 that mount the brake assembly to the transaxle Figure 6 1 8 Remove brake assembly from transaxle Brake Cluster Installation 1 Install in reverse order of disassembly
29. cause of the air leak has been determined remove tire from the rim and repair as required See Tire Removal TIRE INSTALLATION WARNING While mounting or inflating tire keep hands fingers etc from exposed areas between the tire bead and rim 1 Clean both tire beads to remove dirt or other foreign matter 2 Where the tire beads seat clean the wheel rim with a wire brush Wipe away any debris with a clean cloth Note Because tubeless tires require a perfect seal in order to seat keeping the tire and rim clean is very important 3 Apply a liberal amount of tire mounting lubricant soap and water solution to both tire beads and rim flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position tire so that both beads are on the rim flange narrow bead seats 6 Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30 35 psi 2 07 2 42 Bars The three point contact wall floor and hand will help ensure that beads snap into place and form a proper seal as tire is inflated Figure 8 2 See following Quickly remove the air nozzle and install the valve core Adjust air pressure in tire to recommended pressure Immerse the wheel and tire assembly in water to make sure there no leaks oo Service Manual ACG Page 58 TIRE TOOL UPPER
30. connecting the batteries discharge the controller capacitors as follows Turn the key switch to ON and place the Forward Reverse handle in the REVERSE position Slowly depress the accelerator pedal and keep depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged Service Manual ACG Page 56 GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care Keep tires properly inflated Keep lug nuts properly torqued Keep the front end aligned and adjusted WHEELS Read WARNING at beginning of section WHEEL REMOVAL 1 Slightly loosen the lug nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure that the wheels are off the ground 3 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install wheel s and tighten the lug nuts using a crisscross pattern until they are snug 2 Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 Nm TIRES Read WARNING at beginning of section TIRE REMOVAL Note Tire must be removed or installed from the valve stem side of the rim 1 Remove the tire and wheel assembly from the vehicle as instructed above 2 Remove the valve cap and valve core and allow air to escape from the tire 3 If possible use a tire machine to remov
31. damage Replace as necessary Remove the lock nut 26 from the accelerator pivot shaft Figure 5 8 Depress the brake pedal slightly then slide the park brake ratchet 24 toward the end of the accelerator pivot rod Rotate the ratchet and remove it from the pivot rod Remove the pivot rod 6 and spacer 20 from the accelerator pivot rod supports 21 Figure 5 8 Inspect the accelerator pivot rod supports 21 for wear or damage and replace as necessary If the pivot rod supports do not require replacement loosen but do not remove the four bolts 22 and lock nuts 15 to make installation easier Remove the accelerator pedal 1 from the vehicle Service Manual ACG Page 19 ACCELERATOR PEDAL INSTALLATION N Oo w If the accelerator pivot rod supports were replaced position the supports 21 on the vehicle frame and install the four bolts 22 flat washers 8 and lock nuts 15 Finger tighten nuts at this time Figure 5 8 page 5 8 Insert the lower end of the accelerator pedal 1 through the floorboard and install the accelerator pivot rod 6 though the uppermost hole in the pedal Install the plastic spacer 20 on the pivot rod Insert the pivot rod through the pivot rod supports on the vehicle frame Tighten the four bolts 22 attaching the pivot rod supports to the frame to 75 in lb 8 5 Nm Insert the bolt 4 through the lower hole in the pedal and through the pivot rod Install the two washers 25 and nu
32. e base plate contacts the bottom of the steering wheel where it attaches to the steering column Using 1 2 inch drive air impact wrench tighten the anvil screw until the steering wheel breaks free from the steering shaft 10 Remove the steering wheel puller 11 Remove the steering wheel nut and the steering wheel from the steering column STEERING WHEEL INSTALLATION Note To minimize corrosion and to make future removal of the steering wheel easier apply a small amount of oil or anti seize compound to steering shaft splines and taper before installing the steering wheel 1 2 3 Install the steering wheel on the splines of the steering shaft Be sure to align the match marks placed on the wheel and steering column in step 3 above Install the steering wheel nut and tighten to 13 ft lb 17 6 Nm Install the scorecard plate and plate mounting screws Tighten screws to 16 in lb 1 8 Nm Service Manual ACG Page 40 STEERING COLUMN Read WARNING at beginning of this section STEERING COLUMN REMOVAL 1 Disconnect batteries as instructed 2 Remove the steering wheel as previously instructed 3 Remove the front body as instructed in Section 4 Body and Trim 4 Remove the center dash panel 5 Remove the plastic cap covering the mounting screw on each side of the center dash panel 6 Loosen but do not remove the screw on each side of the center dash panel 7 Insert screwdriver at the top center of the dash
