E-Z-GO Terrain 1000 - Gas Owner`s manual

28547-G01
English
OWNER’S MANUAL
AND SERVICE GUIDE
ELECTRIC AND GASOLINE
UTILITY VEHICLES
STARTING MODEL YEAR: 1999
ENGLISH
SAFETY
Read and understand all labels located on the vehicle. For any questions on any of the information, contact an E-Z-GO
representative for clarification.
Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent
loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on
level ground. (See vehicle specification.) Limit speed by applying the service brake.
Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
Use extra caution when towing the vehicle. Do not tow vehicle at speeds in excess of 19 kph. Towing the vehicle at
above the recommended speed may result in personal injury and/or damage to the vehicle and other property.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situations that could result in an unsafe coasting condition.
Be sure that this manual remains as part of the permanent service record should the vehicle be re-sold.
NOTES, CAUTIONS AND WARNINGS
Throughout this guide NOTE, CAUTION and WARNING
will be used.
!
!
A NOTE indicates a condition that should be
observed.
A CAUTION indicates a condition that
may result in damage to the vehicle.
!
!
A WARNING indicates a
hazardous
condition
which could result in
severe injury or death.
Please observe these NOTES, CAUTIONS and WARNINGS; be aware that servicing a vehicle requires
mechanical skill and a regard for conditions that could be
hazardous. Improper service or repair may damage the
vehicle or render it unsafe.
< 140
DO NOT DRIVE ON GREATER
THAN 140 INCLINE
Read and understand the following warnings
before attempting to operate the vehicle:
!
!
To prevent personal
injury or death, observe
the following:
When vehicle is to be left unattended, engage parking
(PARK) brake, move direction selector to neutral
(electric vehicles) forward (gasoline vehicles), turn key
to ‘OFF’ position and remove key.
Drive vehicle only as fast as terrain and safety
considerations allow. Consider the terrain and traffic
conditions. Consider environmental factors which
effect the terrain and the ability to control the vehicle.
Avoid driving fast down hill. Sudden stops or change
of direction may result in a loss of control. Use service
brake to control speed when traveling down an incline.
Use extra care and reduced speed when driving on
poor surfaces, such as loose dirt, wet grass, gravel,
etc.
All travel should be directly up or down hills.
Use extra care when driving the vehicle across an
incline.
Stay in designated areas and avoid steep slopes. Use
the parking brake (PARK) whenever the vehicle is
parked.
Keep feet, legs, hands and arms inside vehicle at all
times.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in
reverse.
Make sure the direction selector is in correct position
before attempting to start the vehicle.
Slow down before and during turns. All turns should
be executed at reduced speed.
Always bring vehicle to a complete stop before
shifting the direction selector.
See GENERAL SPECIFICATIONS for standard vehicle
load and seating capacity.
Read and understand the following text and
warnings before attempting to service vehicle:
In any product, components will eventually fail to perform
properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible component failures or the manner in which each component
may fail.
Be aware that a vehicle requiring repair indicates that the
vehicle is no longer functioning as designed and there-
fore should be considered potentially hazardous. Use
extreme care when working on any vehicle. When diagnosing, removing or replacing any components that are
not operating correctly, take time to consider the safety of
yourself and others around you should the component
move unexpectedly.
Some components are heavy, spring loaded, highly corrosive, explosive or may produce high amperage or reach
high temperatures. Battery acid and hydrogen gas could
result in serious bodily injury to the technician/mechanic
and bystanders if not treated with the utmost caution. Be
careful not to place hands, face, feet or body in a location
that could expose them to injury should an unforeseen
situation occur.
!
!
Before working on the
vehicle,
remove
all
jewelry (rings, watch,
necklaces, etc.).
Be sure no loose clothing or hair can contact moving
parts.
Use care not to touch hot objects.
Raise rear of vehicle and support on jack stands
before attempting to run or adjust powertrain.
Wear eye protection when working on or around the
vehicle. In particular, use care when working around
batteries, using solvents or compressed air.
Hydrogen gas is formed when charging batteries. Do
not charge batteries without adequate ventilation.
Do not permit open flame or anyone to smoke in an
area that is being used for charging batteries. A
concentration of 4% hydrogen gas or more is
explosive.
Engine exhaust gas (carbon monoxide) is deadly.
Carbon monoxide is an odorless, colorless gas that is
formed as a natural part of incomplete combustion of
hydrocarbon fuels. Carbon monoxide is a dangerous
gas that can cause unconsciousness and is
potentially lethal.
The following are symptoms of carbon monoxide
inhalation:
• Dizziness
• Vomiting
• Intense Headache
• Muscular Twitching
• Weakness and Sleepiness
• Throbbing in Temples
If any of these symptoms are experienced, get fresh air
immediately. Never work around or operate a vehicle
in an environment that does not ventilate exhaust
gases from the area.
OWNER’S MANUAL
AND SERVICE GUIDE
ELECTRIC AND GASOLINE
UTILITY TRUCKS
VEHICLES
INDUSTRIAL 800E
WORKHORSE® 800E
WORKHORSE® 800LX E
WORKHORSE® 1000E
WORKHORSE® 1000LX
INDUSTRIAL 800G
WORKHORSE® 800G
WORKHORSE® 800LX G
WORKHORSE® 1200G
WORKHORSE® 1200LX
OASIS™
E-Z-GO Division of Textron reserves the right to make design changes without obligation to make these changes on units previously sold and the information
contained in this manual is subject to change without notice.
E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
CUSTOMER SERVICE DEPARTMENT
OUTSIDE USA PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609
E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA USA 30903-0388
Owner’s Manual and Service Guide
Page i
NOTES
A copy of the International Limited Warranty is located at the end of this manual.
The use of non E-Z-GO parts may void the warranty.
Overfilling batteries may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory
specifications will void the vehicle warranty.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -60° C.
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain. With electric vehicles, the battery charger and the controller are
both sources of electrical drain. For electric vehicles with portable chargers, unplug the
battery charger DC plug from the vehicle receptacle.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
Page ii
Owner’s Manual and Service Guide
TABLE OF CONTENTS
BEFORE INITIAL USE ............................................................................................................... 1
Preparation of Seats for Service .......................................................................................................................... 1
Fig. 1 Initial Service Chart ...................................................................................................................... 1
Portable Charger Installation for Electric Vehicles ............................................................................................... 1
Fig. 2 Charger Installation ...................................................................................................................... 1
Fig. 3 Charger Receptacle ..................................................................................................................... 2
SERIAL NUMBER PLATE LOCATION ...................................................................................... 2
Fig. 4 Serial Number Plate Location ......................................................................................................2
CONTROLS ............................................................................................................................... 2
Key/Light Switch ..................................................................................................................................................2
Fig. 5 Key/Light Switch .......................................................................................................................... 2
Direction Selector ................................................................................................................................................2
Fig. 6 Direction Selector ........................................................................................................................ 3
Accelerator Pedal ................................................................................................................................................3
Combination Service and Parking (PARK) Brake Pedal (Excludes 1200) ........................................................... 3
Fig. 7 Accelerator, Brake and Horn ....................................................................................................... 3
Hand Released Parking Brake (1200 Only) ......................................................................................................... 3
Fig. 8 Hand Released Parking Brake ....................................................................................................3
Horn .....................................................................................................................................................................3
Choke (Gasoline Models Only) ............................................................................................................................ 4
Fig. 9 Choke .......................................................................................................................................... 4
Electric Lift Switch ................................................................................................................................................4
Fig. 10 Electric Lift Switch ...................................................................................................................... 4
LOAD BED ................................................................................................................................. 5
Fig. 11 Load Bed Warning Label ........................................................................................................... 5
Manual Lift Load Bed Operation .......................................................................................................................... 6
Fig. 12 Manual Lift Latch ....................................................................................................................... 6
Fig. 13 Manual Lift Prop .........................................................................................................................6
Electric Lift Load Bed Operation .......................................................................................................................... 6
BEFORE ENTERING VEHICLE ................................................................................................. 6
OPERATING THE VEHICLE ...................................................................................................... 6
Starting the Electric Vehicle ................................................................................................................................. 7
Starting the Gasoline Vehicle .............................................................................................................................. 7
Cold Starting the Gasoline Vehicle ...................................................................................................................... 7
Starting the Vehicle on a Hill ................................................................................................................................ 7
Starting a Gasoline Vehicle with a Discharged Battery ....................................................................................... 8
COASTING ................................................................................................................................. 8
FUEL .......................................................................................................................................... 8
Fig. 14 Fuel Tank Location .................................................................................................................... 8
Fuel Gauge and Indicator Lights .......................................................................................................................... 8
TOWING ..................................................................................................................................... 9
Neutral Lock (Gasoline Vehicles Only) ................................................................................................................ 9
Fig. 15 Neutral Lock ............................................................................................................................... 9
SERVICING THE VEHICLE ....................................................................................................... 9
Break-In (Gasoline Vehicles Only) ..................................................................................................................... 10
Fig. 16 Check Oil Level on Dipstick ..................................................................................................... 10
LIFTING THE VEHICLE ........................................................................................................... 10
Fig. 17 Lifting the Vehicle .................................................................................................................... 10
ROUTINE MAINTENANCE ...................................................................................................... 11
Fig. 18 Lubrication Points .................................................................................................................... 11
REAR AXLE (ELECTRIC VEHICLES) ..................................................................................... 11
Checking the Lubricant Level ............................................................................................................................ 11
Owner’s Manual and Service Guide
Page iii
TABLE OF CONTENTS
Fig. 19 Add, Check and Drain Rear Axle Lubricant on Electric Vehicles ............................................ 11
REAR AXLE (GASOLINE VEHICLES) ..................................................................................... 11
Fig. 20 Add, Check and Drain Rear Axle Lubricant on Gasoline Vehicles .......................................... 12
Checking the Lubricant Level ............................................................................................................................ 12
POWERTRAIN MAINTENANCE FOR GASOLINE VEHICLES ............................................... 12
Direction Selector .............................................................................................................................................. 12
Fig. 21 Shift Cable Adjustment ............................................................................................................ 12
Checking the Oil Level ...................................................................................................................................... 12
Fig. 22 Clean Entire Dipstick ............................................................................................................... 12
Fig. 23 Check Oil Level on Dipstick .................................................................................................... 13
Changing the Oil ............................................................................................................................................... 13
Fig. 24 Oil Viscosity Chart ................................................................................................................... 13
Fig. 25 Clean Top of Engine ............................................................................................................... 13
Fig. 26 Remove Oil Filter .................................................................................................................... 14
Fig. 27 Clean Oil Filter ........................................................................................................................ 14
Fig. 28 Blow Out Oil Filter ................................................................................................................... 14
Fig. 29 Add Engine Oil ........................................................................................................................ 14
AIR CLEANER INSPECTION/REPLACEMENT ....................................................................... 15
Fig. 30 Air Cleaner .............................................................................................................................. 15
STARTER/GENERATOR BELT TENSION .............................................................................. 15
Fig. 31 Checking Belt Tension with Gauge ......................................................................................... 15
Fig. 32 Checking Belt Tension with Finger .......................................................................................... 16
Adjusting the Belt .............................................................................................................................................. 16
Fig. 33 Adjusting Belt Tension ............................................................................................................ 16
AIR INTAKE AND COOLING FINS .......................................................................................... 16
Fig. 34 Cleaning Air Intake .................................................................................................................. 16
Fig. 35 Cleaning the Cooling Fins ....................................................................................................... 16
SPARK PLUGS ........................................................................................................................ 16
Fig. 36 Gapping the Spark Plug .......................................................................................................... 17
BRAKES ................................................................................................................................... 17
Daily Brake Test ................................................................................................................................................ 17
TIRES ....................................................................................................................................... 17
Tire Repair ........................................................................................................................................................ 17
Wheel Installation .............................................................................................................................................. 18
Fig. 37 Wheel Installation .................................................................................................................... 18
PREPARING THE GASOLINE VEHICLE FOR WINTER OR PROLONGED STORAGE ........ 18
LIGHT BULB REPLACEMENT ................................................................................................. 18
CARE AND CLEANING OF THE VEHICLE ............................................................................. 19
VEHICLE CARE PRODUCTS .................................................................................................. 19
VENDING UNIT (OASISTM) ...................................................................................................... 20
Warming Unit .................................................................................................................................................... 20
Fig. 38 Thermostat and Bin Drains ..................................................................................................... 20
Cold Bins ........................................................................................................................................................... 20
Cleaning the Vending Unit ................................................................................................................................ 20
Fig. 39 Empty Water from Bins ........................................................................................................... 20
Moving the Vending Unit ................................................................................................................................... 20
Fig. 40 Releasing Canopy Frame ....................................................................................................... 21
Fig. 41 Releasing Mounting Frame ..................................................................................................... 21
Removing the Vending Unit .............................................................................................................................. 21
Fig. 42 Vending Unit ............................................................................................................................ 21
TOP AND WINDSHIELD ..........................................................................................................22
Page iv
Owner’s Manual and Service Guide
TABLE OF CONTENTS
TRAILERING ............................................................................................................................ 22
TORQUE SPECIFICATIONS ................................................................................................... 22
Fig. 44 Torque Specifications .............................................................................................................. 22
HARDWARE ............................................................................................................................ 22
Fig. 43 Bolt Grades .............................................................................................................................. 22
LABELS USED ON VEHICLE .................................................................................................. 23
Fig. 45 Labels/Pictograms ................................................................................................................... 23
PERIODIC SERVICE SCHEDULE
........................................................................................ 24
Fig. 46 Periodic Service Schedule ....................................................................................................... 24
BATTERIES AND CHARGING FOR ELECTRIC VEHICLES .................................................. 26
Safety ................................................................................................................................................................. 26
BATTERY ................................................................................................................................. 26
BATTERY MAINTENANCE ...................................................................................................... 26
At Each Charging Cycle ..................................................................................................................................... 26
Monthly .............................................................................................................................................................. 27
Electrolyte Level and Water ............................................................................................................................... 27
Fig. 47 Correct Electrolyte Level .......................................................................................................... 27
Fig. 48 Water Purity Table ................................................................................................................... 27
Fig. 49 Automatic Watering Gun .......................................................................................................... 28
Cleaning Batteries ............................................................................................................................................. 28
Fig. 50 Preparing Acid Neutralizing Solution ....................................................................................... 28
Battery Replacement ......................................................................................................................................... 28
Fig. 51 Battery Connections ................................................................................................................ 29
Prolonged Storage ............................................................................................................................................. 29
Fig. 52 Freezing Point of Electrolyte ....................................................................................................29
Battery Charging ................................................................................................................................................29
AC Voltage ......................................................................................................................................................... 30
TROUBLESHOOTING ............................................................................................................. 30
Hydrometer ........................................................................................................................................................ 30
Fig. 53 Hydrometer .............................................................................................................................. 31
Using A Hydrometer .......................................................................................................................................... 31
Fig. 54 Hydrometer Temperature Correction ....................................................................................... 32
BATTERY CHARGER MAINTENANCE ................................................................................... 32
Fig. 55 Cleaning Auxiliary Contact in Charger Plug .............................................................................32
GENERAL SPECIFICATIONS .................................................................................................. 33
INDUSTRIAL 800E ............................................................................................................................................. 34
WORKHORSE® 800E ........................................................................................................................................ 35
WORKHORSE® 800LX E................................................................................................................................... 36
WORKHORSE® 1000......................................................................................................................................... 37
WORKHORSE® 1000LX ................................................................................................................................... 38
INDUSTRIAL 800G............................................................................................................................................. 39
WORKHORSE® 800G ........................................................................................................................................ 40
WORKHORSE® 800LX G .................................................................................................................................. 41
WORKHORSE® 1200......................................................................................................................................... 42
WORKHORSE® 1200LX .................................................................................................................................... 43
OASISTM ............................................................................................................................................................. 44
Fig. 56 Vehicle Dimensions ................................................................................................................. 45
Fig. 57 Vehicle Dimensions (LX Models).............................................................................................. 46
Fig. 58 Vehicle Dimensions (OASISTM) ............................................................................................... 47
Fig. 59 Incline Specifications and Turning Clearance Diameter ..........................................................48
INTERNATIONAL LIMITED WARRANTY ................................................................................. 49
DECLARATION OF CONFORMITY..........................................................................Last 3 pages
Owner’s Manual and Service Guide
Page v
TABLE OF CONTENTS
Notes:
Page vi
Owner’s Manual and Service Guide
SAFETY INFORMATION
This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures
developed by E-Z-GO. Adherence to these procedures and troubleshooting tips will ensure the best possible service
from the product. To reduce the chance of personal injury and/or property damage, the following instructions must be
carefully observed:
GENERAL
Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. E-Z-GO strongly suggests that the owner-operator read this entire manual paying particular
attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees and other
operators be encouraged to do the same.
