SERVICE PARTS MANUAL

1 191718136591516781043111 - INCLUDES ITEMS 3 - 16 ELECTRIC POWERED COASTAL FLEET GOLF CARSISSUED APRIL 2006 REVISED DECEMBER 2007 SERVICE PARTS MANUAL604972 Ref Fcv 17 Page iService PARTS ManualSERVICE PARTS MANUALELECTRIC POWEREDCOASTAL FLEET GOLF CARSCOASTAL FLEET SERIES GOLF CARCOASTAL FLEET PDS GOLF CARSTARTING MODEL YEAR 2006+DISCLAIMER: The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this MANUAL , without obliga-tion to include these changes on units leased/sold information contained in this MANUAL may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice. The E-Z-GO Divi-sion DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL , and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON-SEQUENTIAL DAMAGES resulting from the use of the information and materials in this SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124 OUTSIDE USA PHONE: 001-706-798-4311, FAX: 001-706-771-4609 TEXTRON GOLF, TURF & SPECIALTY PRODUCTS, 388, AUGUSTA, GEORGIA USA 30903-0388 Page iiGENERAL INFORMATIONS ervice PARTS ManualTo obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacture date use of non Original Equipment Manufacturer (OEM) PARTS may void the iiiTABLE OF CONTENTSS ervice PARTS ManualSECTIONPage TO USE THE SERVICE PARTS MANUAL .

2 VILLUSTRATED PARTS BREAKDOWN .. viiACCELERATOR .. A-1 BATTERY CHARGER - PORTABLE 36 VOLT .. B-1 BODY - FRONT .. C-1 BODY - MID SECTION .. C-5 BODY - REAR .. C-7 BODY - ACCESSORIES .. C-11 BODY - ACCESSORIES CONTINUED .. C-13 BODY - ACCESSORIES CONTINUED .. C-15 BRAKES .. D-1 DIRECTION SELECTOR .. E-1 ELECTRICAL SYSTEM - COMMON .. F-1 ELECTRICAL SYSTEM - PDS .. F-5 ELECTRICAL SYSTEM - SERIES.. F-7 ELECTRONIC SPEED CONTROL - SERIES .. G-1 ELECTRONIC SPEED CONTROL - PDS .. G-3 ELECTRIC MOTOR .. H-1 FRONT SUSPENSION/STEERING.. J-1 REAR AXLE .. K-1 REAR SUSPENSION .. L-1 SEATING AND BAG HOLDER - GOLF CAR.. M-1 TOW BAR - PERMANENT .. N-1 TOW BAR - CASUAL.. N-5 WEATHER PROTECTION - GOLF CAR .. P-1 WHEELS AND TIRES .. Q-1 SPECIALTY PRODUCTS .. APPENDIX A-1 OPTIONS/ACCESSORIES .. APPENDIX B-1 Page ivTABLE OF CONTENTSS ervice PARTS ManualNotes:Page vService PARTS ManualThis MANUAL is divided into several sections:GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUALILLUSTRATED PARTS BREAKDOWN Contains illustrations and PARTS lists for all systems of the vehicleAPPENDIX Contains a listing of specialty products and options/accessoriesUSE OF THE MANUALTo use this MANUAL , consult the TABLE OF CONTENTS (page iii) to locate the information or illustration of some revisions varies due to supply of components; therefore, it is possible that various combinations ofcomponents may be found that are not directly reflected by each illustration.

3 Consult the illustration that best suits yoursituation. Locate the serial number plate (see BODY located in the illustrated PARTS Breakdown section of this manualfor its location) and note the complete number shown on the plate. It is important that the serial number of your vehicleand its model number be supplied to SERVICE PARTS when ordering any replacement the serial number plate (see BODY located in the illustrated PARTS Breakdown section of this MANUAL for its loca-tion) and note the complete number shown on the TO USE THE SERVICE PARTS MANUALPage viHOW TO USE THE SERVICE PARTS MANUALS ervice PARTS Manual1. WHEN THE part NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the INDEX OF MAJOR COMPONENTS andselect the most appropriate component description. Turn to the page number indicated and locate the part description in the PARTS list. Read the full accompanyingdescription for specific information regarding the part that was not shown in the index.

4 From the PARTS list, obtain the item number assigned to it and confirm that the part selected is correct by verifyingit with the pictorial representation on the illustrated IF YOU KNOW THE part NUMBER Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on. Turn to the page number indicated and locate the part number in the PARTS list. Refer to the accompanyingdescription for specific information regarding the part . From the PARTS list, obtain the item number assigned to it and confirm that the part selected is correct by verifyingit with the pictorial representation on the illustrated an asterisk (*) appear in the part number column on the PARTS list page, read upwards until a part number isfound. The part number is the lowest assembly sold by SERVICE PARTS . The asterisk (*) indicates that the part depicted isnot available for : Descriptions are indented under the assembly that they are used on.