33. e the tire from the rim a If a tire machine is not available loosen both tire beads by applying pressure to the tire side walls and pushing the tire bead away from the rim flange and into the rim well Figure 8 1 Detail A b With the valve stem side of the wheel up use a tire tool to carefully start the upper bead over the edge of the wheel rim Figure 8 1 Detail B CAUTION To avoid damage to the tire do not use excessive force when starting the bead over the edge of the rim 4 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Detail C and carefully pry the lower bead over the rim flange 5 Once the lower bead is started over the rim the tire can be removed from the rim by hand Service Manual ACG Page 57 TIRE REPAIR 1 Determine the location and cause of the air leak 1 1 Remove the wheel See Wheel Removal Inflate the tire to no more than 20 psi 1 38 Bars 1 2 Immerse the tire in water and then mark the point where bubbles are formed by escaping air 1 3 Determine the cause of the air leak See following Note Note An air leak could be due to a punctured casing faulty valve core improperly seated valve stem or improperly seated tire bead Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores 2 When the
34. ew Tighten to 20 ft lb 27 Nm Install the bolt and lock washer on the upper universal joint and finger tighten Tighten the two nuts and bolts to 17 ft lb 23 Nm Tighten the bolt on the upper universal joint to 15 ft lb 20 Nm Check the other two bolts on the universal joint to ensure that they are properly tightened to 15 ft Ib 20 Nm Reinstall dash pocket and related hardware 0 Reinstall center dash panel in reverse order of disassembly Make sure the key switch terminals do not touch the frame and the center dash panel is properly seated and snapped into place 11 Install front body and bumper See Section 4 Body and Trim NO UP O Service Manual ACG Page 43 STEERING ADJUSTMENT Read WARNING at beginning of this section 1 Turn the steering wheel all the way to the right Note the distance between the passenger side spindle stop 2 and passenger side A plate 3 Figure 7 7 The internal stop on the rack must reach its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the passenger side A plate with vehicle wheels turned to the right If simultaneous contact occurs steering is in correct adjustment Proceed to Step 4 If simultaneous contact does not occur proceed to Step 2 Loosen the nuts 27 and 29 and turn the drag link 28 Figure 7 12 to adjust the drag link rod Adjust the link rod with the steering wheel turned all the way to the right so t
35. gure 1 2 1 3 or 1 4 After disconnecting the batteries discharge the controller capacitors as follows Turn the key switch to ON and place the Forward Reverse handle in the REVERSE position Slowly depress the accelerator pedal and keep depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged Service Manual ACG Page 39 GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel No manual adjustment to the rack and pinion gear assembly is required A spring loaded self adjusting mechanism is incorporated into the assembly STEERING WHEEL Read WARNING at beginning of this section STEERING WHEEL REMOVAL _ gt O 9 Disconnect batteries as instructed See WARNING at beginning of section Remove the two mounting screws and plate Match mark the steering wheel and steering shaft so when the steering wheel is removed it can be place back in exactly the same position on steering column shaft Loosen the steering wheel nut and back it off approximately 1 4 inch 6mm Do not remove the nut Use the steering wheel puller to remove the steering wheel Place the puller anvil through the top opening of the steering wheel Insert the anvil feet through the two slots in the base plate marked B Rotate the anvil screw clockwise until th
36. hanged ratchet tooth engagement is too deep and must be adjusted If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Check for proper brake operation prior to driving the vehicle Adjust accelerator pedal height Loosen the nut and bolt Figure 5 31 securing the accelerator pedal to the pivot plate Clamp the accelerator pedal adjustment tool to the accelerator pedal with the end marked accelerator pedal height closest to the floorboard Figure 5 32 Depress the accelerator pedal until the end of the tool rests against the floorboard pedal height should be 5 5 8 inches 14 3 cm Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft lb 35 3 Nm Adjust the brakes See Brake Adjustment Section 6 Service Manual ACG Page 22 Equalizer bracket may be inverted on some vehicles Figure 5 23 Figure 5 24 Correct pedal position is 6 inches 15 2 cm from floor mat to back of brake pedal k gt Figure 5 25 Service Manual ACG Page 23 1 4 inch to 1 2 inch 6 3 to 12 7 mm Figure 5 26 Figure 5 31 RUBBER STRAP Figure 5 32 Service Manual ACG Page 24 SECTION 6 WHEEL BRAKE ASSEMBLIES WARNING Only trained technicians sho