If you have any questions, contact your closest E-Z-GO representative or write to the address on the back cover of this
publication, Attention: Product Service Department.
E-Z-GO Division of Textron reserves the right to make design changes without obligation to make these changes on
units previously sold and the information contained in this manual is subject to change without notice.
E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result
from the use of the material in this manual.
This vehicle conforms to the current applicable standard for safety and performance requirements.
These vehicles are designed and manufactured for off-road use and are not equipped for operation on public streets.
Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with
local ordinances.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
Never use the chassis or body as a ground connection.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. E-Z-GO prohibits and disclaims
responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when
used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,
terrain and common sense.
GENERAL OPERATION
Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
Always read and observe all warnings and operation instruction labels affixed to the vehicle.
Always follow all safety rules established in the area where the vehicle is being operated.
Always reduce speed to compensate for poor terrain or conditions.
Owner’s Manual and Service Guide
Page vii
SAFETY INFORMATION
Always apply service brake to control speed on steep grades.
Always maintain adequate distance between vehicles.
Always reduce speed in wet areas.
Always use extreme caution when approaching sharp or blind turns.
Always use extreme caution when driving over loose terrain.
Always use extreme caution in areas where pedestrians are present.
MAINTENANCE
Always maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
Always ensure that mechanics performing repairs are trained and qualified to do so.
Always follow the manufacturer’s directions if you do any maintenance on your vehicle. Be sure to disable the vehicle
before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery
wire. When reconnecting battery wire, be sure to reinstall rubber boot.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery(s) or cover exposed terminals with an insulating
material.
Always check the polarity of each battery terminal and be sure to rewire the batteries correctly and reinstall the rubber
boots.
Always use specified replacement parts. Never use replacement parts of lesser quality.
Always use recommended tools.
Always determine that tools and procedures not specifically recommended by the manufacturer will not compromise
the safety of personnel nor jeopardize the safe operation of the vehicle.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a
jack. Lift the vehicle in accordance with the manufacturer’s instructions.
Always empty the fuel tank or plug fuel hoses to prevent fuel leakage.
Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that could result in severe
personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury,
refer the repair or maintenance to a qualified mechanic.
Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of
both vehicular and pedestrian traffic.
Always replace damaged or missing warning, caution or information labels.
Always keep complete records of the maintenance history of the vehicle.
Page viii
Owner’s Manual and Service Guide
SAFETY INFORMATION
VENTILATION
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because
hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air
exchanges per hour is considered the minimum requirement, or conform to local codes.
Never fuel or charge a vehicle in an area that is subject to flame or spark. Pay particular attention to gas water heaters
and furnaces.
Always use a dedicated circuit for each battery charger. Refer to the battery charger for fusing/circuit breaker requirements. Do not permit other appliances to be plugged into the receptacle when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable
electrical code (whichever is higher).
Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.
Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon
monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.
Owner’s Manual and Service Guide
Page ix
SAFETY INFORMATION
Notes:
Page x
Owner’s Manual and Service Guide
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Thank you for purchasing an E-Z-GO vehicle. Before
driving the vehicle, we ask you to spend some time reading this Owner’s Manual and Service Guide. This guide
contains information that will assist you in maintaining
your highly reliable vehicle. This guide covers the operation of several models including electric and gasoline
vehicles, therefore some information may not be applicable to your vehicle.
Most of the service procedures in this guide can be
accomplished by the individual owner using common
automotive hand tools. Refer to an E-Z-GO service representative for information on servicing the vehicle in
accordance with the Periodic Service Schedule.
To facilitate maintenance, a Service Parts Manual and a
Technician’s Repair and Service Manual is available from
a local Distributor, an E-Z-GO Branch or the E-Z-GO Service Parts Department. Provide vehicle model, serial
number and manufacturing date code when ordering service parts.
BEFORE INITIAL USE
Be sure you understand the vehicle, its equipment and
how to use it safely. Although E-Z-GO vehicles have been
designed to provide safe and reliable operation, maintaining good performance depends to a large extent on
the operator.
Hydrogen gas is generated as a natural part of the
charging process. A 4%
concentration of hydrogen gas is explosive. Charging
must take place in an area that is adequately ventilated (minimum of 5 air exchanges per hour or conform
to local codes).
Never charge battery(s) in an area that has open flame
or electrical equipment that could cause an electrical
arc.
Never smoke around battery(s).
!
!
ITEM
SERVICE OPERATION
Battery(s)
Charge battery(s)
Seats
Remove protective plastic covering
Brakes
Check operation and adjust if necessary
Tires
Check pressure
Fuel
Fill tank with correct fuel
Engine
Check oil level
Fig. 1 Initial Service Chart
the plastic covering is to protect the seat bottom and
back rest during shipping. If the plastic covering is left on
the seat and becomes torn, dirt may get under the plastic
covering and be ground into the cover material. Water
getting under the plastic covering can become trapped
and eventually damage the seat assembly.
Portable Charger Installation for Electric
Vehicles
Portable chargers should
be mounted on a platform above the ground
or in such a manner as to permit the maximum air
flow underneath and around the charger. Do not
block or obstruct the louvers as overheating may
result which could cause serious damage to the
charger and create the potential for fire.
!
!
If the charger is operated in an outdoor location, rain and
sun protection must be provided (Ref Fig. 2 on page 1).
Provide protection from elements
Do not block louvered airways
Never smoke in an area where vehicles are being
fueled.
Before a new vehicle is put into operation, it is recommended that the items shown in the INITIAL SERVICE
CHART be performed (Ref Fig. 1 on page 1).
U.S. and Canada
NEMA 15 - 5R Grounded AC Receptacle
110 - 120 VAC. Dedicated 15 AMP Circuit
Vehicle battery(s) must be fully charged before initial use.
Locations outside the U.S. and Canada
Reference appropriate local electrical code
and charger manufacturer recommendations
for AC power requirements
Preparation of Seats for Service
Remove the protective plastic coverings from the seats
before placing the vehicle in service. The only function of
Fig. 2 Charger Installation
Owner’s Manual and Service Guide
Page 1
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Refer to charger manufacturer’s instructions for installation, operation and maintenance of charger. The charger
receptacle is located on the vertical seat panel below the
driver seat (Ref Fig. 3 on page 2).
CONTROLS
The controls on the vehicle consist of:
• key/light switch
• direction selector
• accelerator pedal
• combination service and parking (PARK) brake
pedal (excludes 1200)
• hand released parking brake (1200 only)
• horn
• choke (gasoline models only)
• electric lift switch
Key/Light Switch
Fig. 3 Charger Receptacle
Looping the DC cord through the steering
wheel when charging serves as a good
reminder to store the cord out of the way when finished with
charging. The DC plug can be damaged by driving over or
catching the cord on the vehicle when driving away.
The vehicle is equipped with a combination key/light
switch. Located on the dash panel, this switch enables
the basic electrical system of the vehicle to be turned on
and off by turning the key. This switch also has a position
for operating the lights. The lights will illuminate only
when the key is turned to the light icon position (Ref Fig.
5 on page 2).
An ungrounded electrical
device may become a
ph ys i c al h az a r d tha t
could result in an electrical shock or electrocution.
!
!
The power (AC) cord is equipped with a grounded plug.
Do not attempt to pull out, cut or bend the ground post.
SERIAL NUMBER PLATE LOCATION
The serial and manufacturing numbers are located on a
plate on the passenger side of the dash panel (Ref Fig. 4
on page 2).
Design changes take place on an ongoing basis. In order
to obtain correct components for the vehicle, the manufacturing date code and serial number must be provided
when ordering service parts.
Fig. 5 Key/Light Switch
To prevent inadvertent operation of the vehicle when left
unattended, the key should be turned to the ‘OFF’ position and removed.
If the vehicle is equipped with factory installed
custom accessories, some accessories remain
operational with the key switch in the ‘OFF’ position.
Direction Selector
Located on the seat support panel, this lever permits the
selection of either ‘F’ (forward), ‘R’ (reverse) or neutral
(the position between forward and reverse) (Ref Fig. 6 on
page 3).
Fig. 4 Serial Number Plate Location
Page 2
On electric models, the direction selector should be left in
neutral when the vehicle is left unattended.
Owner’s Manual and Service Guide
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
On gasoline models, the direction selector should be left
in ‘F’ (forward) when the vehicle is left unattended.
Parking Brake
Service Brake
Neutral
Reverse
Forward
Horn
Accelerator
Fig. 6 Direction Selector
To prevent component damage, the
vehicle must be completely stopped
before moving the direction selector.
Accelerator Pedal
Depressing the accelerator pedal starts the motor/
engine. When the pedal is released, the motor/engine
will stop (Ref Fig. 7 on page 3). To stop the vehicle more
quickly, depress the service brake.
If the key switch is ‘ON’
and the parking (PARK)
brake is set, depressing
the accelerator inadvertently will release the parking
(PARK) brake and cause the vehicle to move which
could cause severe personal injury or death.
!
!
Depressing the accelerator pedal will release the parking
(PARK) brake if it is engaged on all models except the
1200. This is a feature to assure that the vehicle is not
driven with the parking (PARK) brake engaged. This is
not the preferred method of releasing the parking (PARK)
brake.
Fig. 7 Accelerator, Brake and Horn
Hand Released Parking Brake (1200 Only)
The 1200 models are equipped with a hand released
parking brake that is located under the dash to the left
side of the operator (Ref Fig. 8 on page 3). Engage parking brake by pressing down on parking brake pedal until
brake locks into place. Disengage parking brake by pulling up on release handle. Unlike the combination brake
and parking (PARK) brake found on other models, this
parking brake will not automatically release when the
accelerator pedal is pressed. To avoid excessive wear to
brake components, be sure to release parking brake
before operating vehicle.
This is a parking brake feature only. For normal
braking during operation, depress the service
brake portion of the combination brake pedal to decrease
speed and stop vehicle.
Release Handle
E
AS
LE
RE
Parking Brake
Depressing the bottom of the brake pedal is
the preferred method of releasing the parking
(PARK) brake to assure the longest service life of brake components.
Combination Service and Parking (PARK)
Brake Pedal (Excludes 1200)
The brake pedal incorporates a parking (PARK) brake
feature. When leaving the vehicle unattended, engage
the parking brake by pushing down on the TOP section of
the pedal until it locks in place. The parking (PARK) brake
will release when the lower section of the brake pedal
(service brake) is depressed. Use the BOTTOM section
of the brake pedal to operate the service brake system
Accelerator
Horn
Service Brake
Fig. 8 Hand Released Parking Brake
Horn
The horn can be activated by depressing the horn button
located on the floor to the left of the brake pedal (Ref Fig.
7 on page 3) (Ref Fig. 8 on page 3).
Owner’s Manual and Service Guide
Page 3
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Choke (Gasoline Models Only)
Electric Lift Switch
Located on the seat support panel, the choke is used to
aid cold starting (Ref Fig. 9 on page 4). Pull the choke
knob out for the first start of the day, or if the vehicle does
not start within ten seconds after partially depressing the
accelerator pedal. Do not operate at full throttle until
engine has reached operating temperature.
The electric lift switch is located on the seat support
panel (Ref Fig. 10 on page 4). See “Electric Lift Load Bed
Operation” for operating information.
Rais
e
Low
er
Fig. 10 Electric Lift Switch
Fig. 9 Choke
Page 4
Owner’s Manual and Service Guide
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
LOAD BED
Never fill a gas can in the
load bed of a vehicle
equipped with a bed liner. Static discharge could ignite gasoline vapor and
cause an explosion.
!
!
The manual lift bed is the standard load bed for the vehicle. The bed may be equipped with an optional electric lift
switch.
A load bed warning label is affixed to the front of the bed
liner (Ref Fig. 11 on page 5). This label must be under-
stood and observed at all times for safe operation of vehicle. See the load bed warning label for maximum load.
The load must be positioned in the bed as far forward as
possible, distributed in such a way that its center of gravity must not be higher than height noted on label, and
securely fastened down. Failure to follow these instructions may result in personal injury, damage the vehicle
and/or cause the vehicle to roll over. Operate the vehicle
with awareness of load.
Do not permit anyone to ride in the load bed.
Before operating, check to ensure no one is standing
behind vehicle.