5 That assembly is, in turn listed under theassembly that it is used on. This process is repeated until the highest final assembly is facilitate the maintenance and repair of the vehicle, a Technician s Repair and SERVICE MANUAL is available from the SERVICE PARTS hand illustration page(continued on right hand pageif required) PARTS list (continued onrear of page if required)Front of Vehicle123101100999812074707164636566671 2112211411911511173721121181161136269949 69582,8781,8684,8983,88102,1041057991921 0710662 - Includes Items 63 - 66, 69 - 74 70 - Includes Items 71 - 74 81 - Includes Items 82 - 84 86 - Includes Items 87 - 89 94 - Includes Items 95, 96 111 - Includes Items 112 - 114 118 - Includes Items 119 - 121126 - Includes Items 127 - 131103*See Body Section for decal information127128129130131126 Page viiService PARTS ManualILLUSTRATED PARTS BREAKDOWNILLUSTRATED PARTS BREAKDOWNPage A-1 SERVICE PARTS Manual16151411121317To HarnessfromDirectionSelector745326323242 9282119202324 1 - Includes Items 3 - 19, 21, 23, 26 - 43 2 - Includes Items 3 - 17, 20, 21, 24 - 4331 - Includes Items 32 - 3533 - Includes Items 34, 35 Ref Acl 1-1 AAACCELERATORPage A-2 SERVICE PARTS ManualACCELERATORTo HarnessfromDirectionSelector343732423741 433938454635 Ref Acl 1-2 Page A-3 SERVICE PARTS ManualWhere applicable.

6 THE USE OF NON UL PARTS WILL VOID ANY UL ordering PARTS , please specify the model and serial number of the product.* Indicates a component that is not available as an individual ** Indicates consult Customer SERVICE Department for additional part NO. BOX ASSEMBLY (INCLUDES ITEMS 3 - 19, 21, 23, 26 - 43) ..1273333-G10 PEDAL BOX ASSEMBLY, PDS MODEL ONLY(INCLUDES ITEMS 3 - 17, 20, 21, 24 - 43) ..1325853-G01 PEDAL BOX AND COVER (SEAL AND BEARING)..1425854-G01 INDUCTIVE THROTTLE SENSOR ..1500983-G01 SELF THREADING NUT, 3/16" .. ROD ..11200532-G4 NUT, 5/16 - YOKE (ADJUSTABLE) ..11417677-G2 SPRING RETAINER, 3/8" ..11573046-G01 COMPRESSION SPRING ..11617979-G1 ACCELERATOR ROD BUSHING ..11717677-G1 SPRING RETAINER, 1/2" ..1181925861-G01 MICRO SWITCH (PDS MODEL ONLY)..12101050-G01 SCREW, #4 - 14 X 5/8" LG ..2222325879-G03 WIRING HARNESS (PEDAL BOX ASSEMBLY) ..12425879-G05 WIRING HARNESS (PEDAL BOX ASSEMBLY) (PDS MODEL ONLY) ..1252600684-G6 SCREW, #8 - 32 X 3/4" LG (STAINLESS STEEL).

7 2272870116-G02 ACCELERATOR PEDAL , #8 - 16 X 1/2" LG ..4 Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL ordering PARTS , please specify the model and serial number of the product.* Indicates a component that is not available as an individual ** Indicates consult Customer SERVICE Department for additional part NO. A-4 SERVICE PARTS ManualACCELERATOR303125799-G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 32 - 35)..132 *ACCELERATOR PEDAL ..13327844-G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 34, 35)..13427512-G01 ACCELERATOR PEDAL PAD ..13515766-G1 OVAL RIVET 3/16" X 7/16" LG ..6363717838-G1 NYLON BUSHING ..33874432-G01 PEDAL PIVOT PIN ..13912064-G6 PUSHNUT, 9/32" ..1404110386-G3 CLEVIS PIN, 5/16" X 13/16" LG ..14217255-G1 TEFLON WASHER, 5/16" ..14310387-G3 COTTER PIN, 3/32" X 3/4" LG ..1444500715-G2 BOLT, 5/16 - 18 X 4/5" LG ..44670135-G01 PEDAL PIVOT COVER ..1 Page B-1 SERVICE PARTS Manual76713 671 - Includes Items 3 - 632 - Includes Items 3 - 13, 18 - 63, 70 - 7610899 TransformerWire1113109911812 POWERWISE POWERWISE +Ref Bcp 1-1 7475701545 BBATTERY CHARGER - PORTABLE 36 VOLTPage B-2 SERVICE PARTS ManualBATTERY CHARGER - PORTABLE 36 VOLT2524DE3129302020 WHT fromTransformer1918212233.

