Ezgo ST SPORT Owner`s manual

OWNER'S MANUAL
&
SERVICE GUIDE
ST SPORT 2+2
SAFETY
Read and understand all labels located on the vehicle. For any questions on any of the information, contact a 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 GENERAL SPECIFICATIONS). 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.
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 condition.
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
BATTERIES
CONTAIN LEAD
AND RELATED PARTS
WASH HANDS
AFTER HANDLING!
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
Be sure that this manual remains as part of the permanent service record should the vehicle be resold.
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 that
could result in severe
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.
Battery posts, terminals
and related accessories
contain lead and lead
compounds. Wash hands after handling.
!
!
injury or death.
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
OWNER’S MANUAL AND
SERVICE GUIDE
ELECTRIC POWERED
UTILITY VEHICLES
ST SPORT 2+2
Starting Model Year 2005
E-Z-GO Division of TEXTRON, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.
E-Z-GO Division of TEXTRON, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this
manual.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175
INTERNATIONAL:
PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852
Owner’s Manual and Service Guide
Page i
GENERAL INFORMATION
This vehicle has been designed and manufactured in the United States of America (USA) as
a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in
the USA unless otherwise indicated.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling batteries may void the warranty.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75° F (-60° C).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain. The battery charger and the controller are both sources of
electrical drain. 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
SAFETY ................................................................................................................ inside covers
GENERAL INFORMATION ....................................................................................................... ii
SAFETY INFORMATION ......................................................................................................... vii
WELCOME ................................................................................................................................. 1
BEFORE INITIAL USE .............................................................................................................. 1
Fig. 1 Initial Service Chart .........................................................................................................1
PORTABLE CHARGER INSTALLATION ................................................................................. 2
Fig. 2 Proper Charger Installation .............................................................................................2
Fig. 3 Charger Receptacle Location .........................................................................................2
CONTROLS AND INDICATORS ............................................................................................... 2
KEY/LIGHT SWITCH............................................................................................................................................2
HOUR METER......................................................................................................................................................2
STATE OF CHARGE METER .............................................................................................................................3
DIRECTION SELECTOR .....................................................................................................................................3
Fig. 4 Direction Selector ...........................................................................................................3
ACCELERATOR PEDAL .....................................................................................................................................3
Fig. 5 Key/Light Switch & State of Charge Meter .....................................................................3
COMBINATION SERVICE AND PARK BRAKE PEDAL .....................................................................................3
HORN .................................................................................................................................................................. 3
Fig. 6 Accelerator, Brake and Horn ...........................................................................................3
LOAD BED ................................................................................................................................. 4
MANUAL LIFT BED .............................................................................................................................................4
Fig. 7 Manual Bed Latch............................................................................................................4
Fig. 8 Gas Strut..........................................................................................................................4
SEATING ................................................................................................................................... 5
VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER ..................................................................................5
STORAGE .................................................................................................................................. 5
VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER ..................................................................................5
CARGO PLATFORM ...........................................................................................................................................5
Fig. 9 Cargo Platform and Rear Compartment ..........................................................................5
REAR STORAGE COMPARTMENT ...................................................................................................................5
GLOVE COMPARTMENTS .................................................................................................................................5
CARGO BASKET ................................................................................................................................................5
OPERATING THE VEHICLE ...............................................................................................................................6
TERRAIN ................................................................................................................................... 6
MODIFICATIONS TO VEHICLE ................................................................................................ 6
STARTING AND DRIVING ........................................................................................................ 6
STARTING THE VEHICLE ON A HILL ................................................................................................................7
COASTING ..........................................................................................................................................................7
LABELS AND PICTOGRAMS ................................................................................................... 7
VEHICLE CAPACITY ................................................................................................................ 7
SUN TOP AND WINDSHIELD (If Equipped) ............................................................................ 7
VEHICLE CLEANING AND CARE ............................................................................................ 7
VEHICLE CLEANING ..........................................................................................................................................7
Fig. 10 Load Bed Configurations and Capacities .....................................................................8
Fig. 11 Cargo Basket 8
Fig. 12 Gun Holder and Glove Compartments ..........................................................................8
COMMON SENSE OPERATION ............................................................................................. 10
GUN HOLDER ......................................................................................................................... 10
Owner’s Manual and Service Guide
Page iii
TABLE OF CONTENTS
ENVIRONMENTAL CONCERNS ..................................................................................................................... 10
REPAIR .................................................................................................................................... 11
LIFTING THE VEHICLE .................................................................................................................................... 11
Fig. 13 Lifting the Vehicle ....................................................................................................... 11
WHEELS AND TIRES .............................................................................................................. 11
TIRE INSPECTION ........................................................................................................................................... 11
TIRE REPAIR ................................................................................................................................................... 11
WHEEL INSTALLATION ................................................................................................................................... 12
Fig. 14 Wheel Installation ....................................................................................................... 12
UNIDIRECTIONAL TIRES ................................................................................................................................ 12
Fig. 15 Unidirectional Tire Wheel Installation ......................................................................... 12
LIGHT BULB REPLACEMENT ................................................................................................ 13
Fig. 16 Headlight Replacement .............................................................................................. 13
Fig. 17 Tail and Brake Light Bulb Replacement ..................................................................... 13
Fig. 18 Tail and Brake Light Bulb Replacement ..................................................................... 13
FUSE REPLACEMENT ............................................................................................................ 13
TRANSPORTING VEHICLE .................................................................................................... 13
TOWING ........................................................................................................................................................... 13
HAULING .......................................................................................................................................................... 13
SERVICE AND MAINTENANCE.............................................................................................. 14
SERIAL NUMBER LABEL LOCATION ................................................................................... 14
Fig. 19 Serial Number Label Location .................................................................................... 15
Fig. 20 Periodic Service Schedule ......................................................................................... 15
TIRE INSPECTION ........................................................................................................................................... 16
BRAKES ............................................................................................................................................................ 16
PERIODIC BRAKE TEST FOR MECHANICAL BRAKES ................................................................................. 17
Fig. 21 Typical Brake Performance Test ................................................................................ 17
REAR AXLE ...................................................................................................................................................... 17
CHECKING THE LUBRICANT LEVEL ............................................................................................................. 17
LUBRICATION .................................................................................................................................................. 17
Fig. 22 Add, Check and Drain Axle Lubricant ........................................................................ 18
Fig. 23 Lubrication Points 18
CAPACITIES AND REPLACEMENT PARTS........................................................................... 18
Fig. 24 Capacities and Replacement Parts ............................................................................ 18
HARDWARE ............................................................................................................................ 19
Fig. 25 Torque Specifications ................................................................................................. 19
BATTERIES AND CHARGING ................................................................................................ 20
SAFETY ............................................................................................................................................................ 20
BATTERY ......................................................................................................................................................... 20
BATTERY MAINTENANCE .............................................................................................................................. 20
AT EACH CHARGING CYCLE ......................................................................................................................... 20
MONTHLY ........................................................................................................................................................ 21
ELECTROLYTE LEVEL AND WATER ............................................................................................................. 21
Fig. 26 Correct Electrolyte Level ............................................................................................ 21
Fig. 27 Water Purity Table ..................................................................................................... 21
Fig. 28 Automatic Watering Gun ............................................................................................ 21
BATTERY CLEANING ...................................................................................................................................... 22
Fig. 29 Preparing Acid Neutralizing Solution .......................................................................... 22
BATTERY REPLACEMENT ............................................................................................................................. 22
36 Volt System Battery Connections ................................................................................................................ 23
BATTERY CHARGING ..................................................................................................................................... 23
AC VOLTAGE ................................................................................................................................................... 23
TROUBLESHOOTING ...................................................................................................................................... 23
HYDROMETER ................................................................................................................................................ 24
Fig. 30 Hydrometer ................................................................................................................ 24
Page iv
Owner’s Manual and Service Guide
TABLE OF CONTENTS
USING A HYDROMETER .................................................................................................................................24
Fig. 31 Hydrometer Temperature Correction ..........................................................................25
BATTERY CHARGER MAINTENANCE ............................................................................................................25
PROLONGED STORAGE ....................................................................................................... 25
Fig. 32 Freezing Point of Electrolyte .......................................................................................25
GENERAL SPECIFICATIONS.................................................................................................. 27
Fig. 33 Vehicle Dimensions andVehicle Incline Specifications................................................29
Fig. 34 Turning Clearance Diameter........................................................................................30
VEHICLE WARRANTIES ......................................................................................................... 31
DOMESTIC WARRANTY ...................................................................................................................................32
INTERNATIONAL WARRANTY (2005) ..............................................................................................................33
DECLARATION OF CONFORMITY (EUROPE ONLY)............................................................ 35
LABELS AND PICTOGRAMS .............................................................................................. A - 1
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Label Locations........................................................................................ Appendix A - 3
Pictogram Definitions............................................................................... Appendix A - 4
Pictogram Definitions............................................................................... Appendix A - 5
Pictogram Definitions............................................................................... Appendix A - 6
Pictogram Definitions............................................................................... Appendix A - 7
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 the manufacturer. 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:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-ZGO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured
vehicle is modified an any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER
FERERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of
Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer
MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for
LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the
requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in the
places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final
Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPERATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE
REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-ZGO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this
SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has reason to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or
through the Internet at the website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
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. The manufacturer 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 representative or write to the address on the back cover of this publication, Attention: Product Service Department.