Label on 800E and 800G models
Label on 1000E models
Label on 1200G models
Fig. 11 Load Bed Warning Label
Owner’s Manual and Service Guide
Page 5
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Manual Lift Load Bed Operation
Exercise caution while
operating the manual lift
load bed to ensure the
bed is not accidentally dropped during lifting or lowering process. Severe injury could result if bed is
released and traps fingers or other body parts.
!
!
To raise the manual lift bed, pull back on the latch release
handle directly behind the driver seat (Ref Fig. 12 on
page 6). Raise the bed using the handle on the side of
the bed.
Electric Lift Load Bed Operation
Exercise caution while
!
! operating the electric lift
load bed to ensure clothing is not snagged during lifting or lowering process.
Severe injury could result if bed is accidentally
dropped and traps fingers or other body parts.
Move the toggle switch upward to raise and downward to
lower the load bed (Ref Fig. 10 on page 4).
BEFORE ENTERING VEHICLE
1. Check for correct tire inflation.
2. Inspect for fluid leaks.
3. Be certain everything is properly stored and secured.
All electric vehicles are equipped with an interlock system that disables the controller and prevents the vehicle
from being operated while the portable charger is connected. The interlock functions even if the DC plug is not
fully connected in the vehicle receptacle. Remove
charger plug from vehicle receptacle and properly store
cable prior to moving vehicle.
Fig. 12 Manual Lift Latch
Ensure the bed prop rod is securely seated in one of the
slots of the prop bracket before releasing the bed handle
(Ref Fig. 13 on page 6).
OPERATING THE VEHICLE
Improper use or operation of the vehicle or the lack of proper maintenance
may result in decreased performance or damage to the vehicle.
Read and understand the following warnings
before attempting to operate the vehicle.
Drive the vehicle only as
fast as terrain and safety
considerations allow.
Consider the terrain and traffic conditions. Also consider the environmental factors which effect the terrain and the ability to control the vehicle.
Avoid driving fast down hill. A sudden stop or change
of direction may result in loss of control. Use service
brake to control speed when traveling down an
incline.
Keep feet, legs, hands and arms inside the vehicle
perimeter at all times.
Use extra care and reduced speed when driving on
poor surfaces, such as loose dirt, wet grass, gravel,
etc.
Stay in designated areas and avoid steep slopes. Use
!
Fig. 13 Manual Lift Prop
To lower the manual lift bed, grasp the bed handle and
raise the bed sufficiently to release the prop rod from the
prop bracket slot and slide the prop rod forward in the
bracket track while lowering the bed to the rest position.
Be sure hands can not be trapped by bed.
Page 6
Owner’s Manual and Service Guide
!
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
the parking (PARK) brake whenever the vehicle is
parked.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in
reverse.
Make sure that the direction selector is in the correct
position before attempting to start the vehicle.
Slow down before and during turns. All turns should
be executed at reduced speed.
Always bring the vehicle to a complete stop before
shifting direction selector.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Always remain seated and hold on while vehicle is in
motion.
Do not allow vehicle to coast.
All travel should be directly up or down hills.
Use extra care when driving the vehicle across any
incline.
When vehicle is to be left unattended, engage parking
(PARK) brake, move direction selector to neutral
(electric vehicles) forward (gasoline vehicles), turn
key to ‘OFF’ position and remove key.
Starting the Electric Vehicle
Apply the service brake, place the key in the key switch
and turn to the ‘ON’ position. Move the direction selector
to the direction desired, release the service brake pedal
and depress the accelerator pedal to start the motor.
When the direction selector is in the reverse
position, a warning signal will sound. This is a
device to indicate the vehicle is ready to run in reverse.
The motor stops when the accelerator pedal is released.
To stop the vehicle more quickly, depress the bottom of
the brake pedal.
When the direction selector is in the reverse
position, a warning signal will sound. This is a
device to indicate the vehicle is ready to run in reverse.
When the accelerator pedal is released, the ignition circuit is de-energized and the engine stops. To stop the
vehicle more quickly, depress the service brake pedal.
Cold Starting the Gasoline Vehicle
Starting a cold engine may require the use of the choke.
Depress the accelerator approximately 2.5 cm or until the
starter just begins to operate. Pull the choke out as
required. Accelerate slowly and push the choke in completely when the engine runs smoothly.
Do not allow the starter to operate continuously for more than 30 seconds.
Allow 10 seconds before attempting a second time. If the vehicle
does not start on the third attempt, turn the key switch off, lock
the parking (PARK) brake and determine the cause of the problem.
If the vehicle has been running and the engine does not
start within 10 seconds, use the choke.
Starting the Vehicle on a Hill
To start a vehicle on a hill, use the service
brake to hold the vehicle in position. When the
motor/engine starts, accelerate smoothly while releasing service brake.
Do not hold vehicle on hill by using
accelerator and motor/engine. This will
damage the motor and cause premature and excessive wear to
drive train components.
When starting the vehicle on a hill, it is important to follow
this procedure to prevent excessive roll-back or permanent damage to the drive system.
Place left foot on service brake and release the parking
(PARK) brake. Place right foot on accelerator. As accelerator is depressed with the right foot, release the service
brake by removing left foot.
Starting the Gasoline Vehicle
Depressing the accelerator pedal energizes the starter
and ignition circuits which cause the engine to run. To
start the gasoline vehicle, apply the service brake, place
the key in the key switch and turn it to the ‘ON’ position.
Move the direction selector to the direction desired.
Slowly depress the accelerator pedal to start the engine.
Release service brake when engine starts.
Owner’s Manual and Service Guide
Page 7
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Starting a Gasoline Vehicle with a
Discharged Battery
!
!
Do not attempt to ‘jump
start’ a vehicle using
another vehicle.
The vehicle is equipped with a starter/generator. When
starting the engine, the starter/generator functions as a
starter and with the engine running, it functions as a generator.
With the short running times associated with this kind of
vehicle, the generator is more than adequate to maintain
the battery charge level. The generator is not designed to
charge a discharged battery.
To prevent a possible
explosion, do not smoke
near the fuel tank or refuel near open flame or electrical items which could
produce a spark.
Always wear safety glasses while refueling to prevent
possible eye injury from gasoline or gasoline vapor.
When refueling, inspect the fuel cap for leaks or
breaks that could result in fuel spillage.
!
!
Do not handle fuel in an area that is not adequately
ventilated. Do not permit anyone to smoke in an area
where vehicles are being fueled.
Since the engine stops when the accelerator is released,
jump starting should not be attempted.
If the vehicle battery has become discharged, it must be
charged using a 12V charger that is rated at 10 amps or
less.
FUEL
2.5 cm minimum
Observe all instructions provided by the manufacturer of
the charger.
COASTING
On steep hills, it is possible for vehicles to coast at faster
than normal speeds that may be encountered on a flat
surface. To prevent loss of vehicle control, speeds should
be limited to no more than the maximum speed on level
ground (see vehicle specification for speed). Limit speed
by releasing the accelerator and applying service brake.
Severe damage to the drive train components due to
excessive speed may result from driving the vehicle
above specified speed. Damage caused by excessive
speed may cause a loss of control, is costly, is considered abuse and will not be covered under warranty.
FUEL
Fig. 14 Fuel Tank Location
The fuel tank is located under the seat on the passenger
side of the vehicle (Ref Fig. 14 on page 8). Fill the tank
with fresh, clean, automotive grade, unleaded, 87 octane
(minimum) gasoline. High altitude or heavy use/load
applications may benefit from higher octane gasoline.
Do not overfill the fuel tank. Allow adequate space for the expansion of gasoline. Leave at least 2.5 cm space below bottom of filler neck.
Page 8
Fuel Gauge and Indicator Lights
Some gasoline vehicles may be equipped with an
optional electric fuel gauge that is located to the right of
the key switch.
An optional dash mounted low fuel indicator light may be
on some vehicles. It illuminates indicating the fuel level in
the tank is low.
An optional dash mounted low oil pressure indicator light
may be on some vehicles. It illuminates indicating the oil
pressure is low.
Owner’s Manual and Service Guide
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
TOWING
SERVICING THE VEHICLE
Tow bars are available from the E-Z-GO Service Parts
Department.
Before attempting any
type of servicing operations, read and understand all notes, cautions and warnings in this manual.
!
!
To prevent personal injury or damage to towing
components, do not ride
on vehicle(s) being towed.
Use extra caution when towing vehicle.
Do not tow vehicle at speeds in excess
of 19 kph. Towing vehicle at above recommended speed may
result in damage to vehicle and other property.
Tow bars are not intended for road use.
!
It is in the best interest of both vehicle owner and servicing dealer to carefully follow the procedures recommended in this manual. Adequate preventative
maintenance, applied at regular intervals, is the best
guarantee for keeping the E-Z-GO vehicle both dependable and economical.
To reduce the possibility
of causing an electrical
arc, which could result in
a battery explosion, turn off all electrical loads from
the batteries before removing any heavy gauge battery wires.
Wear eye protection when working on or
around vehicle. In particular, use care
when working around batteries, or when
using solvents or compressed air.
Servicing requiring adjustments to be made to the
powertrain while the motor or engine is running, must
be made with both drive wheels raised.
!
For electric vehicles, place direction selector in neutral position
prior to towing to prevent possible damage to electric motor.
For gasoline vehicles, the direction selector should be put in
neutral. The neutral lock, located on the rear axle, should be
used to lock the direction selector in position. This will prevent it
from moving into ‘F’ (forward) or ‘R’ (reverse) while being towed,
causing damage to the rear axle.
Neutral Lock (Gasoline Vehicles Only)
To prevent the rear axle from turning the driven clutch
while being towed, and causing wear to the belt, a neutral
lock is located on the rear axle (Ref Fig. 15 on page 9).
!
!
Never operate vehicle at full throttle for more than 4-5
seconds while vehicle is in a “no load” condition.
Unlocked
Position
Unlocked
1
Long Tab
2
Pull out and rotate 180 o
to lock
Locked
Position
Locked
1
Short Tab
Pull out and rotate 180 o
to unlock
2
Fig. 15 Neutral Lock
Owner’s Manual and Service Guide
Page 9
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Break-In (Gasoline Vehicles Only)
An initial oil change is required at 100 hours. Check for
any oil or fuel leaks that could have developed in shipment from the factory. As in normal driving, avoid full
throttle starts and rapid acceleration until the engine has
achieved operating temperature.
All engines consume more oil than normal during the first
hours of operation. As internal moving parts are run in,
oil consumption should gradually decrease until the rate
of consumption stabilizes. All engines use some oil even
when in perfect condition and properly broken in. During
the initial period, check the oil level at least every 8 operational hours. Add oil if the level on the dipstick indicates
that oil is in the lower portion of the safe operating range
(Ref Fig. 16 on page 10).
Fill Cold Engine
To This Point
L
Maximum Oil Level
For Hot Engine
Do Not Overfill
ADD
To prevent possible injury or death, be sure the
vehicle is on a firm and
level surface. Never get under a vehicle while it is
supported by a jack. Use jack stands and test the stability of the vehicle on the stands before getting under
the vehicle. Always place chocks in front and behind
the wheels not being raised. Use extreme care since
the vehicle is extremely unstable during the lifting
process.
!
!
When lifting vehicle, position jacks and
jack stands only on areas indicated.
To raise the entire vehicle, install chocks in front and
behind each front wheel (Ref Fig. 17 on page 10). Center
the jack under the rear frame crossmember. Raise the
vehicle and locate a jack stand under the outer ends of
the rear axle.
F
Safe Full
Low Add Oil
Operating Range
Hot Engine
Fig. 16 Check Oil Level on Dipstick
Never overfill the engine with oil, foaming may result and enter the breather
system.
Both the oil dipstick and fill cap must be in
place before operating the engine. Failure to
install the dipstick and fill cap will result in oil being discharged
into the engine compartment.
The oil should be changed after the first 100 hours of
operation and should be drained while the engine is
warm. See POWERTRAIN MAINTENANCE for checking
oil level and changing oil procedures.
View from Underside of Vehicle
LIFTING THE VEHICLE
Tool List
Qty. Required
Floor jack..................................................................... 1
Jack stands.................................................................. 4
Chocks ........................................................................ 4
Some servicing operations may require the front, rear or
the entire vehicle to be raised.
Page 10
Fig. 17 Lifting the Vehicle
Lower the jack and test the stability of the vehicle on the
two jack stands.
Place the jack at the center of the front axle. Raise the
vehicle and position jack stands under the frame crossmember as indicated.
Owner’s Manual and Service Guide
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Lower the jack and test the stability of the vehicle on all
four jack stands.
If only the front or rear of the vehicle is to be raised, place
the chocks in front and behind each wheel not being
raised in order to stabilize the vehicle.
Lower the vehicle by reversing the lifting sequence.
REAR AXLE (ELECTRIC VEHICLES)
The only maintenance required for the first five years is
the periodic inspection of the lubricant level. The electric
rear axle is provided with a lubricant level check/fill plug
located on the bottom of the differential. Unless leakage
is evident, the lubricant need only be replaced after five
years.
ROUTINE MAINTENANCE
Checking the Lubricant Level
This vehicle will give years of satisfactory service providing it receives regular maintenance. Refer to the Periodic
Service Schedule (Ref Fig. 46 on page 24) for appropriate service intervals. Refer to Lubrication Points (Ref Fig.
18 on page 11) for lubrication locations.
Tool List
Some maintenance items must be serviced
more frequently on vehicles used under severe
driving conditions.
Do not use more than three (3) pumps
of grease in each grease fitting at any
one time. Excess grease may cause grease seals to fail or
grease migration into areas that could damage components.
(2) Ball Joint
King Pin
Qty. Required
Socket, 13 mm, 3/8" drive ........................................... 1
Ratchet, 3/8" drive ....................................................... 1
Funnel ......................................................................... 1
Shop cloth ................................................................... 1
Clean the area around the check/fill plug and remove
plug. The correct lubricant level is just below the bottom
of the threaded hole. If lubricant is low, add as required.
Add lubricant slowly until lubricant starts to seep from the
hole. Install the check/fill plug. In the event that the lubricant is to be replaced, the vehicle must be elevated and
the oil pan removed or the oil siphoned out through the
check/fill hole (Ref Fig. 19 on page 11).
King Pin
Idler Arm
Ball Joint
Ball Joint
Check/Fill Plug
Steering
Unit
Ball Joint
on Rack
and Rod
Fig. 19 Add, Check and Drain Rear Axle
Lubricant on Electric Vehicles
REAR AXLE (GASOLINE VEHICLES)
Fig. 18 Lubrication Points
The gasoline rear axle is provided with a lubricant level
check plug located on the driver’s side at the rear of the
housing (Ref Fig. 20 on page 12). Unless leakage of rear
axle lubricant is evident, an annual lubricant check is sufficient.