37. harge Adjust tires to recommended tire pressure Lubricate front suspension and do all other semiannual periodic lubrication See Periodic Lubrication Schedule Section 10 Periodic Maintenance in the appropriate Maintenance and Service Supplement Thoroughly clean front body rear body seat battery compartment and underside of vehicle Do engage the park brake Chock the wheels to prevent the vehicle from rolling Keep batteries fully charged during storage RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE BOD If necessary connect batteries Fully charge batteries Adjust tire to recommended pressure Perform the Pre Operation and Daily Safety Checklist in Section 10 Periodic Maintenance in the appropriate maintenance and service supplement Service Manual ACG Page 11 SECTION 4 BODY AND TRIM WARNING Only trained technicians should repair or service the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Following the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing vehicle Moving parts
38. he passenger side spindle stop lightly touches the passenger side A plate The internal stop on the rack must reach its limit of travel at the same time the spindle stops against the passenger side A plate with vehicle wheels turned to the right See following CAUTION CAUTION The drag link has both left and right hand threads The end of the drag link toward the spindle has left hand threads and the end toward the rack has right hand threads To prevent damage to threaded parts care should be taken when servicing the drag link 3 When all adjustments have been completed tighten the nuts 27 and 29 on the drag link assembly with an open end wrench Tighten nuts to 21 ft lb 28 4 Nm Figure 7 12 CAUTION When tightening the nuts 27 and 29 make sure the drag link 28 does not turn Figure 7 12 4 Straighten wheels and then turn steering wheel from lock to lock Wheels should turn smoothly and easily If steering wheel does not turn smoothly and easily inspect steering assemblies e g ball joints 23 Figure 7 12 and 6 and 13 Figure 7 20 spindle bushings 3 and 4 Figure 7 21 wave washers 20 Figure 7 21 and rack assembly 17 Figure 7 12 Also inspect front suspension assemblies e g A plates 1 Figure 7 20 urethane bushings 2 Figure 7 20 and leaf springs 6 Figure 7 21 Replace components as necessary Figure 7 7 Adjusting Steering Alignment Figure 7 8 Ball Joint Tool Service Manual
39. he rear of the tires The difference is the toe in Proper toe in is 1 8 to 3 8 of an inch 3 2 to 9 5 mm 6 If adjustment is necessary loosen the jam nut on each tie rod ball joint and rotate the tie rod to increase or decrease toe in Figure 7 19 CAUTION The tie rod has right hand threads on one end and left hand threads on the other end Right hand threads are identified by a groove in the tie rod 7 Tighten nuts loosened in Step 6 to 21 ft lb 28 Nm and recheck toe in 8 After toe in adjustment is made and with wheels in the straight ahead position the steering wheel should be at the center of its travel There should be equal travel to the left and right Note If the minimum turning radius is not the same for both left and right turns adjust the steering See Steering Adjustment Service Manual ACG Page 53 FRONT SUSPENSION COMPONENTS Read WARNING at beginning of this section TAPERED LEAF SPRING REMOVAL 1 ouhwn Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands Remove both front wheels Remove the nuts 14 and bolts 25 from the bottom of each king pin 26 Figure 7 21 Remove the four bolts 30 four nuts 32 four lock washers 31 and bottom spring plate 29 Remove tapered leaf spring 6 Check the condition of the urethane bushings
40. ishes Small scratches that cannot be buffed out Gouges punctures tears large scratches and abrasions Front Body Front body removal Front body installation Rear Body Rear body removal Rear body installation Floor mat Floor mat removal Floor mat installation SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP General information Brake Pedal and Park Brake Brake pedal removal Brake pedal installation Park brake removal Park brake installation Accelerator Pedal Accelerator pedal removal Accelerator pedal installation Service Manual ACG Page 3 SECTION 6 WHEEL BRAKE ASSEMBLIES General Information Brake Shoe Removal Brake Assembly Cleaning Brake Shoe Installation Brake Adjustment Brake Cluster Removal and Installation Brake Cable Removal and Installation SECTION 7 STEERING AND FRONT SUSPENSION General Information Steering Wheel Steering wheel removal Steering wheel installation Steering Column Steering column removal Steering column disassembly Steering column assembly Steering column installation Steering Adjustment Rack and Pinion Rack and pinion removal Rack and pinion disassembly Rack and pinion assembly Rack and pinion installation Tie Rod and Drag Link Tie rod and drag link removal Tie rod and drag link installation Front Suspension Lubrication Wheel alignment Front Suspension Component Tapered leaf spring removal Tapered leaf spring installation Kingpin and steering spindle removal Kingpin and stee