The manufacturer 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.
The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result from the
Owner’s Manual and Service Guide
Page vii
SAFETY INFORMATION
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. They do not conform to Federal Motor Vehicle Safety
Standards 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. The manufacturer 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.
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.
Page viii
Owner’s Manual and Service Guide
SAFETY INFORMATION
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.
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 batteries or cover exposed terminals with an insulating
material.
Always check the polarity of each battery terminal and be sure to rewire the batteries correctly.
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.
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.
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.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
Always use a dedicated circuit for each battery charger. 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).
Owner’s Manual and Service Guide
Page ix
SAFETY INFORMATION
Notes:
Page x
Owner’s Manual and Service Guide
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
GENERAL
The following text is provided as recommended by part II
of ASME/ANSI B56.8-1988. The manufacturer strongly
endorses the contents of this specification.
manual without the manufacturer’s prior written authorization. Where authorized modifications have been made,
the user shall ensure that capacity, operation, warning,
and maintenance instruction plates, tags, or decals are
changed accordingly.
PART II
FOR THE USER
4.3.3 As required under paras. 4.3.1 or 4.3.2, the
manufacturer shall be contacted to secure new nameplates, warnings, or instructions which shall then be
affixed in their proper place on the carrier.
4 GENERAL SAFETY PRACTICES
4.4
4.1
Introduction
4.1.1 Like other machines, carriers can cause injury
if improperly used or maintained. Part II contains broad
safety practices applicable to carrier operations. Before
operation, the user shall establish such additional specific safety practices as may reasonably be required for
safe operation.
4.2
Stability
4.2.1
Experience has shown that this vehicle, which
complies with this standard, is stable when properly
operated and when operated in accordance with specific
safety rules and practices established to meet actual
operating terrain and conditions. However, improper
operation, faulty maintenance, or poor housekeeping
may contribute to a condition of instability and defeat the
purpose of the standard. Some of the conditions which
may affect stability are failure of the user to follow safety
practices; also, ground and floor conditions, grade,
speed, loading, the operation of the carrier with improper
loads, battery weight, dynamic and static forces, and the
judgement exercised by the carrier operator.
(a) The user shall train carrier operators to adhere
strictly to the operating instructions stated in this Standard.
(b) The user shall survey specific operating conditions
and environment, and establish and train carrier operators to comply with additional, specific safety practices.
4.3
Nameplates, Markings, Capacity, and Modifications
4.3.1 The user shall maintain in a legible condition
all nameplates, warnings, and instructions which are
supplied by the manufacturer.
4.3.2 The user shall not perform any modification or
addition which affects capacity or safe operation, or
make any change not in accordance with the owner’s
Fuel Handling and Storage
4.4.1 The user shall supervise the storage and handling of liquid fuels (when used) to be certain that it is in
accordance with appropriate paragraphs of ANSI/NFPA
505 and ANSI/NFPA 30.
4.4.2 Storage and handling of liquefied petroleum
gas fuels shall be in accordance with appropriate paragraphs of ANSI/NFPA 505 and ANSI/NFPA 58. If such
storage or handling is not in compliance with these standards, the user shall prevent the carrier from being used
until such storage and handling is in compliance with
these standards.
4.5
Changing and Charging Storage Batteries for
Electric Personnel and Burden Carriers
4.5.1 The user shall require battery changing and
charging facilities and procedures to be in accordance
with appropriate paragraphs of ANSI/NFPA 505.
4.5.2 The user shall periodically inspect facilities
and review procedures to be certain that appropriate
paragraphs of ANSI/NFPA 505, are strictly complied with,
and shall familiarize carrier operators with it.
4.6
Hazardous Locations
4.6.1 The user shall determine the hazard classification of the particular atmosphere or location in which
the carrier is to be used in accordance with ANSI/NFPA
505.
4.6.2 The user shall permit in hazardous areas only
those carriers approved and of the type required by
ANSI/NFPA 505.
4.7
Lighting for Operating Areas
4.7.1 The user, in accordance with his responsibility
to survey the environment and operating conditions, shall
determine if the carrier requires lights and, if so, shall
equip the carrier with appropriate lights in accordance
with the manufacturer’s recommendations.
Owner’s Manual and Service Guide
Page xi
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
4.8
Control of Noxious Gases and Fumes
turer;
4.8.1 When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be maintained within limits specified in the
American Conference of Governmental Industrial
Hygienists publication, “Threshold Limit Values for
Chemical Substances and Physical Agents in the Workroom Environment”. This shall be accomplished by ventilation provided by the user, and/or the installation, use,
and proper maintenance of emission control equipment
recommended or provided by the manufacturer of the
equipment.
(b) emphasis on safety of passengers, material loads,
carrier operator, and other employees;
4.9
(e) operational performance tests and evaluations
during, and at completion of, the program.
Warning Device(s)
4.9.1 The user shall make periodic inspections of
the carrier to be certain that the sound-producing and/or
visual device(s) are maintained in good operating condition.
(c) general safety rules contained within this Standard
and the additional specific rules determined by the user
in accordance with this Standard, and why they were formulated;
(d) introduction of equipment, control locations and
functions, and explanation of how they work when used
properly and when used improperly, and surface conditions, grade, and other conditions of the environment in
which the carrier is to be operated;
5.3
Personnel and Burden Carrier Operator
Responsibility
4.9.2 The user shall determine if operating conditions require the carrier to be equipped with additional
sound-producing and/or visual devices and be responsible for providing and maintaining such devices, in accordance with the manufacturer’s recommendations.
5.3.1 Operators shall abide by the following safety
rules and practices in paras. 5.4, 5.5, 5.6, and 5.7.
5 OPERATING SAFETY RULES AND
PRACTICES
5.4.2 Riding on the carrier by persons other than the
operator is authorized only on personnel seat(s) provided
by the manufacturer. All parts of the body shall remain
within the plan view outline of the carrier.
5.1
Personnel and Burden Carrier Operator
Qualifications
5.1.1 Only persons who are trained in the proper
operation of the carrier shall be authorized to operate the
carrier. Operators shall be qualified as to visual, auditory,
physical, and mental ability to safely operate the equipment according to Section 5 and all other applicable
parts of this Standard.
5.2
Personnel and Burden Carrier Operators’
Training
5.2.1 The user shall conduct an operators’ training
program.
5.2.2 Successful completion of the operators’ training program shall be required by the user before operation of the carrier. The program shall be presented in its
entirety to all new operators and not condensed for those
claiming previous experience.
5.2.3 The user should include in the operators’ training program the following:
(a)
instructional material provided by the manufac-
Page xii
5.4
General
5.4.1 Safeguard the pedestrians at all times. Do not
drive carrier in a manner that would endanger anyone.
5.4.3 When a carrier is to be left unattended, stop
carrier, apply the parking brake, stop the engine or turn
off power, turn off the control or ignition circuit, and
remove the key if provided. Block the wheels if machine
is on an incline.
5.4.4 A carrier is considered unattended when the
operator is 25 ft. (7.6 m) or more from the carrier which
remains in his view, or whenever the operator leaves the
carrier and it is not within his view. When the operator is
dismounted and within 25 ft. (7.6 m) of the carrier still in
his view, he still must have controls neutralized, and the
parking brake(s) set to prevent movement.
5.4.5 Maintain a safe distance from the edge of
ramps and platforms.
5.4.6 Use only approved carriers in hazardous locations, as defined in the appropriate safety standards.
5.4.7 Report all accidents involving personnel,
building structures, and equipment.
5.4.8
rier.
Operators shall not add to, or modify, the car-
Owner’s Manual and Service Guide
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
5.4.9 Carriers shall not be parked or left unattended
such that they block or obstruct fire aisles, access to
stairways, or fire equipment.
5.5
Traveling
5.5.1 Observe all traffic regulations, including authorized speed limits. Under normal traffic conditions keep
to the right. Maintain a safe distance, based on speed of
travel, from a carrier or vehicle ahead; and keep the carrier under control at all times.
5.5.2 Yield the right of way to pedestrians, ambulances, fire trucks, or other carriers or vehicles in emergency situations.