Owner’s Manual and Service Guide
Page 11
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Direction Selector
Check Plug
The direction selector is a mechanical device that operates cables connected to the transmission. The cables
are sealed and do not require lubrication, but may require
occasional adjustment (Ref Fig. 21 on page 12). The
only other maintenance required is periodic lubrication of
the linkage and related moving parts.
Factory
Installed
Length
3.5 cm
Drain Plug
Fig. 20 Add, Check and Drain Rear Axle
Lubricant on Gasoline Vehicles
NEUTRAL
Checking the Lubricant Level
Tool List
Qty. Required
Socket, 13 mm, 3/8" drive ........................................... 1
Ratchet, 3/8" drive ....................................................... 1
Funnel ......................................................................... 1
Shop cloth ................................................................... 1
Clean the area around the check and fill plugs. Remove
the check plug. The correct lubricant level is just below
the bottom of the threaded hole. If lubricant is to be
added, remove the fill plug and add lubricant using a funnel. Add lubricant slowly until lubricant starts to seep
from the check plug hole. Install the check plug and the
fill plug. In the event that the lubricant is to be replaced, a
drain plug is provided at the bottom of the differential
housing. Capacity of axle is 1.2 liters.
Fig. 21 Shift Cable Adjustment
Checking the Oil Level
Do not overfill engine. Too much oil
may cause smoking or allow oil to enter
the air filter enclosure.
The oil should be checked with the engine warm. The
vehicle should be on a level surface with the parking
(PARK) brake locked. Allow adequate time for oil to drain
into the crankcase before checking.
Remove the dipstick and wipe off the entire area indicated with a lint free cloth (Ref Fig. 22 on page 12).
POWERTRAIN MAINTENANCE FOR
GASOLINE VEHICLES
Access the powertrain by raising/removing seat. Additional access may be obtained by raising or removing the
load bed. Some service procedures may require the
vehicle to be lifted. Refer to LIFTING THE VEHICLE for
proper lifting procedure and safety information.
When raising the load
bed, always install a posi ti ve s to p to p r e ve n t
severe injury that could occur if the load bed should
fall.
!
Page 12
L
F
!
Fig. 22 Clean Entire Dipstick
Owner’s Manual and Service Guide
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Insert the dipstick fully into the dipstick hole and remove.
Examine the level of oil on the dipstick.
load applications will require 10W-40 oil after a break-in
period of 100 hours (Ref Fig. 24 on page 13).
The engine can be operated safely as long as the oil is
within the safe operating range as indicated on the dipstick. Do not operate vehicle if oil level is below the
safe area indicated on the dipstick (Ref Fig. 23 on
page 13).
HEAVY DUTY WORK
Fill Cold Engine
To This Point
L
10W-30
Maximum Oil Level
For Hot Engine
Do Not Overfill
ADD
LIGHT DUTY WORK
10W-30
F
Safe Full
Low Add Oil
Operating Range
Hot Engine
Co -30
Oil should be added to bring the level into the safe operating range. Remember that oil expands as it gets hot.
Do not overfill. Check that the oil fill cap is firmly in
place.
When adding oil between oil changes, do not
mix brands and viscosity grades of oil.
Both the oil dipstick and fill cap must be in place before operating the engine. Failure to install the dipstick and fill cap will
result in oil being discharged into the engine compartment.
Changing the Oil
Qty. Required
Socket, 3/8" drive, 10 mm ........................................... 1
Ratchet, 3/8" drive....................................................... 1
Extension, 3/8" drive ................................................... 1
Oil drain pan................................................................ 1
-20
30
40
If the vehicle is to be stored over the winter
months, it can be stored with the old oil left in
the engine. The oil should be changed as part of spring maintenance. This will remove any moisture that has accumulated during storage.
Be aware that engine fluids may be hot and contact to the skin may
cause severe burns. Wear rubber gloves to protect
skin from exposure to the old oil and degreaser.
!
!
The oil should be changed with the engine warm. Park
the vehicle on a level surface, engage the parking
(PARK) brake and remove the key. Place a drain pan
under the engine. Wipe the top of the engine clean with a
cloth (Ref Fig. 25 on page 13). Remove the oil fill cap.
For maximum performance and longevity, the engine oil
should be replaced after the first 100 hours of operation.
After the initial oil change, it should be changed every
200-250 hours of operation or yearly, whichever comes
first. Vehicles used under harsh or dirty conditions should
have the oil changed every 100-150 hours of operation.
Never exceed 300 hours of operation before an oil
change.
The selection of oil is dependent upon the service that
the vehicle will perform. Most vehicles require 10W-30
oil, whereas vehicles used at capacity or near capacity
-10
0
10
20
(AIR TEMPERATURE)
Fig. 24 Oil Viscosity Chart
Fig. 23 Check Oil Level on Dipstick
Tool List
10W-40
Oil Fill Cap
Fig. 25 Clean Top of Engine
Owner’s Manual and Service Guide
Page 13
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Clean the area around the filter. Remove the three bolts
securing the oil filter to the engine. Remove the filter by
pulling it from the engine and allow the oil to drain. (The
‘O’ rings may remain on the engine or the filter) (Ref Fig.
26 on page 14).
8 cm
Minimum
'O' Rings
210 kPa Maximum
Oil Filter
Fig. 28 Blow Out Oil Filter
'O' Ring
Fig. 26 Remove Oil Filter
Inspect the filter. At the first oil change, small metal chips
and lint may be found. This is normal, resulting from the
break-in period. Inspect the filter at every oil change. The
presence of large metal chips could indicate possible
damage to the engine.
!
!
Wear eye protection to
prevent splashed solvent
from contacting the eyes
when cleaning oil filter.
Clean the filter by washing in any shop degreaser and
brushing the metal screen clean with a soft brush (Ref
Fig. 27 on page 14).
Wipe the area around the filter mount with a clean, lint
free cloth and inspect both filter ‘O’ rings for damage;
replace if necessary. Install the filter into the engine. The
filter engages over a short nipple in the engine. The filter
should slide easily onto the nipple and seat against the
engine using light hand pressure only. Align the holes in
the filter mounting plate with the holes in the engine.
Install and snug the bolts before tightening them firmly.
Oil capacity is 1.4 liters. Add slightly less than 1.4 liters to
allow for possible residual oil left in engine (Ref Fig. 29
on page 14). The oil must be high quality oil that meets or
exceeds API SF, SG, CC standards. Check oil level on
dipstick. Oil should be slightly below ‘F’ to allow for
expansion. If necessary, continue to add oil slowly and
allow time for oil to flow down into engine. Check oil level
on dipstick. Do not overfill.
Do not overfill engine. Too much oil
may cause smoking or allow oil to enter
the air filter enclosure.
'O' Ring
'O' Ring
Fig. 27 Clean Oil Filter
Blow out the filter with low pressure air 210 kPa or less
from no closer than 8 cm and allow to air dry (Ref Fig. 28
on page 14).
Page 14
Fig. 29 Add Engine Oil
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Inspect ‘O’ ring and replace if necessary. Install the oil fill
cap. Run the vehicle for one or two minutes and check
the filter for oil leaks.
As a final check, check the oil level again with the vehicle
on level ground. Like all liquids, oil increases in volume
when warm. The full ‘F’ mark on the dipstick is calibrated
for an engine at operating temperature. When the engine
is cold, the oil will be below the full mark. The engine can
be operated safely as long as the oil is within the safe
operating range as indicated on the dipstick. Do not
operate vehicle if oil level is below the safe area indicated
on the dipstick.
AIR CLEANER INSPECTION/REPLACEMENT
The air cleaner element is accessible by unsnapping the
top clips from the air box and swinging the cover open.
Remove the cover and the air filter element (Ref Fig.
30 on page 15). Clean inside of cover and enclosure.
If the element is in acceptable condition, loose dirt may
be removed by tapping the filter lightly. The air cleaner
element may be washed if required up to two times but
replacement is recommended for optimum performance.
Replacement is mandatory at the first signs of filter paper
deterioration or if the element has holes in it. After the initial cleaning, the second cleaning may be required
sooner than the first due to the deterioration of the filter
material.
To wash the element, gently clean the element in a mixture of non-sudsing cleaner (automatic liquid dishwasher
detergent) and water. Rinse in ‘non-pressurized’ clear
water. Allow to air dry completely before reinstalling. Do
not force dry the filter.
Do not use pressurized water or compressed air to clean the air filter. Doing
so will damage the filter and may damage the engine.
Install the element in the same way it was removed,
being sure that the filter seal is correctly installed. Attach
cover to the lower portion of the enclosure and swing it
up into place. Squeeze housing together and secure with
top clips. Be sure all clips are fastened securely.
STARTER/GENERATOR BELT TENSION
Tool List
Qty. Required
Belt tension gauge....................................................... 1
Wrench, 3/4"................................................................ 1
Wrench, 9/16".............................................................. 2
Ratchet, 3/8" drive ....................................................... 1
Socket, 3/4", 3/8" drive ................................................ 1
The starter/generator belt tension should be checked
after the first 15-20 hours and set to 34-36 kg.
A loose belt can cause audible vibration and
squeal.
Tighten a new starter/generator belt to 41-50 kg tension
when a gauge is applied half way between the two pulleys (Ref Fig. 31 on page 15).
Fig. 30 Air Cleaner
The air cleaner unit on the vehicle is a washable dry unit. Do not use oil on the filter element or any part of the unit.
Fig. 31 Checking Belt Tension with Gauge
Owner’s Manual and Service Guide
Page 15
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Although not as accurate, the belt may be depressed
with a finger. A maximum deflection of 10 mm is acceptable (Ref Fig. 32 on page 16).
Using a 3/4" socket and open end wrench, tighten the
starter/generator pivot bolt.
AIR INTAKE AND COOLING FINS
10 mm Maximum
Deflection (New Belt)
13 mm Maximum
Deflection (Existing Belt)
Fig. 32 Checking Belt Tension with Finger
Fig. 34 Cleaning Air Intake
Re-tighten an existing belt to 34-36 kg tension using the
same technique. A maximum deflection of 13 mm is
acceptable.
Adjusting the Belt
Every 20 hours, check for a build up of debris in the air
intake and cooling fins (Ref Fig. 34 on page 16) (Ref Fig.
35 on page 16). Blow or brush out debris from these
areas.
Using a 3/4" socket and open end wrench, loosen the
starter/generator pivot bolt.
While holding the lower adjusting nut with a 9/16"
wrench, loosen the upper jam nut with another 9/16"
wrench. Move the lower nut up or down the adjustment
bolt until proper belt tension is achieved. Hold the lower
nut in place and tighten the upper jam nut against it (Ref
Fig. 33 on page 16).
Fig. 35 Cleaning the Cooling Fins
SPARK PLUGS
Tool List
Qty. Required
Spark plug wrench, 13/16" ..........................................1
Plug gauge, wire type ..................................................1
Fig. 33 Adjusting Belt Tension
Page 16
Using a 13/16" spark plug wrench, remove the spark
plugs at 250-300 hours or annually and inspect. Clean
and gap to .71-.76 mm (Ref Fig. 36 on page 17). If a plug
has been burned beyond .89 mm, it should be replaced.
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
TIRES
Plug
Tool List
Lug wrench, 3/4" ......................................................... 1
Impact socket, 3/4", 1/2" drive ..................................... 1
Impact wrench, 1/2" drive ............................................ 1
Torque wrench, 1/2" drive............................................ 1
.71-.76 mm
Gap
Tire condition should be inspected on a daily basis. Inflation pressures should be checked on a weekly basis
when the tires are cool.
Fig. 36 Gapping the Spark Plug
Fouled spark plugs are indicated by a wet, black appearance. This could be caused by a dirty air filter element or
other restrictions in the air intake system. Incorrectly
adjusted valves, spark plug wires which are in poor condition or poor quality fuel could also contribute to the
problem. All new spark plugs should be properly gapped
to .71-.76 mm. Use NGK BPR4ES for replacement plugs.
Tighten to 24 Nm torque.
Use care not to over tighten the plug.
Overtightening can cause damage to
the aluminum cylinder head threads.
BRAKES
After the vehicle has been put into service, it is recommended that the brakes be checked daily by performing
the following test:
!
!
Qty. Required
All driving brake tests
must be done in a safe
location with regard for
the safety of all personnel.
!
!
Never exceed inflation
pressure rating on tire
sidewall.
Use caution when inflating tires. Due to the low volume of these small tires, overinflation can occur in a
matter of seconds. Overinflation could cause the tire
to separate from the wheel or cause the tire to
explode, either of which could cause personal injury.
Tire inflation should be determined by the condition of
the terrain. See GENERAL SPECIFICATIONS section for
recommended tire inflation pressure. For outdoor applications with major use on grassy areas, the following
should be considered. On hard turf, it is desirable to have
a slightly higher inflation pressure. On very soft turf, a
lower pressure prevents tires from cutting into the turf.
For vehicles being used on paved or hard surfaces, tire
inflation pressure should be in the higher allowable
range, but under no condition should inflation pressure
be higher than recommended on tire sidewall. All four
tires should have the same pressure for optimum handling characteristics. Be careful not to overinflate. Due to
the low volume of these small tires, overinflation can
occur in a matter of seconds. Be sure to install the valve
dust cap after checking or inflating.
Tire Repair
Daily Brake Test
Determine the braking performance of the vehicle by
latching the parking brake at a common point on a flat,
dry, clean paved surface while traveling at maximum
speed. Observe the vehicle stopping location.
If the vehicle stops in a significantly greater distance than
normal or pulls to one side, it should be tested again.
If the vehicle fails the second test, it should immediately
be removed from service. The vehicle needs to be
inspected by a qualified mechanic who should refer to
the BRAKES section in the Technician’s Repair and Service Manual.
To prevent injury caused
by a broken socket, use
only sockets designed
for impact wrench use. Never use a conventional
socket.
!
!
The vehicle is fitted with low pressure tubeless tires
mounted on one piece rims.
Generally, the most cost effective way to repair a flat tire
resulting from a puncture in the tread portion of the tire is
to use a commercial tire plug.
Owner’s Manual and Service Guide
Page 17
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Tire plug tools and plugs are available at most
automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel.
It is important to follow the ‘cross sequence’
pattern when installing lug nuts. This will
assure even seating of the wheel against the hub.
If the tire is flat, remove the wheel and inflate the tire to
the maximum recommended pressure for the tire.