41. link rod 28 left hand threads to full thread depth Figure 7 12 Install the ball joint 23 on the spindle arm riser 33 then install the retaining nut 25 and a new cotter pin 22 Figure 7 12 Tighten nut to 18 ft lb 24 4 Nm then install cotter pin Adjust wheel toe in and steering Service Manual ACG Page 51 FRONT SUSPENSION Read WARNING at beginning of this section LUBRICATION Five grease fittings are provided one in each spindle housing one in the ball joint on each end of the tie rod and on in the ball joint of the steering drag link Lubricate these fittings at the recommended interval with the proper lubricant CAUTION To ensure proper lubrication of the front suspension and steering linkages raise front of vehicle to lubricate WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe in of the front wheels There is also a drag link adjustment to equalize the turning radius in both directions See Steering Adjustment Note Prior to making any front suspension adjustments inspect components for wear or damage and repair or replace as necessary Camber Adjustment 1 Check each front wheel with a framing square At the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 16 2 Loosen do not remove the four bolts 30 that secure the leaf spring 6 to the bottom spring plate
42. n some vehicles Figure 5 5 Service Manual ACG Page 16 PARK BRAKE REMOVAL 1 2 Disconnect battery ies as instructed See WARNING on page 14 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place Jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING WARNING 4 Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands for proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Remove the park brake assembly 3 1 To remove the park brake rod and pawl assembly 16 19 and 35 remove the push nut 18 and disconnect the ball joint sleeve 20 from the park brake pedal 24 Figure 5 5 See following note Note New push nuts 18 and 27 must be used when reassembling the park brake 3 2 To remove the park brake pedal 1 remove the push nut 27 disconnect the torsion spring 21 Figure 5 6 and slide the pedal off of the shaft See preceding note Inspect all parts for wear or damage and replace as necessary PARK BRAKE INSTALLATION NO From the bo
43. nc factory trained technician It is the policy of American Custom Golf Cars Inc to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical representatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent American Custom Golf Cars Inc s continuing commitment to customer support This manual used in conjunction with the appropriate maintenance and service supplement covers all aspects of typical vehicle service However unique situations do sometimes arise when servicing a vehicle If it appears that a service question is not answered in this manual or supplement you may write to us at American Custom Golf Cars Inc 15740 El Prado Rd Chino CA 91710 Attention Technical Support Or call 909 597 2885 and ask for a technician Service Manual ACG Page 2 CONTENTS SECTION 1 SAFETY General Warning SECTION 2 VEHICLE SPECIFICATIONS General Information SECTION 3 GENERAL INFORMATION Serial Number Identification Safety Committee Storage Preparing the vehicle for extended off season storage Returning the vehicle to service SECTION 4 BODY AND TRIM Cleaning the vehicle Seat Front and Rear Body Repair Stress lines or streaks Minor impact damage deformations Minor scratches and surface blem
44. ngs reverse the removal procedure See the following CAUTION CAUTION When positioning the spring on the transaxle be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle 2 Tighten the nuts on the U bolts to 35 ft lb 46 5 Nm 3 Tighten nylon lock nuts on spring mounting bolts 15 to 27 ft lb 36 6 Nm Service Manual ACG Page 62 Figure 9 2 Figure 9 3 Service Manual ACG Page 63 Manufactured by American Custom Golf Cars Inc ACG 15740 El Prado Rd Chino CA 91710 USA 909 597 2885 909 597 7183 fax www californiaroadster com Copyright 2009 American Custom Golf Cars Inc American Custom Golf Cars Inc ACG and California Roadster Are registered trademarks of American Custom Golf Cars Inc Effective July 1 2009