5.5.3 Do not pass another carrier or vehicle traveling in the same direction at intersections, blind spots, or
at other dangerous locations.
5.5.4 Keep a clear view of the path of travel,
observe other traffic and personnel, and maintain a safe
clearance.
5.5.5 Slow down or stop, as conditions dictate, and
activate the sound-producing warning device at cross
aisles and when visibility is obstructed at other locations.
5.5.6
Ascend or descend grades slowly.
5.5.7 Avoid turning, if possible, and use extreme
caution on grades, ramps, or inclines; normally travel
straight up and down.
5.5.8 Under all travel conditions the carrier shall be
operated at a speed that will permit it to be brought to a
stop in a safe manner.
smooth, sweeping motion.
5.6
Loading
5.6.1 Handle only stable and safely arranged loads.
When handling off-center loads which cannot be centered, operate with extra caution.
5.6.2 Handle only loads within the capacity of the
carrier as specified on the nameplate.
5.6.3 Handle loads exceeding the dimensions used
to establish carrier capacity with extra caution. Stability
and maneuverability may be adversely affected.
5.7
Operator Care of Personnel and Burden
Carriers
5.7.1 At the beginning of each shift during which the
carrier will be used, the operator shall check the carrier
condition and inspect the tires, warning devices, lights,
battery(s), speed and directional controllers, brakes, and
steering mechanism. If the carrier is found to be in need
of repair, or in any way unsafe, the matter shall be
reported immediately to the designated authority and the
carrier shall not be operated until it has been restored to
safe operating condition.
5.7.2 If during operation the carrier becomes unsafe
in any way, the matter shall be reported immediately to
the designated authority, and the carrier shall not be
operated until it has been restored to safe operating condition.
5.7.3 Do not make repairs or adjustments unless
specifically authorized to do so.
5.5.9 Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift the load,
endanger passengers, or overturn the carrier.
5.7.4 The engine shall be stopped and the operator
shall leave the carrier while refueling.
5.5.10 Do not indulge in dangerous activities, such as
stunt driving or horseplay.
5.7.5 Spillage of oil or fuel shall be carefully and
completely absorbed or evaporated and fuel tank cap
replaced before starting engine.
5.5.11 Slow down when approaching, or on, wet or
slippery surfaces.
5.5.12 Do not drive carrier onto any elevator unless
specifically authorized to do so. Approach elevators
slowly, and then enter squarely after the elevator car is
properly leveled. Once on the elevator, neutralize the
controls, shut off power, and set parking brakes. It is
advisable that all other personnel leave the elevator
before a carrier is allowed to enter or exit.
5.5.13 Avoid running over loose objects, potholes,
and bumps.
5.5.14 To negotiate turns, reduce speed to improve
stability, then turn hand steering wheel or tiller in a
5.7.6 Do not operate a carrier with a leak in the fuel
system or battery(s).
5.7.7 Do not use open flames for checking electrolyte level in storage battery(s) or liquid level in fuel tanks.
6 MAINTENANCE PRACTICES
6.1
Introduction
6.1.1 Carriers may become hazardous if maintenance is neglected. Therefore, maintenance facilities,
trained personnel, and procedures shall be provided.
Such facilities may be on or off the premises.
Owner’s Manual and Service Guide
Page xiii
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
6.2
Maintenance Procedures
6.2.1 Maintenance and inspection of all carriers
shall be performed in conformance with the manufacturer’s recommendations and the following practices.
(a) A scheduled preventive maintenance, lubrication,
and inspection system shall be followed.
(b) Only qualified and authorized personnel shall be
permitted to maintain, repair, adjust, and inspect carriers.
(c) Before undertaking maintenance or repair, follow
the manufacturer’s recommendations for immobilizing
the carrier.
(d) Block chassis before working underneath it.
(e) Before disconnecting any part of the engine fuel
system of a gasoline or diesel powered carrier with gravity feed fuel systems, be sure shutoff valve is closed, and
run engine until fuel system is depleted and engine stops
running.
(f) Before disconnecting any part of the engine fuel
system of LP gas powered carriers, close the LP gas cylinder valve and run the engine until fuel in the system is
depleted and the engine stops running.
(g) Operation to check performance of the carrier shall
be conducted in an authorized area where safe clearance exists.
(h) Before commencing operation of the carrier, follow
the manufacturer’s instructions and recommended procedures.
prevent the use of the carrier until the leak has been
eliminated.
(o) The carrier manufacturer’s capacity, operation,
and maintenance instruction plates, tags, or decals shall
be maintained in legible condition.
(p) Batteries, motors, speed and directional controllers, limit switches, protective devices, electrical conductors, and connections shall be inspected and maintained
in conformance with manufacturers recommended procedures.
(q) Carriers shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose or
defective parts.
(r) Modifications and additions which affect capacity
and safe machine operation shall not be performed by
the customer or user without manufacturer’s prior written
authorization; where authorized modifications have been
made, the user shall ensure that capacity, operation,
warning, and maintenance instruction plates, tags, or
decals are changed accordingly.
(s) Care shall be taken to ensure that all replacement
parts are interchangeable with the original parts and of a
quality at least equal to that provided in the original
equipment.
END OF ASME/ANSI B56.8-1988 TEXT
(i) Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame
to check level or leakage of fuel, battery electrolyte, or
coolant. Do not use open pans of fuel or flammable
cleaning fluids for cleaning parts.
(j) Properly ventilate the work area.
(k) Handle LP gas cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken the tank and make it unsafe for use.
(l) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices shall be inspected
regularly and maintained in a safe operating condition.
(m)
Special carriers or devices designed and
approved for hazardous area operation shall be
inspected to ensure that maintenance preserves the original approved safe operating features.
(n) Fuel systems shall be checked for leaks and condition of parts. If a leak is found, action shall be taken to
Page xiv
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Thank you for purchasing this vehicle. Before driving the
vehicle, we ask you to spend some time reading this
Owner’s Manual and Service Guide. This Guide contains
the information that will assist you in the safe operation of
the vehicle. It will also assist you in maintaining this
highly reliable vehicle. Some illustrations show items that
may be optional for your vehicle. This guide covers the
operation of several vehicles; therefore, some pictorial
views may not represent your vehicle. Physical differences in controls will be illustrated.
This vehicle has been designed and manufactured as a
‘World Vehicle’. Some countries have individual requirements to comply with their specifications; therefore,
some sections may not apply in your country.
Most of the service procedures in this guide can be
accomplished using common automotive hand tools.
Contact your service representative on servicing the
vehicle in accordance with the Periodic Service Schedule.
Service Parts Manuals and Technician’s Repair and Service Manuals are available from a local Distributor, an
authorized Branch or the Service Parts Department.
When ordering parts or requesting information for your
vehicle, provide vehicle model, serial number and manufacture code.
Hydrogen gas is generated as a natural part of the
lead acid battery charging process. A 4% concentration of hydrogen gas is explosive and could cause
severe injury or death. Charging must take place in an
area that is adequately ventilated (minimum of 5 air
exchanges per hour).
To reduce the chance of battery explosion that could
result in severe injury or death, never smoke around
or charge batteries in an area that has open flame or
electrical equipment that could cause an electrical
arc.
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.
Never charge a vehicle in an area that is subject to flame
or spark. Pay particular attention to natural gas or propane gas water heaters and furnaces.
Before a new vehicle is put into operation, the items
shown in the INITIAL SERVICE CHART must be performed.
ITEM
BEFORE INITIAL USE
SERVICE OPERATION
Batteries
Charge batteries
Read, understand and follow the safety label on the
instrument panel. Be sure you understand how to operate the vehicle, its equipment and how to use it safely.
Maintaining good performance depends to a large extent
on the operator.
Seats
Remove protective plastic covering
Brakes
Check operation and adjust if necessary
Tires
Check air pressure (see SPECIFICATIONS)
Improper use of this
vehicle could result in
severe injury or death.
The ST series are light duty utility vehicles. They are
NOT All Terrain Vehicles (ATV’s).
This vehicle is not a toy and using it while engaging in
horseplay is dangerous.
Plan carefully before using the vehicle to go significant distances over questionable terrain. Remember
that a one hour drive may take many hours to walk
out should you run out of battery power or be stranded by becoming stuck on unsuitable terrain.
Portable
Charger
Remove from vehicle and properly mount
!
!
Establish acceptable stopping distance
Ref Isc 1
Fig. 1 Initial Service Chart
Vehicle batteries must be fully charged before initial use.
Check for leaks that could have developed in shipment
from the factory.
Determine and record braking distance required to stop
vehicle for future brake performance tests.
Remove the protective clear plastic, that protect the seat
bottom and back rest during shipping, before placing the
vehicle in service.