Immerse the tire in water to locate the leak and mark with
chalk. Insert tire plug in accordance with manufacturer’s
specifications.
Do not tighten lug nuts to more than
115 Nm torque.
If the tire is to be removed or mounted, the tire changing
machine manufacturer’s recommendations must be followed in order to minimize possibility of personal injury.
Pressurize tire with small
amount of air applied
intermittently to seat
beads. Never exceed the tire manufacturer’s recommendation.
Protect face and eyes from escaping air when removing valve core.
Be sure mounting/demounting machine is anchored
to floor.
Wear safety equipment when mounting/demounting
tires.
!
!
Follow all instructions and safety warnings provided
by the mounting/demounting machine manufacturer.
Wheel Installation
With the valve stem to the outside, mount the wheel onto
the hub with lug nuts. Finger tighten lug nuts in a ‘cross
sequence’ pattern (Ref Fig. 37 on page 18). Then,
tighten lug nuts to 73 - 115 Nm torque in 30 Nm increments following the same ‘cross sequence’ pattern.
'Cross Sequence'
1
3
Tire style
may vary
2
4
PREPARING THE GASOLINE VEHICLE FOR
WINTER OR PROLONGED STORAGE
Keep hands, clothing
and jewelry away from
moving parts. Use care
not to contact hot objects. Raise the rear of the vehicle and support on jack stands before attempting to
run the engine.
!
!
Preparing the engine for winter or a prolonged storage
calls for a few simple steps to prevent a build up of varnish or gum in the carburetor and corrosion in the engine.
Raise the rear of the vehicle and support on jack stands.
Refer to LIFTING THE VEHICLE for lifting procedure and
safety information. Add fuel stabilizer to the tank in accordance with the manufacturer’s recommendations. Disconnect the fuel line from the engine at the fuel tank.
With proper ventilation, start the engine and allow to run
until the engine stops due to lack of fuel. Drain carburetor
bowl using drain screw and re-tighten the drain screw.
Remove the air filter and spray a commercial fogging or
cylinder oil into the carburetor while operating the starter
for 2-3 seconds. Reinstall the air filter and reattach the
fuel line to the tank.
LIGHT BULB REPLACEMENT
To prevent premature bulb failure, do
not touch new bulbs with bare fingers.
Use clean, dry tissue or paper towel to handle the glass portion
of the bulb.
Determine which bulb needs to be replaced. Reach
underneath light bar to access bulb from rear. Turn the
bulb socket a quarter turn counterclockwise to unlock
and pull out bulb. Insert new bulb and rotate quarter turn
clockwise to secure.
To replace the taillight bulb, remove hardware securing
lens and remove lens. Install replacement bulb.
Fig. 37 Wheel Installation
Page 18
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
CARE AND CLEANING OF THE VEHICLE
To prevent cosmetic damage, do not
use any abrasive or reactive solvents to
clean plastic parts.
It is important that proper techniques and cleaning materials be used.
Normal cleaning of vinyl seats and plastic or rubber trim
requires the use of a mild soap solution applied with a
sponge or soft brush and wipe with a damp cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require
the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive
appearance and durable protection. Frequent washing
with lukewarm or cold water is the best method of preserving painted surface.
Do not use hot water, strong soap or harsh chemical
detergents.
Rubber parts should be cleaned with non-abrasive
household cleaner.
Occasional cleaning and waxing with non-abrasive products designed for ‘clear coat’ automotive finishes will
enhance the appearance and durability of the painted
surfaces.
Corrosive materials used as fertilizers or for dust control
can collect on the underbody of the vehicle. These materials will accelerate corrosion of underbody parts. It is
recommended that the underbody be flushed occasionally with plain water. Thoroughly clean any areas where
mud or other debris can collect. Sediment packed in
closed areas should be loosened to ease its removal,
taking care not to chip or otherwise damage paint.
If the gasoline engine does not start or runs
improperly after washing, remove the spark
plug wires (by pulling the spark plug boots, never the wires)
and blow them dry. Reinstall the wires. Remove moisture from
coil by blowing across top.
Owner’s Manual and Service Guide
Page 19
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
VENDING UNIT (OASISTM)
The vending unit is equipped with a thermostatically controlled warming unit, cold bins, a food display cabinet and
cup dispensers on each side.
Warming Unit
A lighted rocker switch is located on the panel behind the
warming unit which turns the warmer on and off.
The temperature control for the warming unit is located at
the rear of the vending unit, behind the door (Ref Fig. 38
on page 20).
The thermostat setting should be no more than 1/4 turn
from the OFF position.
Ensure the warming unit is turned off and has cooled
down before attempting to clean the unit. Always turn the
warming unit off when not in use.
To drain the rear bins, open the door at the rear of the
unit and attach a section of plastic hose to the left side
valve and open the valve (Ref Fig. 38 on page 20). The
front bin can be drained through the right side valve.
Cleaning the Vending Unit
The entire unit should be cleaned using warm soapy
water. Wipe all surfaces with clean warm water.
To empty water from the cold bins, open lower door at
rear of vending unit and connect the clear hose to the
end of the PVC pipe on side wall (Ref Fig. 39 on page
20). (The valve on the left side empties rear bins, while
the valve on the right side empties the front bin.)
Turn release valve as shown to open and keep open until
all waste water has emptied.
The warming unit is powered by a separate battery and is
charged by the vehicle charging unit. Extensive use of
the warming unit and/or insufficient operation of the vehicle may result in the battery becoming discharged. If
recharge is necessary, use an automotive type 12V
charger rated at 10 amps or less. Follow all directions
and observe all manufacturers warnings provided with
charger.
Open
Position
Closed
Position
Clear Hose
MAX
Fig. 39 Empty Water from Bins
Moving the Vending Unit
Tool List
Qty. Required
Wrench, 1/2" ................................................................2
Use caution when moving the vending unit to
ensure the unit does not
trap fingers or other body parts that may cause
severe injury.
!
Fig. 38 Thermostat and Bin Drains
Cold Bins
The rear cold bin on each side of the vending unit are
shared bins with a perforated wall. The front bin on each
side is a separate bin.
Page 20
!
The vending unit may be moved to the rear for access to
the powertrain for maintenance and service.
To move the vending unit to the rear for powertrain maintenance and service, release the swell latch securing the
canopy frame to the top support strut (Ref Fig. 40 on
page 21).
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Canopy
Frame
Fig. 41 Releasing Mounting Frame
To return vehicle to operation, move vending unit to forward location and secure in reverse order of release.
Rear bolts must be installed before operating the vehicle.
The vending unit could inadvertently move during vehicle
operation and cause a loss of driver control if mounting
frame is not securely attached to vehicle chassis.
Fig. 40 Releasing Canopy Frame
Using a 1/2" wrench, remove the hardware securing the
vending unit mounting frame tab to the rear cross frame
(Ref Fig. 41 on page 21).
While lifting the canopy frame at the front slightly to
relieve the weight of the canopy frame on the front strut,
slide the unit to the rear (approximately 11 cm). Be sure
that canopy frame does not distort front support during
movement.
Removing the Vending Unit
Tool List
Qty. Required
Wrench, 9/16".............................................................. 2
Should the vending unit need to be removed completely,
use a 9/16" wrench and remove the hardware around the
perimeter of the vending unit securing unit to the mounting frame and lift the unit off the mounting frame.
Canopy
Canopy Frame
Cup Holder
Vending Unit
Food Display
Warming Unit Switch
Warming Unit
Cold Bins
Thermostat Control and Bin Drain Valves
Fig. 42 Vending Unit
Owner’s Manual and Service Guide
Page 21
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
TOP AND WINDSHIELD
!
!
cle. The rated capacity of the trailer towing a gasoline
vehicle must exceed the weight of the vehicle and load
(see GENERAL SPECIFICATIONS for vehicle weight).
For electric vehicles, add 178 kg for weight of batteries.
Lock the parking brake and secure the vehicle to the
trailer using ratchet tie downs.
The top does not provide
protection from roll over
or falling objects.
The windshield does not provide protection from tree
limbs or flying objects.
HARDWARE
Clean with lots of water and a clean cloth. Minor
scratches may be removed using a commercial plastic
polish or Plexus plastic cleaner available from E-Z-GO.
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref Fig. 44 on page
22). Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
torque values.
TRAILERING
Personal injury to occupants of other highway
vehicles may occur if
vehicle and contents are not adequately secured to
trailer.
Do not ride on vehicle being trailered.
Remove windshield before trailering. Maximum speed
with top is 80 kph.
!
!
Generally, two grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three
marks on the hexagonal head. Unmarked hardware is
Grade 2 (Ref Fig. 43 on page 22).
If the vehicle is to be transported on a trailer at highway
speeds, the windshield must be removed and the seat
bottom secured. Always check that the vehicle and contents are adequately secured before trailering the vehi-
Grade 2
Grade 5
TORQUE SPECIFICATIONS
ALL TORQUE FIGURES ARE IN Nm
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
The table below specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when installed
are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
BOLT SIZE
1/4"
5/16"
3/8"
7/16"
1/2"
9/16"
5/8"
3/4"
7/8"
1"
Grade 2
5
11
20
33
47
75
102
176
169
258
Grade 5
8
18
31
47
75
108
149
271
434
651
Fig. 44 Torque Specifications
Page 22
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
LABELS USED ON VEHICLE
It is important to understand the labels/pictograms
located on the vehicle. A breakdown of the pictograms
with an explanation of each is provided (Ref Fig. 45 on
Read Owner's Manual
before operating vehicle
Use caution when operating
in poor weather
Do not drink or use drugs
when operating vehicle
Caution
Vehicle is not intended
for use on highways
Warning: Risk of electric
shock present
Keep away from
flame
Dropping a metal object on batteries
may cause an explosion
Unleaded fuel from
grounded pump only
Do not ground to positive
Negative ground
Unleaded fuel only
Warning: Batteries contain
acid which may cause
damage or personal injury
To go forward, select 'F'. To go
in reverse, select 'R' (A warning
will sound when 'R' is selected)
Do not drive across slopes
in excess of 140
Keep hands away
Operate vehicle
from drivers seat only
If fuel is spilled, clean with water before
operating engine
page 23). Cross reference these with the pictorial representation of each label and be sure each label/pictogram
is fully understood.
Keep seated and
keep arms and legs
inside vehicle
Batteries contain Lead.
Dispose of batteries properly
(Do not place in trash can)
Do not fuel vehicle when
engine is hot
Bed load not to exceed specified weight
Place load at front of bed. Tie down load
Warning: Battery gases
are explosive
Danger of vehicle
tilting over
Do not lift dump bed when someone
is standing behind bed
Do not fill gas
can in load bed
Specified height maximum
on center of gravity load
Do not carry passengers
in load bed
Fig. 45 Labels/Pictograms
Owner’s Manual and Service Guide
Page 23
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
PERIODIC SERVICE SCHEDULE
Always ensure that mechanics performing repairs are
trained and qualified to do so.
✓ Check
♦ Clean, Adjust, etc.
▲ Replace
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions
DAILY
BODY
♦ Clean body components as required
BRAKE PEDAL
✓ Check for smooth operation
SERVICE BRAKE
✓ Check brake performance and adjust if required
PARKING BRAKE
✓ Check brake performance and adjust if required
REVERSE WARNING DEVICE
✓ Check operation when direction selector is in reverse
TIRES
✓ Examine for cuts, excessive wear and pressure (See GENERAL SPECIFICATIONS)
WHEELS
✓ Check for bent rims, missing or loose lug nuts
BATTERIES (ELECTRIC VEHICLES)
✓ Recharge to full state of charge after each day’s use
CHARGER / RECEPTACLE
✓ Inspect connector system at each charge
FUEL GAUGE
✓ Check for proper operation (at fueling), and fuel cap vent is free of dirt
MONTHLY - 20 HOURS (includes items listed in previous table & the following)
BATTERY(S)
♦ Clean battery(s) & terminals with 60 ml baking soda to 6 liters water solution, rinse with
clear water
✓ Check charge condition and all connections
WIRING
✓ Check all wiring for loose connections and broken/missing insulation
CHARGER / RECEPTACLE
♦ Clean connections, keep receptacles free of dirt and foreign matter
ACCELERATOR
✓ Check for smooth movement
DIRECTION SELECTOR
✓ Check attachment, tighten if required
STEERING ASSEMBLY
✓ Check for abnormal play, tightness of all hardware
TIE RODS/LINKAGES
✓ Check for excessive play, bent components or loose connections
PDS SYSTEM
✓ Check for proper operation of system
REAR AXLE
✓ Check for leakage, add SAE 30 oil as required
CHOKE CABLE
✓ Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE
CARBURETOR LINKAGE
✓ Check attachment, adjust as required
ENGINE
✓ Check for unusual noise, vibration, acceleration, oil leaks
STARTER/GENERATOR BELT
✓ Check for tension, wear, cracks
COOLING FAN
✓ Check for build-up of foreign matter inside blower housing and fins, clean if required
QUARTERLY - 50 HOURS (includes items listed in previous tables & the following)
FRONT AXLE
✓ Check for damage to axle and loose or missing hardware
Fig. 46 Periodic Service Schedule
Page 24
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
FRONT SHOCK ABSORBERS
✓ Check for oil leakage and loose mounting hardware
FRONT SPRINGS
✓ Check for loose hardware, cracks at attachments
FRONT WHEEL ALIGNMENT
✓ Check for unusual tire wear, align if required
PARKING (PARK) BRAKE
✓ Check for bent/binding linkage rod
✓ Check for damage or wear to latch arm or catch bracket
♦ Lubricate, use light oil. DO NOT LUBRICATE CABLES OR BRAKE LATCH
REAR SHOCK ABSORBERS
✓ Check for oil leakage, loose mounting hardware
ENGINE ELECTRICAL SYSTEM
✓ Check coil/spark plug wires for cracks/loose connections
FUEL SYSTEM
✓ Check for leaks at tank cap, lines, filters, pump, carburetor
✓ Check fuel lines for cracks/deterioration
THROTTLE/GOVERNOR LINKAGE
✓ Check operation and governed speed
CHARGER PLUG
♦ Clean auxiliary contact (see BATTERY CHARGER MAINTENANCE)
SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)
DIRECTION SELECTOR
✓ Check for wear and smooth movement (lubricate shaft with light oil if required)
KING PINS
✓ Check for excessive play and tightness of retaining nuts
♦ Lubricate, use wheel bearing grease
STEERING ASSEMBLY
♦ Lubricate linkage, use wheel bearing grease
TIE RODS/LINKAGES
♦ Lubricate, use wheel bearing grease
REAR AXLE
✓ Check for unusual noise and loose or missing mounting hardware
AIR CLEANER
✓ Check filter element, clean/replace as required
ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)
FRONT WHEEL BEARINGS
♦ Adjust, see Technician’s Repair and Service Manual
♦ Pack, use wheel bearing grease, see Technician’s Repair and Service Manual
REAR AXLE
✓ Check lubricant, add lubricant (SAE 30 oil) as required
▲ Replace lubricant after 5 years
SERVICE BRAKES
♦ Clean and adjust, see Technician’s Repair and Service Manual
✓ Check brake shoe linings, see Technician’s Repair and Service Manual
ENGINE OIL
▲ Replace with SAE 10W-30 or 10W-40 that meets or exceeds SF, SG, CC oil - DO NOT
OVERFILL
FUEL FILTER
✓ Check for dirt build-up
OIL FILTER
♦ Clean in solvent (at oil change), replace ‘O’ ring if required
SPARK PLUGS
▲ Gap .71 - .76 mm (replace if required)
MUFFLER/EXHAUST
✓ Check mounting hardware; check for leaks at head and muffler gaskets
VALVES
✓ Check cold at cam (intake/exhaust) per Technician’s Repair and Service Manual
TIMING BELT
✓ Check tension, and for signs of wear/damage, see Technician’s Repair and Service
Manual
Fig. 46 Periodic Service Schedule
Owner’s Manual and Service Guide
Page 25
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
BATTERIES AND CHARGING FOR ELECTRIC
VEHICLES
Safety
Always observe the following warnings when
working on or near batteries:
Wrap wrenches with vinyl
tape to prevent the possibility of a dropped wrench from
‘shorting out’ a battery,
which could result in an explosion and severe personal injury or death.