45. o Ge K a AMERICAN CUSTOM GOLFCARS INC m 2009 Neighborhood Electric Vehicle NEV SERVICE MANUAL HOLLYwon e re Effective July 1 2009 FOREWORD American Custom Golf Cars Inc vehicles are designed and built to provide maximum efficiency and performance however proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation This manual provides detailed procedures for the maintenance and repair of those components that are common to American Custom Golf Cars Inc vehicles and should be used in conjunction with the appropriate maintenance and service supplement The supplement will provide maintenance and repair procedures for those components specific to a particular type of vehicle This manual and the corresponding supplement should be thoroughly reviewed prior to servicing the vehicle The procedures must be properly implemented and the DANGER WARNING and CAUTION statements must be heeded This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair f the technician does not have such knowledge and skills attempted service or repairs to the vehicle may render it unsafe For this reason American Custom Golf Cars Inc advises that all repairs and or service be performed by an authorized American Custom Golf Cars Inc distributor dealer representative or by American Custom Golf Cars I
46. olt to 17 ft lb 23 Nm Install the wave washer 20 on the king pin Install the steering spindle on the king pin Then install the thrust washer 19 upper plate clevis 16 and nut 17 If lock washer was present do not reinstall Tighten the nut to 40 ft lb 54 2 Nm Figure 7 21 Attach the ball joints 6 and 13 to the spindle arm 23 install and tighten the nut 20 and install the cotter pin 22 Figure 7 20 Install the drag link ball joint See Tie Rod and Drag Link Installation Install front hub and wheel See Front Wheel Bearings and Hub Installation Service Manual ACG Page 54 DELTA A PLATE REMOVAL 1 PON Loosen lug nuts on both front wheels and raise front of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands Remove wheel Remove bolts 10 and 24 A plate straps 14 and nuts 5 Figure 7 20 Remove the lower shock absorber mounting nut 9 then slide the shock absorber free of the Delta A Plate Remove the Delta A Plate 1 Inspect the bushings 2 and sleeves 3 and 4 in the Delta A Plate and replace them if necessary DELTA A PLATE INSTALLATION 1 2 3 Install the A Plate in reverse order of removal Tighten the A plate suspension bolts 10 and 24 to 20 ft lb 27 Nm Figure 7 20 Tighten shock absorber mounting nut 9 to 20 ft lb 27 1 Nm Install the wheels and adjust
47. omotive cleaners with a soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate American Custom Golf Cars Inc does not recommend any type of pressure washing or steam cleaning Such a process especially if the vehicle has a composite rear body that is removed will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains Note Dispose of waste water properly SEAT To preserve seat appearance clean regularly with mild soap or detergent applied with a sponge or soft cloth Use a soft bristle brush to clean areas that are especially soiled Use the following guidelines Light Soiling A solution of 10 liquid dish soap and warn water applied with a soft damp cloth is recommended A soft bristle brush may be used if necessary Wipe off any residue with a water dampened cloth Difficult Stains Dampen a soft white cloth with a solution of 10 household bleach sodium hypochlorite and 90 water Rub gently to remove stain and then rinse with water dampened cloth to remove bleach concentration More Difficult Stains Perform previous procedure using full strength bleach or allow bleach to puddle on affected area for approximately 30 minutes Rinse with a
48. r exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Turn the key switch OFF and remove key place Forward Reverse handle or switch in the NEUTRAL position and chock the wheels prior to servicing the vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 After disconnecting the batteries discharge the controller capacitors as follows Turn the key switch to ON and place the Forward Reverse handle in the REVERSE position Slowly depress the accelerator pedal and keep depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged Service Manual ACG Page 60 GENERAL INFORMATION The rears suspension of the DS vehicle is completely independent It consists of two leaf springs controlled by two shock absorbers moun
49. ring spindle installation Delta A plate removal Delta A plate installation Shock absorber removal Shock absorber installation Front Wheel Bearings and Hubs Front wheel free play inspection Front wheel bearing and hub removal Front wheel bearing and hub installation Service Manual ACG Page 4 SECTION 8 WHEELS AND TIRES General Information Wheels Wheel removal Wheel installation Tires Tire removal Tire repair Tire installation SECTION 9 REAR SUSPSENSION General Information Shock Absorbers Shock absorber removal and inspection Shock absorber installation Lear Springs Leaf spring removal Leaf spring installation Service Manual ACG Page 5 SECTION 1 SAFETY To ensure the safety of those servicing American Custom Golf Cars Inc vehicles and to protect the vehicles from possible damage resulting from improper service or maintenance the procedures in this manual must be followed It is important to note that throughout this manual there are statements labeled DANGER WARNING or CAUTION These special statements relate to specific safety issues and must be read understood and heeded before proceeding with procedures There are statements labeled NOTE which provide other essential service or maintenance information DANGER indicates an immediate hazard that will result from severe personal injury or death WARNING indicates an immediate hazard that could result in severe personal injury or dea