Owner’s Manual and Service Guide
Page 1
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
PORTABLE CHARGER
INSTALLATION
batteries are fully charged and the DC plug can be
removed to permit use of the vehicle.
To prevent overheating
!
! that may cause serious
damage to the charger
and create the potential for fire, do not block or
obstruct the airways. Portable chargers must 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.
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.
Provide Protection From Elements
Do Not Block
Louvered Airways
NEMA 15 - 5R Grounded AC Receptacle
110 - 120 VAC. Dedicated 15 AMP Circuit
Locations outside the US and Canada: Reference
appropriate local electrical code and charger manufacturer recommendations for AC power requirements
To prevent a physical
hazard that could result
in an electrical shock or
electrocution, be sure that the charger plug is not
damaged and is inserted into a grounded receptacle.
The power (AC) cord is equipped with a grounded
plug, do not attempt to pull out, cut or bend the
ground post.
The charging (DC) cord is equipped with a polarized
connector which fits into a matching receptacle on
the vehicle.
!
!
The power (AC) cord is equipped with a grounded plug.
Do not attempt to remove, cut or bend the ground post.
Ref Pci 1S
Fig. 2 Proper Charger Installation
Portable chargers are shipped with the vehicle. Prior to
vehicle or charger operation, chargers must be removed
and mounted on a platform or wall above the ground to
permit maximum air flow around and underneath the
charger. If the charger is operated in an outdoor location,
rain and sun protection must be provided (Ref. Fig. 2 on
page 2). A dedicated circuit is required for the charger.
Refer to the charger manual for appropriate circuit protection. The charger may remain plugged in to the AC
outlet. To charge the vehicle, refer to the instruction
labels on the charger. Insert the polarized DC plug completely into the vehicle receptacle (Ref. Fig. 3 on page 2).
If vehicle is to be charged with a non PowerWise™ charger, refer to the instructions supplied with the charger.
CONTROLS AND INDICATORS
Vehicle controls and indicators consist of:
• key/light switch
• hour meter
• state of charge meter (optional)
• direction selector
• accelerator pedal
• combination service and
park brake pedal
• horn
KEY/LIGHT SWITCH
Front of
Vehicle
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. To prevent inadvertent operation of the vehicle when
left unattended, the key should be turned to the ‘OFF’ position
and removed.
Charger
Receptacle
If the vehicle is equipped with factory installed
custom accessories, some accessories remain
operational with the key switch in the ‘OFF’ position.
Ref Crl 1S
Fig. 3 Charger Receptacle Location
The charger will automatically start a few seconds after
plug insertion. The charger will automatically stop when
Page 2
HOUR METER
The hour meter indicates total hours of operation.
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Key/Light Switch
State of Charge Meter
is ‘ON’ and park brake is set, depressing the accelerator
inadvertently will release the park brake and will cause
the vehicle to move which could cause severe injury or
death.
Depressing the accelerator pedal will release the park
brake if it is engaged. This is a feature to assure the vehicle is not driven with the park brake engaged. Depressing the accelerator pedal is not the preferred method of
releasing the park brake.
OFF
ON
Ref Kes 5
Fig. 4 Key/Light Switch & State of Charge Meter
If the vehicle is equipped with lights, the key switch has a
position to operate them, indicated by the light icon.
STATE OF CHARGE METER
Located in the dash, the state of charge meter indicates
the amount of usable power in the batteries (Ref. Fig. 4
on page 3).
DIRECTION SELECTOR
To reduce the possibility of component
damage, the vehicle must be completely stopped before moving the direction selector.
COMBINATION SERVICE AND PARK BRAKE
PEDAL
The brake pedal incorporates a park brake feature (Ref.
Fig. 6 on page 3). To engage, push down on the upper
section of the pedal until it locks in place. The park brake
will release when the service brake pedal is depressed.
Use the lower section of the brake pedal to operate the
service brake system.
HORN
The horn is operated by pushing the horn button located
on the floor to the left of the brake pedal (Ref. Fig. 6 on
page 3).
Horn
H
Located on the seat support panel, this lever permits the
selection of either ‘F’ (forward) or ‘R’ (reverse) (Ref. Fig.
5 on page 3). Electric powered vehicles should be left in
‘N’ when unattended
Depressing the lower section of the brake
pedal is the preferred method of releasing the
park brake to assure the longest service life of brake components.
Park
Brake
Service
Brake Accelerator
ORN
(Neutral)
Forward
Reverse
Ref Abh 1S
Ref Dsl 2S
Fig. 5 Direction Selector
Fig. 6 Accelerator, Brake and Horn
ACCELERATOR PEDAL
Unintentional movement
!
! of the accelerator pedal
will release the park
brake and may cause the vehicle to move which could
result in severe injury or death.
With the key switch ‘ON’, depressing the accelerator
pedal starts the motor. When the pedal is released, the
motor will stop (Ref. Fig. 6 on page 3). To stop the vehicle more quickly, depress the service brake. If key switch
Owner’s Manual and Service Guide
Page 3
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
LOAD BED
To reduce the possibility
of severe injury or death,
read, understand and follow the Danger label affixed to the front of the load
bed.
!
!
A load bed warning label is affixed to the front of the bed.
See Appendix A. For safe operation of the vehicle, this
label must be understood. 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 secured. Failure to follow
these instructions may result in severe injury, damage
the vehicle and/or cause the vehicle to tip over. Use extra
care when operating loaded vehicle.
Do not permit any one to ride in the bed.
Front of Vehicle
Manual Load Bed
Latch Handle
Pull Up To Release
And Lift Bed
Ref Mbl 4
Do not drive the vehicle with the load bed raised or with
the tailgate unsupported.
Fig. 7 Manual Bed Latch
When using a load bed, be sure to avoid backing up to
the edge of a drop off, such as a loading dock or ravine.
A misjudgment of distance or an unstable surface could
result in the vehicle falling backwards.
Never fill a gas can in the
bed of a vehicle. Static
discharge could ignite
gasoline vapor and cause an explosion.
!
!
Always place a gas can on the ground before filling.
Never fill a gas can in the bed of the vehicle. Static electricity is built up during the fueling process and could discharge causing the gasoline vapor to ignite.
MANUAL LIFT BED
Ref Gss 1
Exercise caution while
!
! operating the manual lift
bed to ensure the bed is
not released during lifting or lowering procedure.
Severe injury could result if bed is released and traps
fingers or other body parts.
To lift the manual lift bed, pull back on the latch release
handle immediately behind the driver seat (Ref. Fig. 7 on
page 4). Raise the bed using the handle on the side of
the bed.
The gas strut will assist in raising the empty load bed and
will keep the bed raised (Ref. Fig. 8 on page 4).
Over time, the gas strut may allow the loadbed
to slowly lower. If this condition is evident,
replacement of gas strut is required.
Page 4
Owner’s Manual and Service Guide
Fig. 8 Gas Strut
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
SEATING
VEHICLES EQUIPPED WITH CONVERTIBLE
CARRIER
To prevent severe injury
or death, rear seat passengers should hold on
to both the hip restraints and the rear hand hold when
the vehicle is in motion. Always be sure that all passengers are seated and holding on before operating
vehicle.
!
!
Be sure that all passengers are seated and holding onto
both the hip restraint and the rear hand hold (rear facing
passengers) before operating vehicle.
Front of Vehicle
REAR SEAT FOLDED UP
Rear
Handrail
STORAGE
Cargo
Platform
VEHICLES EQUIPPED WITH CONVERTIBLE
CARRIER
Rear
Storage
Compartment
CARGO PLATFORM
Passengers should never be allowed to ride on
the cargo platform.
Severe injury or death could result if they should fall
out or the vehicle is involved in an accident or sudden
maneuver.
!
!
To prevent damage to rear seat, be sure
to move any obstructing accessories
mounted to rear handrail when folding seat up or down.
The cargo platform is accessed by folding the rear seat
down (Ref. Fig. 9 on page 5). Be careful when loading
the vehicle. Tie down loads to prevent shifting. Do not
overload vehicle. The cargo platform is limited to a maximum load of 250 lbs. (115 kg). The load must be positioned on the platform as far forward as possible, its
center of gravity must not be higher than 4" (10 cm)
above the platform, and securely fastened down. Failure
to follow these instructions could cause personal injury,
damage to the vehicle and/or cause the vehicle to tip
over. Be aware that increased loads may effect driving
characteristics.
REAR STORAGE COMPARTMENT
The rear storage compartment is not
weather tight.
The rear storage compartment can be accessed with the
rear seat folded down by reaching under the central por-
Ref Rse 1S
REAR SEAT FOLDED DOWN
Fig. 9 Cargo Platform and Rear Compartment
tion of the cargo platform and lifting the platform up (Ref.