Keep all smoking materials, open flame or sparks
away from the batteries.
Hydrogen gas is formed when charging batteries. Do
not charge batteries without adequate ventilation. A
4% concentration of hydrogen gas is explosive.
Be sure that the key switch is off and all electrical
accessories are turned off before starting work on
vehicle.
Never disconnect a circuit under load at a battery terminal.
Batteries are heavy. Use proper
lifting techniques when moving
them. Always lift the battery with
a commercially available battery
lifting device. Use care not to tip
batteri es when removing or
installing them; spilled electrolyte
can cause burns and damage.
The electrolyte in a storage battery is an acid solution
which can cause severe burns to the skin and eyes.
Treat all electrolyte spills to the body and eyes with
extended flushing with clear water. Contact a physician immediately.
Always wear a safety shield or approved
safety goggles when adding water or
charging batteries.
BATTERY
Any electrolyte spills should be neutralized with a
solution of 60 ml sodium bicarbonate (baking soda)
dissolved in 6 liters of water and flushed with water.
Overfilling batteries may result in electrolyte being
expelled from the battery during the charge cycle.
Expelled electrolyte may cause damage to the vehicle
and storage facility.
Aerosol containers of battery terminal protectant
must be used with extreme care. Insulate the metal
container to prevent the metal can from contacting
battery terminals which could result in an explosion.
At Each Charging Cycle
Page 26
A battery is defined as two dissimilar metals immersed in
an acid. If the acid is absent or if the metals are not dissimilar, a battery has not been created. The batteries
most commonly used in these vehicles are lead acid.
A battery does not store electricity, but is able to produce
electricity as the result of a chemical reaction which
releases stored chemical energy in the form of electrical
energy. The chemical reaction takes place faster in warm
conditions and slower in cold conditions. Temperature is
important when conducting tests on a battery and test
results must be corrected to compensate for temperature
differences.
As a battery ages, it still performs adequately except that
its capacity is diminished. Capacity describes the time
that a battery can continue to provide its design amperes
from a full charge.
A battery has a maximum life, therefore good maintenance is designed to maximize the available life and
reduce the factors that can reduce the life of the battery.
BATTERY MAINTENANCE
Tool List
Qty. Required
Insulated wrench, 9/16" ...............................................1
Battery carrier..............................................................1
Hydrometer ..................................................................1
Battery maintenance kit P/N 25587-G01 .....................1
Never attach a battery
charger to a vehicle that
is to be unattended
beyond the normal charging cycle. Overcharging
could cause damage to the vehicle batteries and
result in extreme overheating. The charger should be
checked after 24 hours and unplugged after the
charge cycle is complete.
Owner’s Manual and Service Guide
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Before charging the batteries, inspect the plug of the battery charger and vehicle receptacle housing for dirt or
debris.
Charge the batteries after each days use.
Monthly
• Inspect all wiring for fraying, loose terminations,
corrosion or deterioration of insulation.
• Check that the electrolyte level is correct and add
•
suitable water as required.
Clean the batteries and wire terminations.
Electrolyte Level and Water
The correct level of the electrolyte is 13 mm above the
plates in each cell (Ref Fig. 47 on page 27).
Vent Cap
Expansion
Space
Gas Vent
6 to 10 mm
This gas is hydrogen which is lighter than air. Water and
sulfuric acid droplets will be carried out of the battery
vents by the hydrogen gas; however, this loss is minimal.
If the battery electrolyte level is too high, the electrolyte
will block the vent tube and the gas will force it out of the
vent tube and battery cap. The water will evaporate but
the sulfuric acid will remain where it can damage vehicle
components and the storage facility floor. Sulfuric acid
loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery.
Over the life of the battery, a considerable amount of
water is consumed. It is important that the water used be
pure and free of contaminants that could reduce the life
of the battery by reducing the chemical reaction. The
water must be distilled or purified by an efficient filtration
system. Water that is not distilled should be analyzed
and if required, filtration installed to permit the water to
meet the requirements of the water purity table (Ref Fig.
48 on page 27).
Impurity
Parts Per
Million
Vent
Color................................................................................ Clear
Suspended ......................................................................Trace
13 mm
Plates
Electrolyte level should
be at least 13 mm
above the plates and
6 to 10 mm below vent
Total Solids ...................................................................... 100
Calcium & Magnesium Oxides .......................................... 40
Iron ..................................................................................... 5
Ammonia ............................................................................ 8
Organic & Volatile Matter .................................................. 50
Nitrites ................................................................................ 5
Fig. 47 Correct Electrolyte Level
Nitrates .............................................................................. 10
This level will leave approximately 6 - 10 mm of space
between the electrolyte and the vent tube. The electrolyte
level is important since any portion of the plates
exposed to air will be ruined beyond repair. Of equal
importance is too much water which will result in electrolyte being forced out of the battery due to gassing and
the increase in volume of the electrolyte that results from
the charging cycle.
Chloride .............................................................................. 5
Do not overfill batteries. The charging
cycle will expel electrolyte and result in
component damage.
Unless the electrolyte is at or below the plates, all watering
should be done after charging.
A battery being charged will ‘gas’ with the majority of the
gassing taking place at the end of the charging cycle.
Fig. 48 Water Purity Table
Even if the water is colorless, odorless, tasteless and fit
for drinking, the water should be analyzed to see that it
does not exceed the impurity levels specified in the table.
Automatic watering devices such as the one included in
the E-Z-GO Battery Maintenance Kit (P/N 25587-G01)
can be used with an approved water source (Ref Fig. 49
on page 28). These watering devices are fast and accurate to use and maintain the correct electrolyte level
within the battery cells.
The watering device should only be used if the
electrolyte level is less than 13 mm above top
of plates.
Owner’s Manual and Service Guide
Page 27
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Watering gun similar to the type included in the
E-Z-GO Battery Maintenance Kit
6 liters
Clear Water
60 ml
Sodium Bicarbonate
(Baking Soda)
Valve consistently
fills to a
predetermined
level
Non Metalic
Wand
Electrolyte
Level
Pure Water
7.5 liter
Garden Sprayer
Single Battery Cell
Fig. 49 Automatic Watering Gun
Cleaning Batteries
When cleaning the outside of the batteries and terminals,
do not use a water hose without first spraying with a solution of sodium bicarbonate (baking soda) and water to
neutralize any acid deposits.
Use of a water hose without first neutralizing any acid,
will move acid from the top of the batteries to another
area of the vehicle or storage facility where it will attack
the metal structure or the concrete/asphalt floor. After
hosing down the batteries, a residue will be left on the
batteries which is conductive and will contribute to the
discharge of the batteries.
To prevent battery damage, be sure that
all battery caps are tightly installed.
The correct cleaning technique is to spray the top and
sides of the batteries with a solution of sodium bicarbonate (baking soda) and water. This solution is best applied
with a garden type sprayer equipped with a non metallic
spray wand. The solution should consist of 60 ml of
sodium bicarbonate (baking soda) mixed with 6 liters of
clear water (Ref Fig. 50 on page 28). In addition to the
batteries, special attention should be paid to metallic
components adjacent to the batteries which should also
be sprayed with the sodium bicarbonate (baking soda)
solution.
Page 28
Fig. 50 Preparing Acid Neutralizing Solution
Allow the solution to sit for at least three minutes; use a
soft bristle brush or cloth to wipe the tops of the batteries
in order to remove any residue that could cause the self
discharge of the battery. Rinse the entire area with low
pressure clear water. All of the items required for complete battery cleaning and watering are contained in the
E-Z-GO Battery Maintenance Kit (P/N 25587-G01).
Cleaning should take place once a month or more often
under extreme conditions.
Battery Replacement
Remove battery hold downs and cables. Lift out batteries
with a commercially available lifting device.
If the batteries have been cleaned and any acid in the
battery rack area neutralized as recommended, no corrosion to the battery racks or surrounding area should be
present. Any corrosion found should be immediately
removed with a putty knife and a wire brush. The area
should be washed with a solution of sodium bicarbonate
(baking soda) and water and thoroughly dried before
priming and painting with a corrosion resistant paint.
The batteries should be placed into the battery racks and
the battery hold downs tightened to 5 - 6 Nm torque, to
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
prevent movement but not tight enough to cause distortion of the battery cases.
Inspect all wires and terminals. Clean any corrosion from
the battery terminals or the wire terminals with a solution
of sodium bicarbonate (baking soda) and brush clean if
required.
Use care to connect the battery wires as shown (Ref Fig.
51 on page 29). Tighten the battery post hardware to 7 10 Nm torque.
+
Front of Vehicle
-
+
-
-
+
+
-
-
+
BL +
-
BL -
+
Fig. 51 Battery Connections
Aerosol containers of
battery term inal protectant must be used
with extreme care. Insulate the metal container to prevent the metal can from contacting battery terminals
which could result in an explosion.
Protect the battery terminals and battery wire terminals
with a commercially available protective coating. Reinstall all rubber boots at each terminal.
Prolonged Storage
Battery charger and controller must be
disconnected since they will contribute
to the premature discharge of batteries. Other electronic devices
may need to be disconnected.
During periods of storage, the batteries will need attention to keep them maintained and prevent discharge.
In high temperatures the chemical reaction is faster,
while low temperatures cause the chemical reaction to
slow down. A vehicle that is stored at 32° C will lose .002
of specific gravity each day. If a fully charged battery has
a specific gravity of 1.275, and the battery is allowed to
sit unused, it will become partially discharged. When it
reaches 1.240, which it will do in less than twenty days, it
should be recharged. If a battery is left in a discharged
state, sulfating takes place on and within the plates. This
condition is not reversible and will cause permanent
damage to the battery. In order to prevent damage, the
battery should be recharged. A hydrometer (E-Z-GO P/N
50900-G1) can be used to determine the specific gravity
and therefore the state of charge of a battery.
In winter conditions, the battery must be fully charged to
prevent the possibility of freezing (Ref Fig. 52 on page
29). A fully charged battery will not freeze in temperatures above -60° C. Although the chemical reaction is
slowed in cold temperatures, the battery must be stored
fully charged, and disconnected from any circuit that
could discharge the battery. Disconnect the charging
plug from the vehicle receptacle. The batteries must be
cleaned and all deposits neutralized and removed from
the battery case to prevent self discharge. The batteries
should be tested or recharged at thirty day minimum
intervals.
E
L
E
C
T
R
O
L
Y
T
E
O
C
-9
-15
-21
-26
-32
-37
T
E
M
P
E
R
A
T
U
R
E
-43
-48
-54
-60
-65
-71
1.100 1.140 1.180 1.220 1.260 1.300
1.120 1.160 1.200 1.240 1.280
SPECIFIC GRAVITY
ELECTROLYTE FREEZING POINT
Fig. 52 Freezing Point of Electrolyte
Battery Charging
The battery charger is designed to fully charge the battery set. If the batteries are severely deep cycled, some
automatic battery chargers contain an electronic module
that may not activate and the battery charger will not
function. Automatic chargers will determine the correct
duration of charge to the battery set and will shut off
Owner’s Manual and Service Guide
Page 29
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
when the battery set is fully charged. Always refer to the
instructions of the specific charger used.
Before charging, the following should be observed:
Do not overfill batteries. The charging
cycle will expel electrolyte and result in
component damage.
• The electrolyte level in all cells must be at the rec•
•
•
•
•
ommended level and cover the plates.
The charging must take place in an area that is
well ventilated and capable of removing the hydrogen gas that is generated by the charging process. A minimum of five air exchanges per hour is
recommended, or comply with local codes.
The charging connector components are in good
condition and free from dirt or debris.
The charger connector is fully inserted into the
vehicle receptacle.
The charger connector/cord set is protected from
damage and is located in an area to prevent injury
that may result from personnel running over or
tripping over the cord set.
The charger is automatically turned off during the
connect/disconnect cycle and therefore no electrical arc is generated at the DC plug/receptacle
contacts.
In some portable chargers, there will be a rattle
present in the body of the charger DC plug.
This rattle is caused by an internal magnet contained within the
charger plug. The magnet is part of the interlock system that
prevents the vehicle from being driven when the charger plug is
inserted in the vehicle charging receptacle.
AC Voltage
Battery charger output is directly related to the input voltage. If multiple vehicles are receiving an incomplete
charge in a normally adequate time period, low AC voltage could be the cause and the power supplier should be
consulted.
TROUBLESHOOTING
In general, troubleshooting will be done for two distinct
reasons. First, a battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the
manufacturer’s warranty. Different manufacturers have
different requirements. Consult the battery manufacturer
or an E-Z-GO representative for specific requirements.
Page 30
The second reason is to determine why a particular vehicle does not perform adequately. Performance problems
may result in a vehicle that runs slowly or in a vehicle that
is unable to operate for the time required.