50. s 27 and 29 on the drag link Figure 7 12 Remove the cotter pin 22 and ball joint retaining nut 25 Figure 7 12 Remove the cotter pins 21 and ball joint retaining nuts 20 Figure 7 21 Use a ball joint removal tool to remove ball joints 13 and 6 Figure 7 20 and 23 Figure 7 12 from the spindles Remove the ball joints from the tie rod 11 Figure 7 20 Remove the drag link 28 from the inner ball joint assembly 3 and drag link ball joint 23 Figure 7 12 TIE ROD AND DRAG LINK INSTALLATION 1 Thread ball joints 6 and 13 into tie rod 11 to a depth of 1 2 inch 12 5 mm Figure 7 20 WARNING The ball joints must be threaded into the rod at least 5 16 of an inch 8 mm Failure to thread ball joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being operated possibly resulting in loss of vehicle control and severe personal injury CAUTION The tie rod and drag link have right hand threads on one end and left hand threads on the other end Right hand threads are identified by a groove in the tie rod or drag link 2 3 Install ball joint ends 6 and 13 into the left and right hand spindle arms 23 then install the retaining nuts 20 and cotter pins 22 Figure 7 20 Thread the drag link rod 28 all the way onto the threaded stud of the inner ball joint assembly 3 right hand threads Figure 7 12 Thread the ball joint 23 into the drag
51. se a steering column retaining ring tool to seat the remaining ring to the proper depth Support end of tube while pressing If you do not have the recommended too use the same tube as was used in step 2 to press the retaining ring onto the top of the shaft The retaining ring should be pressed on the shaft until 2 to 2 1 8 inches 5 1 5 4 cm of the shaft extends from the top of the bearing seat in the steering tube Figure 7 5 20 BEARING PRESS TOOL CCI 1014264 WEDGE SEATING INTO THE INNER RACES OF BEARING WEDGE SEATING INTO THE INNER RACES OF BEARING STEP 3 STEP 2 Figure 7 5 Steering Shaft Bottom End Figure 7 6 Steering Shaft Top End Service Manual ACG Page 42 STEERING COLUMN INSTALLATION Install boot Reinstall mount onto the end of the steering column Tighten bolts to 20 ft lb 27 Nm 2 For ease of assembly and to prevent corrosion apply a light coat of anti seize or lubricating compound to both splined ends of the steering shaft 3 Position the steering column assembly in the vehicle while inserting the steering column shaft into the upper universal joint The flat portion of the steering shaft spline must be aligned with the bolt hole in the universal joint before sliding the spline into the universal joint While holding the steering column in place attach it to the frame using bolts washers and nuts Thread the nuts onto the bolts but do not tighten them Reinstall washer and scr
52. t 23 on the bolt Finger tighten hardware at this time Install the ball stud 16 through the pivot rod Install the spring retainer 11 onto the ball stud Secure these parts with the nut 10 Figure 5 8 Tighten the nut to 50 in Ib 5 5 Nm Depress the brake pedal slightly and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of vehicle slide the ratchet onto the pivot rod do not slide ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet until its tip is pointed downward The ratchet should now rotate freely on the rod Rotate ratchet clockwise until it touches the park brake pawl then slide the ratchet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclockwise slightly to align the splines Move the pivot rod back toward the driver side of the vehicle and line up the scribed match marks on the pivot rod and ratchet Rotate the pivot rod back and forth slightly to align the splines and slide the ratchet onto the splines Install nylon lock nut 26 on pivot rod and tighten the nut to 18 ft lb 24 5 Nm Figure 5 8 Install the accelerator rod assembly 17 18 19 Adjust the accelerator pedal height Adjust the accelerator rod Service Manual ACG Page 20 FLOORBOARD REMOVED FOR CLARITY P TYP