Fig. 9 on page 5).
GLOVE COMPARTMENTS
An optional lockable glove compartment is located on
each side of the instrument panel (Ref. Fig. 12 on page
8).
CARGO BASKET
Never overload the
basket. An overloaded basket could negatively affect vehicle handling characteristics
and cause the vehicle to tip over or cause structural damage to the vehicle.
!
!
Do not overload basket (Ref. Fig. 11 on page 8). The
basket is limited to a maximum load of 25 lbs. (11 kg).
Failure to follow these instructions could cause personal
injury, damage to the vehicle and/or cause the vehicle to
tip over. Be aware that increased loads may effect driving
characteristics.
Owner’s Manual and Service Guide
Page 5
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
OPERATING THE VEHICLE
Make sure that the direction selector is in correct
position before attempting to start the vehicle.
Always bring the vehicle to a complete stop
before shifting the direction selector.
Do not take vehicle out of ‘gear’ while in motion
(coast).
Check the area behind the vehicle before operating in reverse.
All occupants must be seated. Keep entire body
inside vehicle and hold on while vehicle is in
motion.
Improper use of the vehicle or the lack
of proper maintenance may result in
damage or decreased performance.
Read and understand the following warnings before
attempting to operate the vehicle.
To reduce the possibility
of severe injury or death
resulting from loss of
vehicle control, the following warnings must be
observed:
When driving vehicle, consider the terrain, traffic
conditions and the environmental factors which
effect the terrain and the ability to control the
vehicle.
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 extremely
rough terrain.
Maintain a safe speed when driving down hill. Use
service brake to control speed when traveling
down an incline. A sudden stop or change of
direction may result in loss of control.
Slow down before and during turns. All turns
should be made at reduced speed.
Never drive vehicle up, down, or across an incline
that exceeds 14° (25% grade).
To reduce the possibility
!
! of severe injury or death
resulting from improper
vehicle operation, the following warnings must be
observed:
Refer to GENERAL SPECIFICATIONS for seating
capacity.
Depressing accelerator pedal will release foot
operated park brake and may cause inadvertent
vehicle movement. Turn the key to the ‘OFF’ position whenever the vehicle is parked.
To prevent inadvertent movement when the vehicle is to be left unattended, engage the park
brake, move direction selector to neutral position
(electric powered vehicles), turn key to ‘OFF’
position and remove key.
!
Page 6
!
TERRAIN
The vehicle is designed for use on improved roads (but
not on public highways). The vehicle may also be used
on established trails or open terrain that is free from
stumps, large rocks or holes.
The vehicle should not be used to cross water.
MODIFICATIONS TO VEHICLE
Changes to the weight
distribution or the center
of gravity may make
vehicle unstable or prone to roll over which could
result in severe injury or death to the operator or passengers.
!
!
Do not modify the vehicle in any manner that will change
the weight distribution of the vehicle. Changes to the
weight distribution or the center of gravity may make it
unstable or prone to roll over which could result in severe
injury or death to the operator or passengers.
STARTING AND DRIVING
To reduce the possibility
of roll-back which could
result in severe injury or
vehicle damage, do not release service brake until
motor has started.
!
!
To operate 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.
• Release the park brake by depressing the service
brake pedal until the park brake releases.
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
• Slowly depress the accelerator pedal to start the
•
motor. Release service brake when motor starts.
When the accelerator pedal is released, the motor
stops. To stop the vehicle more quickly, depress
the service brake pedal.
When the direction selector is in the reverse
position, a warning signal will sound to indicate
that the vehicle is ready to run in reverse.
STARTING THE VEHICLE ON A HILL
To reduce the possibility
!
! of roll-back which could
result in severe injury or
vehicle damage, do not release service brake until
motor has started.
Do not hold vehicle on hill by using
accelerator and motor. This will cause
premature and excessive wear to drive train components.
To reduce the possibility of permanent damage to the
drive system, it is important to prevent excessive rollback when starting the vehicle on a hill.
Place left foot on service brake and release the park
brake. Depress accelerator with right foot and release
the service brake by lifting left foot.
COASTING
To reduce the possibility
of severe injury or death
from coasting at above
recommended speeds, limit speed with service brake.
!
!
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). 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.
LABELS AND PICTOGRAMS
Vehicles may be labeled with pictograms as a method of
conveying information or warnings. Appendix A illustrates and explains pictograms that may appear on the
vehicle. Not all pictograms shown in Appendix A will be
found on your vehicle.
VEHICLE CAPACITY
Due to the variety of
ways the vehicle may be
used, it is important that
the operator consider any potential hazards before
use to prevent serious injury or death.
!
!
The vehicle may be configured with a variety of load bed
options. (Ref. Fig. 10 on page 8). The weight of the driver
and passengers plus any options or accessories must be
deducted from the total payload rating to determine the
cargo capacity. Never exceed the rated capacity of the
load bed.
SUN TOP AND WINDSHIELD
(If Equipped)
The top does not provide
protection from roll over
or falling objects.
The windshield does not provide protection from tree
limbs or flying objects.
!
!
The top and windshield provide some protection from the
elements; however, they will not keep the operator and
passengers dry in a downpour. For complete protection
from the elements, a weather enclosure can be installed.
This vehicle is not equipped with seat belts and has not
been designed to provide roll over protection.
VEHICLE CLEANING AND CARE
VEHICLE CLEANING
To reduce the possibility
of severe injury or vehicle damage, read and
understand all instructions supplied by manufacturer
of pressure washer.
!
!
When pressure washing exterior of
vehicle, do not use pressure in excess
of 700 psi. (4800 kpa) To reduce the possibility of 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. Using excessive water pressure may
cause severe injury to operator or bystander, damage to
seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi (4800 kpa)
to wash exterior of vehicle.
Owner’s Manual and Service Guide
Page 7
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
CONVERTIBLE CARRIER
(Rear Facing Seat/Cargo
Deck)
2 Persons. or Cargo not to exceed 200 Lbs (90 kg)
Maximum Vehicle Capacity 800 lbs. (360 kg)
FIXED ROTOMOLDED BED
Maximum Bed Capacity 250 lbs. (115 kg)
Maximum Vehicle Capacity 650 lbs. (290 kg)
ROTOMOLDED BED
with Manual Dump
or Optional Electric Dump
Maximum Bed Capacity 500 lbs. (225 kg)
Maximum Vehicle Capacity 800 lbs. (360 kg)
Ref Lbc 2 S
Fig. 10 Load Bed Configurations and Capacities
Lockable Glove
Compartments
Ref Ghr 1S
Ref Bsk1S
Fig. 11 Cargo Basket
Page 8
Gun
Holder
Fig. 12 Gun Holder and Glove Compartments
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Clean windshield with lots of water and a clean cloth.
Minor scratches may be removed using a commercial
plastic polish or Plexus® plastic cleaner available from
the service parts department.
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 and mild detergent is
required to preserve the painted surfaces.
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 cause corrosion of underbody parts unless
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
it’s removal, taking care not to chip or otherwise damage
paint.
If the motor does not start or runs improperly
after washing, remove the spark plug wires (by
pulling the spark plug boots, never the wires). Dry all connections with forced air. Reinstall the wires.
Owner’s Manual and Service Guide
Page 9
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
COMMON SENSE OPERATION
!
To prevent severe injury
or death, observe the following:
Never transport loaded firearms on or in vehicle.
Check that firearms are unloaded with the safety
engaged and are properly secured with muzzle
pointing in a safe direction before operating vehicle.
Be aware of other firearms in proximity to operator and passengers.
!
GUN HOLDER
To prevent severe injury
or death, never transport
loaded firearms on or in
vehicle. Check that firearms are unloaded with the
safety engaged and are properly secured with muzzle
pointing in a safe direction before operating vehicle.
!
!
The gun holder is mounted to the floor of the vehicle near
the accelerator pedal (Ref. Fig. 12 on page 8). Check
that firearms are unloaded with the safety engaged
before securing to holder. A maximum of two firearms
can be secured in the gun holder.
Slow down when in unfamiliar terrain. Slow down when
cresting a hill in an area that you are unfamiliar with.
Some hills are too steep to climb. If you attempt to climb
a hill that is too steep or if you are unable to achieve adequate traction, do not attempt to turn around on the
hill. Slowly back straight down the hill using the service brake to control speed.
ENVIRONMENTAL CONCERNS
As a responsible user,
!
! practice respect for all
wildlife and their habitat.
Respect private property and comply with all local
laws and regulations governing the use of light duty
utility vehicles. To prevent severe injury or death
while driving, be aware of the following:
Environmental hazards such as steep slopes,
overhanging limbs, etc.
Danger of fire when vehicle is operated over dry
combustible organic material.