8 66A20 CTo groundingTo Black/Control BoardTo Amp FuseTo TransformerTo PowerInput BoardRef Bcp 1-2 26 Page B-3 SERVICE PARTS ManualBATTERY CHARGER - PORTABLE 36 VOLTDCDCAMPERESAMPERES1010202030300 WHT from DC CordAMMETER INSTALLATION474849504851525453515351 HeatSink4853 46B5045 Chassis55 GRNXFWHTBRN from Control BoardORN from Control BoardBLK from TransformerBLK from TransformerBLK from AC CordWHT fromAC CordGRN toGroundBRNORNYEL72 POWER INPUT BOARDINSTALLATION58 APOWERWISE +CONTROL / POWER INPUTBOARD INSTALLATIONBLK fromTransformerBLK fromTransformerBLK fromAC CordWHT fromAC CordGRN toGround1657 AGRNXFWHTRED toHeat SinkBLACK fromDC PlugPOWERWISE Ref Bcp 1-3 63626061 ACCordPor tFront ofCharger GRN toPowerInputBoardGRN toAC CordDGROUNDING DETAIL436736383935424033 - Includes Items 34 - 4366 - Includes Items 34 - 42, 6737414134DC CABLE ASSEMBLYECToCapacitorTo XF on Power Input BoardTo Norm. Openon Power Input BoardTo Diodes565453 ToDCCordTRANSFORMERDETAIL552827 Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL ordering PARTS , please specify the model and serial number of the product.

9 * Indicates a component that is not available as an individual ** Indicates consult Customer SERVICE Department for additional part NO. B-4 SERVICE PARTS ManualBATTERY CHARGER - PORTABLE 36 VOLT128115-G01 POWERWISE CHARGER (10' CORD) (INCLUDES ITEMS 3 - 63)..1228115-G02 POWERWISE + CHARGER (PORTABLE, 10' CORD) (INCLUDES ITEMS 3 - 13, 18 - 63, 70 - 76)..13*CHASSIS ..1400513-G6 SCREW, #8 - 18 X 1 3/4" LG ..2500559-G4 WASHER, #8 ..2611572-G3 EXPANSION SINK ..1800372-G4 SCREW, #8 - 32 X 1/2" LG ..4900559-G4 WASHER, #8 ..410 00565-G4 LOCK WASHER, #8 ..41100526-G1 NUT, #8 - 32 .. *LABEL (POWERWISE ) ..11628667-G01 CONTROL / POWER INPUT BOARD ..11718*COVER ..11928102-G01 HANDLE ..12000614-G4 SCREW, #8 - 18 X 1/2" LG ..62128136-G01 LABEL (VENTILATION)..12228136-G02 LABEL (CORD CONDITION)..1232426979-G01 CAPACITOR ..12600969-G01 SCREW, #8 - 32 X 3/8" LG ..32700414-G5 BOLT, 1/4 - 20 X 5/8" LG ..32811027-G2 LOCK NUT, 1/4 - CORD ..1 Page B-5 SERVICE PARTS ManualWhere applicable, THE USE OF NON UL PARTS WILL VOID ANY UL ordering PARTS , please specify the model and serial number of the product.

10 * Indicates a component that is not available as an individual ** Indicates consult Customer SERVICE Department for additional part NO. CHARGER - PORTABLE 36 VOLT3013557-G2 STRAIN RELIEF (AC)..13113557-G3 STRAIN RELIEF (DC)..1323373345-G01DC CORD AND HANDLE ASSEMBLY (INCLUDES ITEMS 34 - 43) ..13473051-G11 PLUG (TOP HALF)..13573051-G12 PLUG (BOTTOM HALF)..13673051-G27 AUXILARY CONTACT ..13773051-G14 MALE , #10 - 32 X 1/2" LG (BRASS) ..23973051-G15 MAGNET ..14073051-G16 SCREW, #6 - 32 X 1/2" LG (STAINLESS STEEL) ..24173051-G10 LOCK NUT, #6 - 32 ..44273051-G17 SCREW, #6 - 32 X 1" LG (STAINLESS STEEL) ..24373344-G01DC CORD, 10' LG ..1444528105-G01 AMMETER ..14601051-G01 SCREW, #8 - 16 X 1/2" LG ..24700559-G4 WASHER, #8 ..24801003-G01 WASHER, #10 (BRASS)..44922589-G2 SHOULDER WASHER, #10 ..15000771-G6 NYLON WASHER, 3/8" ..15100528-G4 NUT, #10 - 32 (BRASS)..35228106-G0150 AMP WASHER, #10 ..45400378-G4 SCREW, #10 - 24 X 1/2" LG ..25500526-G3 NUT, #10 - 24.