A new battery must mature before it will develop its maximum capacity. Maturing may take up to 100 charge/discharge cycles. After the maturing phase, the older a
battery gets, the lower the capacity. The only way to
determine the capacity of a battery is to perform a load
test using a discharge machine.
A cost effective way to identify a poorly performing battery is to use a hydrometer to identify a battery in a set
with a lower than normal specific gravity. Once the particular cell or cells that are the problem are identified, the
suspect battery can be removed and replaced. At this
point there is nothing that can be done to salvage the
battery; however, the individual battery should be
replaced with a good battery of the same brand, type and
approximate age.
Hydrometer
A hydrometer (E-Z-GO P/N 50900-G1) is used to test the
state of charge of a battery cell (Ref Fig. 53 on page 31).
This is performed by measuring the density of the electrolyte, which is accomplished by measuring the specific
gravity of the electrolyte. The greater the concentration of
sulfuric acid, the more dense the electrolyte becomes.
The higher the density, the higher the state of charge.
To prevent a battery
explosion, never insert a
metal thermometer into a
battery. Use a hydrometer with a built in thermometer
that is designed for testing batteries.
Specific gravity is the measurement of a liquid that is
compared to a baseline. The baseline is water which is
assigned a base number of 1.000. The concentration of
sulfuric acid to water in a new battery is 1.280 which
means that the electrolyte weighs 1.280 times the weight
of the same volume of water. A fully charged battery will
test at 1.275 - 1.280 while a discharged battery will read
in the 1.140 range.
Do not perform a hydrometer test on a battery
that has just been watered. The battery must
go through at least one charge and discharge cycle in order to
permit the water to adequately mix with the electrolyte.
The temperature of the electrolyte is important since the
hydrometer reading must be corrected to 27° C. High
quality hydrometers are equipped with an internal ther-
Owner’s Manual and Service Guide
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
mometer that will measure the temperature of the electrolyte and will include a conversion scale to correct the
float reading. It is important to recognize that the electrolyte temperature is significantly different from the ambient
temperature if the vehicle has been operated.
Float
Bulb
1100
Cylinder
1125
1150
1175
1200
Add to Float
Reading
Subtract
from Float
Reading
32
28
24
20
16
12
8
4
0
4
8
12
16
20
24
28
32
36
Using A Hydrometer
1. Draw electrolyte into the hydrometer several times to
permit the thermometer to adjust to the electrolyte
temperature and note the reading. Examine the color
of the electrolyte. A brown or gray coloration indicates
a problem with the battery and is a sign that the battery is nearing the end of its life.
2. Draw the minimum quantity of electrolyte into the
hydrometer to permit the float to float freely without
contacting the top or bottom of the cylinder.
3. Hold the hydrometer in a vertical position at eye level
and note the reading where the electrolyte meets the
scale on the float.
1225
1250
1275
1300
1100
1125
1150
1200
1225
1250
1275
1300
32
28
24
20
16
12
8
4
0
4
8
12
16
20
24
28
32
36
Weight
4. Add or subtract four points (.004) to the reading for
every 6° C the electrolyte temperature is above or
below 27° C. Adjust the reading to conform with the
electrolyte temperature, e.g., if the reading indicates a
specific gravity of 1.250 and the electrolyte temperature is 32° C, add four points (.004) to the 1.250
which gives a corrected reading of 1.254. Similarly if
the temperature was 21° C, subtract four points
(.004) from the 1.250 to give a corrected reading of
1.246 (Ref Fig. 54 on page 32).
5. Test each cell and note the readings (corrected to 27°
C. A variation of fifty points between any two cell
readings (example 1.250 - 1.200) indicates a problem
with the low reading cell(s).
As a battery ages the specific gravity of the electrolyte
will decrease at full charge. This is not a reason to
replace the battery, providing all cells are within fifty
points of each other.
Thermometer
Fig. 53 Hydrometer
Since the hydrometer test is in response to a vehicle
exhibiting a performance problem, the vehicle should be
recharged and the test repeated. If the results indicate a
weak cell, the battery or batteries should be removed
and replaced with a good battery of the same brand, type
and approximate age.
Owner’s Manual and Service Guide
Page 31
ELECTRIC AND GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
BATTERY CHARGER MAINTENANCE
Electrolyte
Temp.
°C
71
66
60
54
49
43
38
32
27
21
16
10
4
-1
-7
-12
The only maintenance required for the charger is the
periodic cleaning of the DC connector auxiliary contact.
+.032
+.030
+.028
+.026
+.024
+.022
+.020
+.018
+.016
+.014
+.012
+.010
+.008
+.006
+.004
+.002
0
-.002
-.004
-.006
-.008
-.010
-.012
-.014
-.016
-.018
-.020
-.022
-.024
-.026
-.028
EXAMPLE #1:
Electrolyte Temp.
above 27°C
Electrolyte temperature
32° C
Hydrometer reading 1.250
1.250 + .004 = 1.254
corrected specific gravity
To clean the auxiliary contact, slide an emery board
between the main contact and auxiliary contact located
in the hole in the end of the charger plug with rounded
corners (Ref Fig. 55 on page 32). Pressing emery board
down to apply pressure to the auxiliary contact, slide in
and out of plug approximately 10 to 20 times, keeping
pressure applied to the scrub contact surface.
Main Contact
Auxiliary Contact
EXAMPLE #2:
Electrolyte Temp.
below 27 °C
Electrolyte temperature
21° C
Hydrometer reading 1.250
1.250 - .004 = 1.246
corrected specific gravity
Fig. 55 Cleaning Auxiliary Contact in Charger Plug
Fig. 54 Hydrometer Temperature Correction
Page 32
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Owner’s Manual and Service Guide
Page 33
GENERAL SPECIFICATIONS
INDUSTRIAL 800E
WEIGHT (without batteries) ..................................................... 308 kg
TIRES (4 ply rated) .................................................................. 18 x 5.70 x 8
TIRE PRESSURE .................................................................... 240 - 310 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ..............................360 kg
LOAD BED ............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Flexible, impact resistant panels. Color coat/clear coat finish
and/or
Heavy duty four way diamond pattern body panels, modified acrylic
topcoat over polyester primer
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL ................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION...............................................................Leaf springs with hydraulic shock absorbers
STEERING............................................................................... Self-compensating single reduction rack and pinion
DASH PANEL ........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
MOTOR .................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper
windings. 1.5 kw at 2800 rpm and 2.2 kw at 2350 rpm
DRIVE TRAIN .......................................................................... Direct motor shaft connected to transaxle pinion shaft
ELECTRICAL SYSTEM ........................................................... 36 volt DC, six, 6 volt deep cycle storage batteries
SPEED CONTROL .................................................................. Solid State continuously variable speed controller
TRANSAXLE............................................................................ High efficiency differential with helical gears, 12.44:1 ratio
SPEED ..................................................................................... 19 - 23 kph
CHARGER ............................................................................... Refer to specifications of charger supplied with vehicle
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Page 34
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
WORKHORSE® 800E
WEIGHT (without batteries)..................................................... 308 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 360 kg
LOAD BED............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers
STEERING .............................................................................. Self-compensating single reduction rack and pinion
DASH PANEL........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
MOTOR.................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper
windings. 1.5 kw at 2800 rpm and 2.2 kw at 2350 rpm
DRIVE TRAIN .......................................................................... Direct motor shaft connected to transaxle pinion shaft
ELECTRICAL SYSTEM ........................................................... 36 volt DC, six, 6 volt deep cycle storage batteries
SPEED CONTROL .................................................................. Solid State continuously variable speed controller
TRANSAXLE ........................................................................... High efficiency differential with helical gears, 12.44:1 ratio
SPEED..................................................................................... 19 - 23 kph
CHARGER ............................................................................... Refer to specifications of charger supplied with vehicle
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Owner’s Manual and Service Guide
Page 35
GENERAL SPECIFICATIONS
WORKHORSE® 800LX E
WEIGHT (without batteries) ..................................................... 308 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 360 kg
LOAD BED ............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL ................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION...............................................................Leaf springs with hydraulic shock absorbers
STEERING............................................................................... Self-compensating single reduction rack and pinion
DASH PANEL ........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
MOTOR .................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper
windings. 1.5 kw at 2800 rpm and 2.2 kw at 2350 rpm
DRIVE TRAIN .......................................................................... Direct motor shaft connected to transaxle pinion shaft
ELECTRICAL SYSTEM ........................................................... 36 volt DC, six, 6 volt deep cycle storage batteries
SPEED CONTROL .................................................................. Solid State continuously variable speed controller
TRANSAXLE............................................................................ High efficiency differential with helical gears, 12.44:1 ratio
SPEED ..................................................................................... 19 - 23 kph
CHARGER ............................................................................... Refer to specifications of charger supplied with vehicle
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Page 36
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
WORKHORSE® 1000
WEIGHT (without batteries)..................................................... 374 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 450 kg
LOAD BED............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’ and electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers
STEERING .............................................................................. Self-compensating single reduction rack and pinion
DASH PANEL........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
MOTOR.................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper
windings. 1.5 kw at 2800 rpm and 2.2 kw at 2350 rpm
DRIVE TRAIN .......................................................................... Direct motor shaft connected to transaxle pinion shaft
ELECTRICAL SYSTEM ........................................................... 36 volt DC, six, 6 volt deep cycle storage batteries
SPEED CONTROL .................................................................. Solid State continuously variable speed controller
TRANSAXLE ........................................................................... High efficiency differential with helical gears, 12.44:1 ratio
SPEED..................................................................................... 19 - 23 kph
CHARGER ............................................................................... Refer to specifications of charger supplied with vehicle
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Owner’s Manual and Service Guide
Page 37
GENERAL SPECIFICATIONS
WORKHORSE® 1000LX
WEIGHT (without batteries) ..................................................... 374 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 450 kg
LOAD BED ............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’ and electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL ................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION...............................................................Leaf springs with hydraulic shock absorbers
STEERING............................................................................... Self-compensating single reduction rack and pinion
DASH PANEL ........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
MOTOR .................................................................................... 36 volt DC high efficiency series wound, brazed armature, solid copper
windings. 1.5 kw at 2800 rpm and 2.2 kw at 2350 rpm
DRIVE TRAIN .......................................................................... Direct motor shaft connected to transaxle pinion shaft
ELECTRICAL SYSTEM ........................................................... 36 volt DC, six, 6 volt deep cycle storage batteries
SPEED CONTROL .................................................................. Solid State continuously variable speed controller
TRANSAXLE............................................................................ High efficiency differential with helical gears, 12.44:1 ratio
SPEED ..................................................................................... 19 - 23 kph
CHARGER ............................................................................... Refer to specifications of charger supplied with vehicle
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Page 38
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
INDUSTRIAL 800G
WEIGHT (dry fuel tank) ........................................................... 354 kg
TIRES (4 ply rated) .................................................................. 18 x 5.70 x 8
TIRE PRESSURE .................................................................... 240 - 310 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 360 kg
LOAD BED............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Flexible, impact resistant panels. Color coat/clear coat finish
and/or
Heavy duty four way diamond pattern body panels, modified acrylic
topcoat over polyester primer
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers
STEERING .............................................................................. Self-compensating single reduction rack and pinion
DASH PANEL........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
ENGINE ................................................................................... 6.7 kw rated, 4 cycle, 295cc twin cylinder air cooled
VALVE TRAIN .......................................................................... Overhead valve, overhead cam, belt drive
LUBRICATION ......................................................................... Pressurized oil system, washable permanent filter
BALANCER ............................................................................. Internal counter rotating balance shaft
IGNITION ................................................................................. Solid State, electronic timing advance and RPM limiter
CARBURETOR ........................................................................ Fixed jet float bowl with remote pulse fuel pump
AIR CLEANER ......................................................................... Engine mounted with replaceable dry cartridge element
DRIVE TRAIN .......................................................................... Automatic, continuously variable transmission (CVT) forward and
reverse
ELECTRICAL SYSTEM ........................................................... External starter/generator, solid state regulator, 12 volt maintenance
free battery, 430 CCA, 60 minute reserve
TRANSAXLE ........................................................................... High efficiency differential with helical gears, 13.32:1 ratio, ground
speed governed
FUEL SYSTEM ........................................................................ 22.5 liter tank with electric, dash mounted fuel gauge, or optional dash
mounted low fuel warning light
SPEED..................................................................................... 24 kph governed speed
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Owner’s Manual and Service Guide
Page 39
GENERAL SPECIFICATIONS
WORKHORSE® 800G
WEIGHT (dry fuel tank)............................................................ 354 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8 (4 ply rated)
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 360 kg
LOAD BED ............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL ................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION...............................................................Leaf springs with hydraulic shock absorbers
STEERING............................................................................... Self-compensating single reduction rack and pinion
DASH PANEL ........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
ENGINE ................................................................................... 6.7 kw rated, 4 cycle, 295cc twin cylinder air cooled
VALVE TRAIN .......................................................................... Overhead valve, overhead cam, belt drive
LUBRICATION ......................................................................... Pressurized oil system, washable permanent filter
BALANCER.............................................................................. Internal counter rotating balance shaft
IGNITION ................................................................................. Solid State, electronic timing advance and RPM limiter
CARBURETOR ........................................................................ Fixed jet float bowl with remote pulse fuel pump
AIR CLEANER ......................................................................... Engine mounted with replaceable dry cartridge element
DRIVE TRAIN .......................................................................... Automatic, continuously variable transmission (CVT) forward and
reverse
ELECTRICAL SYSTEM ........................................................... External starter/generator, solid state regulator, 12 volt maintenance
free battery, 430 CCA, 60 minute reserve
TRANSAXLE............................................................................ High efficiency differential with helical gears, 13.32:1 ratio, ground
speed governed
FUEL SYSTEM ........................................................................ 22.5 liter tank with electric, dash mounted fuel gauge, or optional dash
mounted low fuel warning light
SPEED ..................................................................................... 24 kph governed speed
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Page 40
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
WORKHORSE® 800LX G
WEIGHT (dry fuel tank) ........................................................... 354 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8 (4 ply rated)
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 360 kg
LOAD BED............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes. Automatic
park brake release with self-compensating system
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers
STEERING .............................................................................. Self-compensating single reduction rack and pinion
DASH PANEL........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
ENGINE ................................................................................... 6.7 kw rated, 4 cycle, 295cc twin cylinder air cooled
VALVE TRAIN .......................................................................... Overhead valve, overhead cam, belt drive
LUBRICATION ......................................................................... Pressurized oil system, washable permanent filter
BALANCER ............................................................................. Internal counter rotating balance shaft
IGNITION ................................................................................. Solid State, electronic timing advance and RPM limiter
CARBURETOR ........................................................................ Fixed jet float bowl with remote pulse fuel pump
AIR CLEANER ......................................................................... Engine mounted with replaceable dry cartridge element
DRIVE TRAIN .......................................................................... Automatic, continuously variable transmission (CVT) forward and
reverse
ELECTRICAL SYSTEM ........................................................... External starter/generator, solid state regulator, 12 volt maintenance
free battery, 430 CCA, 60 minute reserve
TRANSAXLE ........................................................................... High efficiency differential with helical gears, 13.32:1 ratio, ground
speed governed
FUEL SYSTEM ........................................................................ 22.5 liter tank with electric, dash mounted fuel gauge, or optional dash
mounted low fuel warning light
SPEED..................................................................................... 24 kph governed speed
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Owner’s Manual and Service Guide
Page 41
GENERAL SPECIFICATIONS
WORKHORSE® 1200
WEIGHT (dry fuel tank) 102 cm bed........................................ 413 kg
WEIGHT (dry fuel tank) 122 cm bed........................................ 418 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 540 kg
LOAD BED ............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL ................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes.