When driving, be aware of environmental hazards such
as steep slopes, overhanging limbs, etc. Be aware of the
danger of fire when the gasoline powered vehicle is operated over dry combustible organic material.
This vehicle is not a toy. If not operated properly and
responsibly, it can cause severe injury or death to the
operator, passengers or bystanders. All operators should
possess a valid driver’s license. Children should not be
permitted to operate the vehicle. Children may not have
the skill, judgement or strength to operate this or similar
vehicles.
Alcohol, drugs and many over the counter medications
reduce the ability of the driver to operate the vehicle
safely. Always review side effects of any medication with
a doctor or pharmacist before operating vehicle.
Protective clothing and an approved motorcycle helmet
are recommended for operator and passengers when
operating vehicle in rough or densely wooded terrain.
When driving at full speed on a dirt road, loose surfaces
or wet grass, vehicle stopping distance will increase. If
the vehicle is fully loaded, it will take longer to stop than
with no load. When operating vehicle in wet weather conditions, remember that the brakes may need to be lightly
applied in order to provide enough friction to dry the
brake unit. If wet, the brakes will lose much of their effect.
Page 10
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
REPAIR
Use extreme care since the vehicle is extremely
unstable during the lifting process.
LIFTING THE VEHICLE
Tool List
When lifting vehicle, position jacks and
jack stands at the areas indicated only.
Qty. Required
Floor jack .................................................................... 1
Jack stands ................................................................. 4
Chocks ........................................................................ 4
Some servicing operations may require the front wheels,
the rear wheels, or the entire vehicle be raised.
To raise the entire vehicle, install chocks in front and
behind each front wheel (Ref. Fig. 13 on page 11). Center the jack under the rear frame crossmember. Raise the
vehicle enough to place a jack stand under the outer
ends of the rear axle.
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 enough to place jack stands under the frame
crossmember as indicated.
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 to stabilize the vehicle.
Lower the vehicle by reversing the lifting sequence.
WHEELS AND TIRES
TIRE INSPECTION
Tire condition should be inspected per the Periodic Service Schedule (Ref. Fig. 20 on page 15). Inflation pressures should be checked when the tires are cool. Be sure
to install the valve dust cap after checking or inflating.
TIRE REPAIR
Tool List
Ref Liv 4S
View from Underside of Vehicle
Fig. 13 Lifting the Vehicle
!
!
To reduce the possibility
of severe injury or death
from a vehicle falling
from a jack:
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.
Always place chocks in front and behind the
wheels not being raised.
Qty. Required
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
A tire explosion can
cause severe injury or
death. Never exceed
inflation pressure rating on tire sidewall.
To reduce the possibility of tire explosion, pressurize
tire with small amount of air applied intermittently to
seat beads. Due to the low volume of the small tires,
overinflation can occur in seconds. Never exceed the
tire manufacturer’s recommendation when seating a
bead. Protect face and eyes from escaping air when
removing valve core.
!
Owner’s Manual and Service Guide
!
Page 11
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
To reduce the possibility of severe injury caused by a
broken socket when removing wheels, use only sockets designed for impact wrench use.
Use caution when inflating tires. Overinflation could
cause the tire to separate from the wheel or cause the
tire to explode, either of which could cause severe
injury.
Use caution when inflating tires. Due to the low volume of
the small tires, overinflation can occur in seconds. Overinflation could cause the tire to separate from the wheel
or cause the tire to explode.
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 reduces the possibility of tires 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 sure to install the valve
dust cap after checking or inflating.
The vehicle is fitted with low pressure tubeless tires
mounted on one piece rims; therefore, the most cost
effective way to repair a puncture in the tread is to use a
commercial tire plug.
WHEEL INSTALLATION
To reduce the possibility of component
damage, do not tighten lug nuts to more
than 85 ft. lbs. (115 Nm) torque.
It is important to follow the ‘cross sequence’
pattern when installing lug nuts. This will
assure even seating of the wheel against the hub.
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. 14 on page 12). Tighten lug
nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in 20 ft. lbs.
(30 Nm) increments following the ‘cross sequence’ pattern.
'Cross Sequence'
1
3
4
Tire style may vary
Ref Whi 3S
Fig. 14 Wheel Installation
UNIDIRECTIONAL TIRES
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.
To reduce the possibility
!
! of severe injury, be sure
mounting/demounting
machine is anchored to floor. Wear OSHA approved
safety equipment when mounting/demounting tires.
If the tire is to be removed or mounted, the tire changing
machine manufacturer’s recommendations must be followed in order to reduce possibility of severe injury.
Page 12
Rot
a
'Cross Sequence'
1
3
n
tio
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
instructions.
2
Front of
Vehicle
Ref Whi 4
4
2
Tire style may vary
Fig. 15 Unidirectional Tire Wheel Installation
Some vehicles may be fitted with unidirectional tires.
These tires may be identified by a directional arrow on
the sidewall. Be sure to position the wheel on hub correctly with arrow indicating direction of rotation when
moving forward. (Ref. Fig. 15 on page 12).
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
LIGHT BULB REPLACEMENT
Roll Rubber
Bezel Away
From Body
To reduce the possibility of 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.
Tail/Brake
Light
For vehicles with headlights, locate the two screws on
backside of cowl that secure headlight (Ref. Fig. 16 on
page 13). Remove screws, pull headlight out and disconnect wires. Connect wires to new headlight, install in cowl
and secure with screws previously removed.
Turn Signal Lens
Rear
Fender
Inside
of Cowl
Ref Tlr 2
Fig. 17 Tail and Brake Light Bulb Replacement
Rear
Fender
Headlight
Bulb
Tail Light
Lens
Turn Signal
Housing
Ref Hdr 2
Fig. 16 Headlight Replacement
To replace the turn signal light bulb, support turn signal
housing from backside of cowl while removing two
screws securing lens. Install new bulb and replace lens.
To replace the tail and brake light bulb, roll the rubber
bezel from around the edge of the taillight and remove
lens (Ref. Fig. 17 on page 13). Install replacement bulb
and replace lens.
To replace the tail and brake light bulb, remove hardware
securing lens and remove lens. Install replacement bulb
See ‘Tail and Brake Light Bulb Replacement’ on page 13.
FUSE REPLACEMENT
To replace fuses, locate the fuse block under the driver
side seat. Pull out old fuse and replace with a new automotive type fuse. Headlight and taillight bulbs and fuses
are available from a local Distributor, an authorized
Branch or the Service Parts Department.
Ref Tlr 1
Tail Light
Bulb
Fig. 18 Tail and Brake Light Bulb Replacement
TRANSPORTING VEHICLE
TOWING
!
!
This vehicle is not
designed to be towed.
It is recommended that the
vehicle be moved by placing the entire vehicle on a
trailer, flatbed truck or other suitable transport.
HAULING
!
!
To reduce the possibility
of severe injury or death
while transporting vehi-
cle:
Secure the vehicle and contents.
Never ride on vehicle being transported.
Owner’s Manual and Service Guide
Page 13
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Always remove windshield before transporting.
Maximum speed with sun top installed is 50
m.p.h. (80 kph).
If the vehicle is to be transported at highway speeds, the
sun top must be removed and the seat bottom secured.
When transporting vehicle below highway speeds, check
for tightness of hardware and cracks in sun top at mounting points. Always remove windshield when transporting.
Always check that the vehicle and contents are adequately secured before transporting. The rated capacity
of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle
weight) and load. Lock the park brake and secure the
vehicle using ratchet tie downs.
SERVICE AND MAINTENANCE
!
!
To reduce the possibility
of severe injury or death
from improper servicing
techniques:
Do not attempt any type of servicing operations
before reading and understanding all notes, cautions and warnings in this manual.
Any servicing requiring adjustments to be made
to the powertrain while the motor is running must
be made with both drive wheels raised and vehicle properly supported on jack stands.
To reduce the possibility of motor damage, never
operate vehicle at full throttle for more than 4 - 5
seconds while vehicle is in a ‘no load’ condition.
Wear eye protection when working on
the vehicle. Use extra care when working around batteries, or using solvents
or compressed air.
Ref Sgl 1S
To reduce the possibility of causing an
electrical arc, which could result in a battery
explosion, turn off all electrical loads from the
battery before removing battery wires.
Wrap wrenches with vinyl tape
to reduce the possibility of a
Ref Isl 1S
dropped wrench ‘shorting out’ a
battery, which could result in an explosion.
Reduce the possibility of accidental starting by
disconnecting battery at negative terminal before
servicing.
The electrolyte in a battery is an acid solution
Page 14
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.
Any electrolyte spills should be neutralized with a
solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liters) of
water and flushed with water.
Aerosol containers of battery terminal protectant
must be used with extreme care. Insulate metal
container to reduce the possibility of can contacting battery terminals which could result in an
explosion.