53. t washers 2 bolts 4 and mounting blocks 23 If the mounting blocks show signs of excessive wear or are damaged they must be replaced with new ones before installing pedal assembly Remove the nut 12 and brake stop bumper 11 BRAKE PEDAL INSTALLATION 1 From the top side of the floorboard insert the brake pedal weldment assembly through the opening in the floor Install the brake pedal stop bumper 11 on the weldment Figure 5 5 page 5 5 Do not tighten the jam nut 12 at this time 2 Attach the equalizer rod 13 to the brake pedal weldment assembly 6 as shown Figure 5 5 page 5 5 Tighten the bolt 14 and nut 15 to 17 in lb 1 9 Nm 3 Position and attach brake pedal assembly and mounting blocks 23 and washers 2 to vehicle frame as shown Tighten the bolts and nuts to 50 in Ib 5 7 Nm Figure 5 5 page 5 5 4 Tighten the nut 2 on the equalizer rod 1 so that brake pedal free play is 1 4 inch to 1 2 inch 6mm to 13mm Figure 5 4 Note Brake pedal free play is the distance the brake pedal can be depressed before the brake actuator arm moves 5 Tighten the jam nut 3 while holding the adjustment nut 2 in the correct position Figure 5 4 Service Manual ACG Page 15 1 4 inch to 1 2 inch 6 3 to 12 7 mm Equalizer bracket may be inverted on some vehicles Figure 5 4 Bes TYPICAL 29 2PLACES T s 7 Egualizer bracket may be inverted o
54. ted between the springs and the vehicle frame SHOCK ABSORBERS Read WARNING at beginning of this section SHOCK ABSORBERS REMOVAL AND INSPECTION 1 2 3 4 Check shock absorbers 7 for damage or fluid leakage the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers Figure 9 1 To remove a shock absorber remove the nut 5 cup washer 9 and rubber bushing 10 from the stem at the top of the shock absorber Remove the nut 5 cup washer 9 and rubber bushing 10 from lower mounting stem Compress the shock absorber to remove it SHOCK ABSORBER INSTALLATION 1 2 To install reverse the removal procedure On the upper and lower shock absorber mounting stems tighten the nuts until the rubber bushing expands to the size of the cup washer Service Manual ACG Page 61 LEAF SPRINGS Read WARNING at beginning of this section LEAF SPRING REMOVAL 1 Loosen but do not remove lug nuts on tire and wheel assembly on the side from which the spring is to be removed Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame cross member between the spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 9 2 See following WARNING WARNING Lift only one end of the vehicle at a time Use a suitable lifting device
55. th CAUTION indicates hazards or unsafe practices that could result in product or property damage or minor personal injury Note Notes are for your information and to make procedures more easily understood Service Manual ACG Page 6 GENERAL WARNING The following safety procedures must be followed whenever the vehicle is being operated repaired or serviced Service technicians should become familiar with these general statements which can be found throughout this manual Also other specific warnings appear throughout this manual and on the vehicle DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or using in an enclosed space Wear a full face shield and rubber gloves when working on or near batteries Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Only trained technicians should repair or service the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGE
56. the vehicle and chock the wheels that remain on the floor When not Service Manual ACG Page 7 performing a test or service procedure that requires movement of the wheels lock the brakes Turn the key switch OFF and remove key place Forward Reverse handle or switch in the NEUTRAL position and chock the wheels prior to servicing the vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge gt lt FRONT OF VEHICLE DISCONNECT BATTERY CABLES HERE cable first Figure 1 1 Service Manual ACG Page 8 SECTION 2 VEHICLE SPECIFICATIONS Overall Length Overall Width Height to top of windshield Weight no batteries Weight curb with batteries Weight GVWR Front Wheels Rear Wheels Front Tire Size Rear Tire Size Front Brakes Rear Brakes Drive Motor Transaxle Electrical System Batteries Speed Controller Steering Chassis Body Interior Material Carpet Forward Speed Braking Distance 12 mph Standard Seating Capacity 123 inches 51 inches 45 inches 738 lb 1262 lb 2000 lb 13 x 7 14 x 7 P165 70 R13 P185 60 R14 Hydraulic disk 7 Mechanical Drum Type Direct Drive 48 Volts DC Series Would 11 hp Double Reduction high speed gears 48 Volts DC Six 8V each in series 48V DC Wolf Performance 500
57. the wheel alignment as instructed SHOCK ABSORBER REMOVAL 1 2 3 4 Inspect the shock absorbers for fluid leakage at the point where the shaft enters the shock absorber body Leaking shock absorbers should be replaced Remove the nut 9 attaching the shock absorber to the A Plate Figure 7 20 Remove the nut 9 and bolt 8 attaching the shock absorber to the shock and gear support Remove the shock absorber SHOCK ABSORBER INSTALLATION Note When installing shock absorbers make sure front shocks have identical part numbers and rear shocks have identical part numbers 1 2 Install the shock absorber by reversing the removal procedure Tighten the nuts to 20 ft lb 27 Nm Service Manual ACG Page 55 SECTION 8 WHEELS AND TIRES WARNING Only trained technicians should repair or service the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injur