Self-compensating foot operated park brake with hand release
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION...............................................................Leaf springs with hydraulic shock absorbers
STEERING............................................................................... Self-compensating single reduction rack and pinion
DASH PANEL ........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
ENGINE ................................................................................... 8.2 kw rated, 4 cycle, 350cc twin cylinder air cooled
VALVE TRAIN .......................................................................... Overhead valve, overhead cam, belt drive
LUBRICATION ......................................................................... Pressurized oil system, washable permanent filter
BALANCER.............................................................................. Internal counter rotating balance shaft
IGNITION ................................................................................. Solid State, electronic timing advance and RPM limiter
CARBURETOR ........................................................................ Fixed jet float bowl with remote pulse fuel pump
AIR CLEANER ......................................................................... Engine mounted with replaceable dry cartridge element
DRIVE TRAIN .......................................................................... Automatic, continuously variable transmission (CVT) forward and
reverse
ELECTRICAL SYSTEM ........................................................... External starter/generator, solid state regulator, 12 volt maintenance
free battery, 360 CCA, 60 minute reserve
TRANSAXLE............................................................................ High efficiency differential with helical gears, 13.32:1 ratio, ground
speed governed
FUEL SYSTEM ........................................................................ 22.5 liter tank with electric, dash mounted fuel gauge, or optional dash
mounted low fuel warning light
SPEED ..................................................................................... 24 kph governed speed
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Page 42
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
WORKHORSE® 1200LX
WEIGHT (dry fuel tank) 102 cm bed........................................ 413 kg
WEIGHT (dry fuel tank) 122 cm bed........................................ 418 kg
TIRES (4 ply rated) .................................................................. 18 x 8.50 x 8
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 540 kg
LOAD BED............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes.
Self-compensating foot operated park brake with hand release
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION .............................................................. Leaf springs with hydraulic shock absorbers
STEERING .............................................................................. Self-compensating single reduction rack and pinion
DASH PANEL........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
ENGINE ................................................................................... 8.2 kw rated, 4 cycle, 350cc twin cylinder air cooled
VALVE TRAIN .......................................................................... Overhead valve, overhead cam, belt drive
LUBRICATION ......................................................................... Pressurized oil system, washable permanent filter
BALANCER ............................................................................. Internal counter rotating balance shaft
IGNITION ................................................................................. Solid State, electronic timing advance and RPM limiter
CARBURETOR ........................................................................ Fixed jet float bowl with remote pulse fuel pump
AIR CLEANER ......................................................................... Engine mounted with replaceable dry cartridge element
DRIVE TRAIN .......................................................................... Automatic, continuously variable transmission (CVT) forward and
reverse
ELECTRICAL SYSTEM ........................................................... External starter/generator, solid state regulator, 12 volt maintenance
free battery, 360 CCA, 60 minute reserve
TRANSAXLE ........................................................................... High efficiency differential with helical gears, 13.32:1 ratio, ground
speed governed
FUEL SYSTEM ........................................................................ 22.5 liter tank with electric, dash mounted fuel gauge, or optional dash
mounted low fuel warning light
SPEED..................................................................................... 24 kph governed speed
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Owner’s Manual and Service Guide
Page 43
GENERAL SPECIFICATIONS
OASIS™
WEIGHT (dry fuel tank)............................................................ 640 kg
TIRES ......................................................................................18 x 8.50 x 8 (4-ply rated) (Front)
18 x 9.50 x 8 (6-ply rated) (Rear)
TIRE PRESSURE .................................................................... 120 - 150 kPa
CLEARANCE AT DIFFERENTIAL ........................................... 10.8 cm
LOAD CAPACITY (including operator, passenger,
cargo and accessories) ............................. 540 kg
LOAD BED ............................................................................... Heavy duty bed and tailgate liners, optional electric lift
CHASSIS ................................................................................. Welded high yield strength tubular steel with powder coat paint
BODY & FINISH ....................................................................... Front: Flexible, impact resistant panels. Color coat/clear coat finish
Rear: Lightweight, replaceable steel panels
SAFETY ................................................................................... Dash mounted key switch, reverse warning indicator, ‘deadman’
accelerator control, integral handgrip on hip restraints, manual forward/
reverse selector with ‘neutral’, electric horn
LIGHTING PACKAGE .............................................................. Headlights, optional taillights, brake lights
STEERING WHEEL ................................................................. Dual handgrips and pencil holder integrated with clipboard
BRAKES .................................................................................. Dual rear wheel, self-adjusting mechanical drum brakes.
Self-compensating foot operated park brake with hand release
FRONT SUSPENSION ............................................................ Leaf springs with hydraulic shock absorbers
REAR SUSPENSION...............................................................Leaf springs with hydraulic shock absorbers
STEERING............................................................................... Self-compensating single reduction rack and pinion
DASH PANEL ........................................................................... Scuff resistant with four drink holders
SEATING.................................................................................. Formed fabric backed vinyl covers over cushion foam. Seating for
operator and one passenger
ENGINE ................................................................................... 8.2 kw rated, 4 cycle, 350cc twin cylinder air cooled
VALVE TRAIN .......................................................................... Overhead valve, overhead cam, belt drive
LUBRICATION ......................................................................... Pressurized oil system, washable permanent filter
BALANCER.............................................................................. Internal counter rotating balance shaft
IGNITION ................................................................................. Solid State, electronic timing advance and RPM limiter
CARBURETOR ........................................................................ Fixed jet float bowl with remote pulse fuel pump
AIR CLEANER ......................................................................... Engine mounted with replaceable dry cartridge element
DRIVE TRAIN .......................................................................... Automatic, continuously variable transmission (CVT) forward and
reverse
ELECTRICAL SYSTEM ........................................................... External starter/generator, solid state regulator, 12 volt maintenance
free battery, 360 CCA, 60 minute reserve
TRANSAXLE............................................................................ High efficiency differential with helical gears, 13.32:1 ratio, ground
speed governed
FUEL SYSTEM ........................................................................ 22.5 liter tank with electric, dash mounted fuel gauge, or optional dash
mounted low fuel warning light
SPEED ..................................................................................... 16 kph governed speed
Specifications subject to change without notice
WARNING
This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be
required to take adequate measures.
Page 44
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
25 cm
119 cm
166 cm
262 cm
85 cm (Front)
97 cm (Rear)
89 cm
WORKHORSE® 800E
INDUSTRIAL 800E
WORKHORSE® 800G
INDUSTRIAL 800G
117 cm
31 cm
116 cm
85 cm (Front)
97 cm (Rear)
196 cm
281 cm
301 cm
122 cm
102 cm
WORKHORSE® 1000
WORKHORSE® 1200
122 cm
Note: Long bed dimensions
applicable to some 1200G
models only
Fig. 56 Vehicle Dimensions
Owner’s Manual and Service Guide
Page 45
GENERAL SPECIFICATIONS
25 cm
123 cm
166 cm
262 cm
85 cm (Front)
97 cm (Rear)
89 cm
WORKHORSE® 800LX E
WORKHORSE® 800LX G
117 cm
31 cm
123 cm
196 cm
281 cm
301 cm
85 cm (Front)
97 cm (Rear)
122 cm
102 cm
WORKHORSE® 1000LX
WORKHORSE® 1200LX
122 cm
Note: Long bed dimensions
applicable to some 1200LX
models only
Fig. 57 Vehicle Dimensions (LX Models)
Page 46
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
118 cm
TM
64 cm
196 cm
281 cm
122 cm
Fig. 58 Vehicle Dimensions (OasisTM)
Owner’s Manual and Service Guide
Page 47
GENERAL SPECIFICATIONS
RECOMMENDED MAX RAMP
25% GRADE or 14o MAX
RECOMMENDED MAX SIDE TILT
25% GRADE or 14o MAX
TURNING CLEARANCE DIAMETER
800E and 800G models - 5.8 m
1000 and 1200 models - 6.4 m
OasisTM- 6.4 m
Fig. 59 Incline Specifications and Turning Clearance Diameter
Page 48
Owner’s Manual and Service Guide
INTERNATIONAL LIMITED WARRANTY
INTERNATIONAL
LIMITED WARRANTY
Owner’s Manual and Service Guide
Page 49
INTERNATIONAL LIMITED WARRANTY
1. WARRANTY: E-Z-GO DIVISION OF TEXTRON INC. (“E-Z-GO”) hereby warrants to the Original Retail Purchaser or the Original
Retail Lessee that any 1999 Model E-Z-GO vehicles and chargers shall be free from any defects in materials and workmanship for
a period of ONE (1) YEAR with respect to parts and labor while in the possession of such Original Retail Purchaser or the Original
Retail Lessee.
2. EXCLUSIONS: Specifically excluded from any E-Z-GO warranty are fuses, belts, hoses, spark plugs, brake shoes, optional equipment and accessories, lubricants, adjustments made due to normal wear, as well as electrical components, such as semiconductors, diodes, etc., which are susceptible to electrical overloads or fluctuations in current beyond the control of E-Z-GO. Also excluded are routine maintenance items, and cosmetic deterioration other than rust through of body panels. E-Z-GO further makes no
warranty with respect to batteries, tires, and ONAN engine components which are warranted by their respective manufacturers.
This warranty also does not apply to Acts of God or other events over which E-Z-GO has no control.
Transportation charges for warranty service, as well as freight charges to receive warranty parts are excluded from this warranty.
3. VOIDING OF WARRANTY: THIS, AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE: IS ABUSED OR OTHERWISE NOT USED IN ITS INTENDED MANNER; IS IN AN ACCIDENT OR COLLISION; SHOWS INDICATIONS THAT THE
SPEED GOVERNOR WAS ADJUSTED OR MODIFIED ALLOWING THE VEHICLE TO OPERATE BEYOND E-Z-GO’S SPECIFICATIONS; SHOWS INDICATIONS THAT IT HAS BEEN ALTERED OR MODIFIED IN ANY WAY FROM E-Z-GO SPECIFICATIONS, INCLUDING BUT NOT LIMITED TO ALTERATIONS TO THE SPEED, BRAKING SYSTEM, STEERING OR OTHER OPERATING SYSTEMS OF THE VEHICLE OR; SHOWS INDICATIONS THAT ROUTINE MAINTENANCE WAS NOT PERFORMED
WHEN, AND IN THE MANNER SPECIFIED IN THE E-Z-GO MAINTENANCE MANUAL. THIS WARRANTY SHALL BE VOID
WITH RESPECT TO ANY DEFECT OR DAMAGE CAUSED BY, OR AS A RESULT OF, OR RELATED TO, PARTS OR ACCESSORIES WHICH ARE NOT MANUFACTURED OR AUTHORIZED BY E-Z-GO, OR WERE NOT INSTALLED PER E-Z-GO’S INSTRUCTIONS, OR, FOR GASOLINE VEHICLES, THE USE OF NON-RECOMMENDED FUELS AND LUBRICANTS.
4. REMEDY: The sole remedy under this warranty and E-Z-GO’s only obligation in the event of a defect in the vehicle, is that E-ZGO will, at its sole option, repair or replace any defective parts. This remedy precludes all other remedies including any lawsuits,
claims or other proceedings alleging strict liability, negligence of contract or any cause of action. E-Z-GO reserves the right to
improve or change the design of any E-Z-GO vehicle without assuming any responsibility to modify previously manufactured vehicles.
5. HOW TO MAKE A CLAIM: In order to make a claim under this Warranty, you must take the vehicle or the defective part to an
authorized E-Z-GO agent.
All replaced parts shall become the property of E-Z-GO.
6. DISCLAIMER: THIS WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES, IMPLIED OR EXPRESSED, INCLUDING
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. E-Z-GO FURTHER DISCLAIMS ANY
LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, TO INCLUDE BUT NOT BE LIMITED TO, PERSONAL INJURY
OR PROPERTY DAMAGE ARISING FROM ANY DEFECT IN THE VEHICLE.
No agent, employee or representative of E-Z-GO, or any other person, has any authority to bind E-Z-GO to any other agreement,
representation, or warranty concerning the goods sold under this warranty.
7. WARNING: ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH ALTERS THE WEIGHT DISTRIBUTION OF THE
VEHICLE, ITS STABILITY OR INCREASES THE SPEED BEYOND THE FACTORY SPECIFICATION, CAN CAUSE SERIOUS
PERSONAL INJURY. DO NOT MAKE ANY SUCH MODIFICATION OR CHANGE.
E-Z-GO PROHIBITS, AND DISCLAIMS RESPONSIBILITY FOR, ANY SUCH MODIFICATIONS OR ANY OTHER ALTERATION
WHICH WOULD ADVERSELY AFFECT THE SAFETY OF THE VEHICLE.
FOR THE PURPOSE OF THIS WARRNTY, “INTERNATIONAL” APPLIES TO ALL COUNTRIES OTHER THAN THE UNITED
STATES AND CANADA.
FOR FURTHER INFORMATION, CALL 010-1-706-798-4311 OR WRITE TO:
E-Z-GO DIVISION OF TEXTRON INC.
ATTN: WARRANTY DEPARTMENT
P.O. BOX 388,
AUGUSTA, GEORGIA 30903-0388.
USA
Page 50
Owner’s Manual and Service Guide
E-Z-GO Division of Textron Inc.
P.O. Box 388 Augusta, Georgia 30903-0388 USA
Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609
Copyrighted Material
This manual may not be reproduced in whole or
in part without the express permission of
E-Z-GO Division of Textron Inc.
Technical Communications Department