58. tion the trailing shoe in the slots in the shoe mounting block and adjuster assembly Figure 6 12 See following NOTE Note The trailing shoe has 17T stamped into the tip of the shoe flange Figure 6 12 The leading shoe is stamped 17L When installing the shoes the stamping on both sides should be oriented to the top of the brake assembly When installing the shoes on the passenger side of the vehicle the side of the trailing shoe flange marked 17T should be facing out and be visible On the driver side the 17L on the leading shoe should be facing out and be visible 2 Install the shoe retainer clip using pliers to compress the clip 1 while turning the clip retaining tab 2 into position Figure 6 13 3 Attach the springs onto the trailing shoe already installed Then hold the leading shoe next to the trailing shoe correctly oriented and attach the spring to it Figure 6 14 4 While maintaining spring attachment on both shoes position tips of leading shoe in the mounting slots and then push shoe into place Hold shoe in position and install retaining clip Figure 6 15 5 After the shoes are installed move them together up and down and side to side to make sure that they will easily slide approximately 1 4 to 3 8 inch 6 3 to 9 5mm without binding Figure 6 16 6 Place a flat blade screwdriver under the adjusting arm and raise the arm off of the adjusting wheel While holding the arm up turn the wheel upward until it stops
59. ttom side of the floorboard insert the park brake rod 16 through the brake pedal assembly opening shown Then install the park brake pawl 35 onto the shaft on the brake pedal assembly weldment 8 and also insert the park brake rod 16 into the park brake pawl Figure 5 6 Install the push nut 18 onto the park brake pawl shaft Install the spacer 22 and torsion spring 21 on the park brake pedal shaft on the brake pedal weldment Install the two bushings 25 in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment Figure 5 6 Then attach the end of the torsion spring to the park brake pedal and to the brake pedal weldment as shown Figure 5 7 Install the push nut 27 on the park brake pedal shaft Figure 5 6 Connect park brake rod 16 ball joint to ball stud on park brake pedal assembly Adjust park brake ratchet pawl gap and pawl engagement Service Manual ACG Page 17 Figure 5 6 Hook one end of spring on park brake weldment o ra A A k V V Ss 4 ie 4 SHAFT Lift other end of spring up and over brake weldment by prying down on shaft with small screwdriver Figure 5 7 Service Manual ACG Page 18 ACCELERATOR PEDAL REMOVAL 1 2 Disconnect batteries as instructed See WARNING on page 14 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Please j
60. uld repair or service the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle owner s manual for proper location of al vehicle warning decals and make sure they are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot motor resistors engine or exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Lift only one end of the vehicle at a time Use a suita
61. ustom Golf Cars Inc Service Parts Department Who should and who should not drive vehicles Instructing first time drivers Maintain vehicles in a safe driving condition How various rules are to be enforced Service Manual ACG Page 10 STORAGE Read DANGER and WARNING in SECTION 1 SAFTEY WARNING Turn the key switch OFF remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode CAUTION Batteries in low state of charge will freeze at low temperatures When washing the vehicle do not direct water stream at the Forward Reverse switch or other electrical components PREPAPRING THE VEHICLE FOR EXTENDED STORAGE 1 2 O P 6 7 8 Fully charge batteries See Section 13 Batteries in the appropriate Maintenance and Service Supplement Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray Store the vehicle in a cool place This will minimize battery self disc
62. y are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot motor resistors engine or exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Turn the key switch OFF and remove key place Forward Reverse handle or switch in the NEUTRAL position and chock the wheels prior to servicing the vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 After disconnecting the batteries discharge the controller capacitors as follows Turn the key switch to ON and place the
63. y or death Check the vehicle owner s manual for proper location of al vehicle warning decals and make sure they are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot motor resistors engine or exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Turn the key switch OFF and remove key place Forward Reverse handle or switch in the NEUTRAL position and chock the wheels prior to servicing the vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 After dis

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