It is in the best interest of both vehicle owner and service
technician, to carefully follow the procedures recommended in this manual. Preventative maintenance,
applied at recommended intervals, is the best guarantee
for keeping the vehicle both dependable and economical.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic
Service Schedule for appropriate service intervals (Ref.
Fig. 20 on page 15). Refer to Lubrication Points for
appropriate lubrication locations (Ref. Fig. 23 on page
18).
To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such
as extreme temperatures, extreme dust/debris conditions, frequent use with maximum load.
To access powertrain for routine maintenance, lift or
remove seat. For major repair, refer to appropriate Technician’s Repair and Service Manual.
Some service procedures may require the vehicle to be
lifted. Refer to LIFTING THE VEHICLE for proper lifting
procedure and safety information.
SERIAL NUMBER LABEL
LOCATION
Two serial number and manufacture date code plates are
on the vehicle. One is placed on the body below the
front, driver side of the seat. The other is located on the
chassis between the seat back supports (Ref. Fig. 19 on
page 15).
Design changes take place on an ongoing basis. In order
to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must
be provided when ordering service parts.
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
PERIODIC SERVICE SCHEDULE
Lift Flap on Access Panel
To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used
under severe driving conditions such as extreme temperatures,
extreme dust/debris conditions, frequent use with maximum
load.
Serial Number
Labels
To access powertrain for routine maintenance, lift or
remove seat. For major repair, refer to appropriate Technician’s Repair and Service Manual.
Some service procedures may require the vehicle to be
lifted. For proper lifting procedure and safety information.
See LIFTING THE VEHICLE on page 11.
Ref Spl 3S
Fig. 19 Serial Number Label Location
✓ Check
♦ Clean, Adjust, etc.
▲ Replace
To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle.
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions
DAILY
BEFORE USE:
✓ Check service brake general operation
✓ Check park brake function
✓ Check warning device function in reverse
✓ Check tire condition
✓ Check overall vehicle condition
♦ Recharge batteries to full state of charge after each day’s use
✓ Inspect charger connector and receptacle at each charge
WEEKLY
TIRES
✓ Examine for cuts, excessive wear and pressure (See GENERAL SPECIFICATIONS)
WHEELS
✓ Check for bent rims, missing or loose lug nuts
MONTHLY - 20 HOURS (includes items listed in previous table & the following)
BATTERIES
♦ Clean batteries & terminals. See BATTERY CLEANING.
✓ 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
SERVICE BRAKES
✓ Conduct brake performance test
Fig. 20 Periodic Service Schedule
Owner’s Manual and Service Guide
Page 15
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
PARK BRAKE
✓ Check brake performance and adjust if required
DIRECTION SELECTOR
✓ Check attachment, tighten if required
STEERING ASSEMBLY
✓ Check for abnormal play, tightness of all hardware
TIE ROD/LINKAGES
✓ Check for excessive play, bent components or loose connections
REAR AXLE
✓ Check for leakage, add SAE 30 oil as required
QUARTERLY - 50 HOURS (includes items listed in previous tables & the following)
FRONT AXLE
✓ Check for damage to axle and loose or missing hardware
FRONT SHOCK ABSORBERS
✓ Check for oil leakage and loose fasteners
FRONT SPRINGS
✓ Check for loose hardware, cracks at attachments
FRONT WHEEL ALIGNMENT
✓ Check for unusual tire wear, align if required
PARK BRAKE
✓ Check for bent/binding linkage rod
✓ Check for damage or wear to latch arm or catch bracket
♦ Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE
LATCH
REAR SHOCK ABSORBERS
✓ Check for oil leakage, loose mounting hardware
HARDWARE AND FASTENERS
✓ Check for loose or missing hardware and components
♦ Tighten or replace missing hardware
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
STEERING ASSEMBLY
✓ Check bellows and pinion seal for damage or grease leakage
RACK END BALL JOINT
♦ Lubricate, use wheel bearing grease
REAR AXLE
✓ Check for unusual noise and loose or missing mounting hardware
ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)
FRONT WHEEL BEARINGS
✓ Check and adjust as required, see Technician’s Repair and Service Manual
REAR AXLE
✓ Check lubricant, add lubricant (SAE 30 oil) as required
▲ Replace 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
Fig. 20 Periodic Service Schedule
TIRE INSPECTION
BRAKES
Tire condition should be inspected per the Periodic Service Schedule (Ref. Fig. 20 on page 15). Inflation pressures should be checked when the tires are cool. Be sure
to install the valve dust cap after checking or inflating.
To reduce the possibility
of severe injury or death,
always evaluate pedal
travel before operating a vehicle to verify some braking function is present.
Page 16
!
Owner’s Manual and Service Guide
!
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Establish the acceptable stopping distance by testing a
new or ‘known to be good’ vehicle and recording the
stopping location or stopping distance. For fleets of vehicles, several vehicles should be tested when new and
the range of stopping locations or distances recorded.
Dry, Level, Clean, Paved Surface
Accelerate To
Maximum Speed
Latch
Parking Brake
and Take Foot
Off Pedal
Line or Marker
Line or Marker
Acceptable
Stopping 4 ft. (1.2 m)
Distance
Ref Bpt 2S
Normal Range of
Stopping Distance
Any vehicles that stop
more than 4 ft. (1.2 m)
beyond the Acceptable
Stopping Distance or
pulls to one side should
be removed from service
and inspected by a
qualified mechanic
Drive the vehicle at maximum speed on a flat, dry, clean,
paved surface (Ref. Fig. 21 on page 17). Quickly depress
the brake pedal to latch the parking brake at the line or
marker in the test area and remove foot from pedal. The
vehicle should stop aggressively. The wheel brakes may
or may not lock. Observe the vehicle stopping location or
measure the vehicle stopping distance from the point at
which the brakes were latched. The vehicle should stop
within the ‘normal’ range of stopping distances. If the
vehicle stops more than 4 ft. (1.2 m) beyond the acceptable stopping distance or pulls to one side, the vehicle
has failed the test and should be tested again.
If the vehicle fails the second test, it should immediately
be removed from service. The vehicle must be inspected
by a qualified mechanic who should refer to the TROUBLESHOOTING section in the Technician’s Repair and
Service Manual.
REAR AXLE
Fig. 21 Typical Brake Performance Test
All driving brake tests must be done in a safe
location with regard for the safety of all personnel.
Over time, a subtle loss of performance may
take place; therefore, it is important to establish
the standard with a new vehicle.
The Periodic Brake Performance Test should be performed regularly (Ref. Fig. 21 on page 17) as an evaluation of braking system performance. It is useful as a
method of identifying subtle loss of performance over
time.
PERIODIC BRAKE TEST FOR MECHANICAL
BRAKES
The purpose of this test is to compare the braking performance of the vehicle to the braking performance of new
or ‘known to be good’ vehicles or to an established
acceptable stopping distance. Actual stopping distances
will be influenced by weather conditions, terrain, road
surface condition, actual vehicle weight (accessories
installed) and vehicle speed. No specific braking distance
can be reliably specified. The test is conducted by latching the park brake to eliminate different pedal pressures
and to include the affects of linkage mis-adjustment.
The rear axle is provided with a lubricant level check/fill
plug located on the bottom of the differential. Unless
leakage is evident, no maintenance is required.
CHECKING THE LUBRICANT LEVEL
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 lubricant 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 oil pan must be
removed or the oil siphoned through the check/fill hole
(Ref. Fig. 22 on page 18).
LUBRICATION
Do not use more than three (3) pumps
of grease in any grease fitting at any
one time. Excess grease may cause grease seals to fail or
grease migration into areas that could damage components.
Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature
bearing failure (Ref. Fig. 23 on page 18).
Owner’s Manual and Service Guide
Page 17
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
CAPACITIES AND
REPLACEMENT PARTS
Rear Axle Oil
40 oz (1.2 liters)
Fuse
15 amp (P/N 18392-G1)
Headlight Sealed Beam
P/N 20209-G2
Turn Signal Light
P/N 19180-G2
Tail Light Bulb
#1157 (P/N 21759-G1)
Ref Cap 5
Fig. 24 Capacities and Replacement Parts
Ref Raf 1
Check/Fill Plug
Fig. 22 Add, Check and Drain Axle Lubricant
King Pin
King Pin
Idler Arm
Steering
Unit
Ball Joint
on Rack
and Rod
Ref Lub 4S
View From Underside Of Vehicle
Fig. 23 Lubrication Points
Page 18
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
HARDWARE
torque values.
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref. Fig. 25 on page
19).
Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three
marks on the hexagonal head and grade 8 hardware is
identified by 6 marks on the head. Unmarked hardware is
Grade 2 (Ref. Fig. 25 on page 19).
ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart 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
4
(5)
8
(11)
15
(20)
24
(33)
35
(47)
55
(75)
75
(102)
130
(176)
125
(169)
190
(258)
Grade 5
6
(8)
13
(18)
23
(31)
35
(47)
55
(75)
80
(108)
110
(149)
200
(271)
320
(434)
480
(651)
Grade 8
6
(8)
18
(24)
35
(47)
55
(75)
80
(108)
110
(149)
170
(230)
280
(380)
460
(624)
680
(922)
BOLT SIZE
M4
M5
M6
M8
M10
M12
M14
Class 5.8
(Grade 2)
5.8
1
(2)
2
(3)
4
(6)
10
(14)
20
(27)
35
(47)
55
(76.4)
Class 8.8
(Grade 5)
8.8
2
(3)
4
(6)
7
(10)
18
(24)
35
(47)
61
(83)
97
(131)
Class 10.9
(Grade 8) 10.9
3
(4)
6
(8)
10
(14)
25
(34)
49
(66)
86
(117)
136
(184)
Ref Tsp 1
Fig. 25 Torque Specifications
Owner’s Manual and Service Guide
Page 19
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
BATTERIES AND CHARGING
SAFETY
Always observe the following warnings when
working on or near batteries:
To prevent battery explosion that could result in
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. Do not tip batteries when removing or installing them;
Ref Lib 1S
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.
!
!
Ref Sgl 1S
Any electrolyte spills should be neutralized with a
solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1 1/2 gallons (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 metal container to prevent can from contacting battery terminals which could result in an explosion.
Page 20
Wrap wrenches with vinyl tape
to prevent the possibility of a
Ref Isl 1S
dropped wrench from ‘shorting
out’ a battery, which could result in an explosion and
severe personal injury or death.
BATTERY
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
AT EACH CHARGING CYCLE
To reduce the possibility
!
! of fire, 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.
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.
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
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 1/2" (13 mm) above
the plates in each cell (Ref. Fig. 26 on page 21). This
Expansion
Space
1/4" to 3/8"
(6 to 10 mm)
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.
27 on page 21).
Vent Cap
Gas Vent
Vent
1/2" (13 mm)
Plates
Ref Cel 1
Electrolyte level should be
at least 1/2" (13 mm) above
the plates and 1/4" to 3/8"
(6 to 10 mm) below bottom
of vent
Wpt 1S
Fig. 26 Correct Electrolyte Level
Fig. 27 Water Purity Table
level will leave approximately 1/4" - 3/8" (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.
Watering gun similar to the type included in the
Battery Maintenance Kit
Do not overfill batteries. The charging
cycle will expel electrolyte and result in
component damage.
A battery being charged will ‘gas’ with the majority of the
gassing taking place at the end of the charging cycle.
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
Valve consistently
fills to a
predetermined
level
Electrolyte
Level
Pure Water
Single Battery Cell
Ref Awg 1
Fig. 28 Automatic Watering Gun
Owner’s Manual and Service Guide
Page 21
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
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 Battery Maintenance Kit (P/N 25587-G01) can be
used with an approved water source (Ref. Fig. 28 on
page 21). 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 1/2" (13 mm)
above top of plates.
BATTERY CLEANING
To prevent battery damage, be sure that
all battery caps (if equipped) are tightly
installed.
To reduce the possibility of damage to vehicle or floor, neutralize acid before rinsing battery.
To reduce the possibility of damage to electrical components
while cleaning, do not use a pressure washer.
Cleaning should take place per the Periodic Service
Schedule (Ref. Fig. 20 on page 15).
When cleaning the outside of batteries and terminals,
first spray with a solution of sodium bicarbonate (baking
soda) and water to neutralize any acid deposits before
rinsing with clear water.
Use of a water hose without first neutralizing any acid will
move acid from the top of batteries to another area of the
vehicle or storage facility where it will attack the metal
structure or the concrete/asphalt floor. Additionally, conductive residue will remain on the batteries and contribute to their self discharge.
To reduce the possibility
of battery explosion that
could result in severe
injury or death, do not use metallic spray wand to
clean battery and keep all smoking materials, open
flame or sparks away from the battery.
!
!
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 or plastic spray bottle. The solution
should consist of the ingredients shown in the illustration
(Ref. Fig. 29 on page 22). In addition, special attention
should be paid to metal components adjacent to the bat-
Page 22
1 quart
(1 liter)
Clear Water
1 1/2 gallons
(6 liters)
Clear Water
1/4 Cup (60 ml)
Sodium Bicarbonate
(Baking Soda)
Non
Metallic
Wand
OR
2 Gallon
(7.5 liter)
Garden
Sprayer
2 Teaspoons
(10 ml)
Sodium
Bicarbonate
(Baking Soda)
Plastic
Spray
Bottle
Ref Pns 1S
Fig. 29 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
to remove any conductive residue. Rinse the entire area
with low pressure clear water. Do not use a pressure
washer. All of the items required for complete battery
cleaning and watering (electric vehicles only) are contained in the Battery Maintenance Kit (P/N 25587-G01).
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 45 - 55 in. lbs. (5 - 6
Nm) torque, to 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.
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
To prevent battery explosion that could result in
severe personal injury or
death, extreme care must be used with aerosol containers of battery terminal protectant. Insulate the
metal container to prevent the metal can from contacting battery terminals which could result in an
explosion.
!
!
Use care to connect the battery wires as shown (Ref. Fig.
30 on page 23) and (Ref. Fig. 30 on page 23). Tighten
the battery post hardware to 80 - 110 in. lbs. (6 - 8 Nm)
torque. Protect the battery terminals and battery wire terminals with a commercially available protective coating.
+
+
+
BL +
Front of Vehicle
-
-
Ref Bat 1
+
-
+
-
• 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.
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 company should
be consulted.
TROUBLESHOOTING
BL -
+
Fig. 30 36 Volt System Battery Connections
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
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 recommended 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.
• The charging connector components are in good
condition and free from dirt or debris.
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 a manufacturer representative for specific requirements.
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 following manufacturer’s
recommendations.
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.
Owner’s Manual and Service Guide
Page 23
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
HYDROMETER
A hydrometer (P/N 50900-G1) is used to test the state of
charge of a battery cell (Ref. Fig. 31 on page 24). 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.
Cylinder
Bulb
Float
1100
1125
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
1150
1175
1200
1225
1250
1275
1100
1125
1300
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.
1200
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.
1225
1250
1275
1300
3. Hold the hydrometer in a vertical position at eye level
and note the reading where the electrolyte meets the
scale on the float.
Weight
Thermometer
Ref Hyd 1S
Fig. 31 Hydrometer
To prevent battery explosion that could result in
severe personal injury or
death, 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 golf car 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.
Page 24
The temperature of the electrolyte is important since the
hydrometer reading must be corrected to 80° F (27° C).
High quality hydrometers are equipped with an internal
thermometer 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.
1150
32
28
24
20
16
12
8
4
0
4
8
12
16
20
24
28
32
36
!
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.
4. Add or subtract four points (.004) to the reading for
every
10° F (-12°C) the electrolyte temperature is above or
below 80° F (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 90° F (32° C), add four points
(.004) to the 1.250 which gives a corrected reading of
1.254. Similarly if the temperature was 70° F (21° C),
subtract four points (.004) from the 1.250 to give a
corrected reading of 1.246 (Ref. Fig. 32 on page 25).
5. Test each cell and note the readings (corrected to 80°
F or 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.
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
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
and replaced with a good battery of the same brand, type
and approximate age.
Electrolyte
Temperature
°F °C
160
71.1
150
65.6
140
60.0
130
54.4
120
48,9
110
43.3
100
37.8
90
32.2
80
26.7
70
21.1
60
15.6
50
10
40
4.4
30
–1.1
20
–6.7
10
–12.12
+.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 Temperature
Above 80°F (27°C)
Electrolyte temperature
90° F (32° C)
Hydrometer reading 1.250
1.250 + .004 = 1.254
corrected specific gravity
EXAMPLE #2:
Electrolyte Temperature
Below 80°F (27 °C)
Electrolyte temperature
70° F (21° C)
Hydrometer reading 1.250
1.250 - .004 = 1.246
corrected specific gravity
Ref Htc 1S
Fig. 32 Hydrometer Temperature Correction
BATTERY CHARGER MAINTENANCE
Plug charger into vehicle receptacle and wait for relay to
turn on. Check to see if charger turns off by moving plug
back and forth in receptacle. If charger does turn off,
check plug for a broken red wire in DC cord.
PROLONGED STORAGE
Battery charger, controller and other
electronic devices need to be disconnected since they will contribute to the premature discharge of
batteries.
During periods of storage, the batteries will need attention to keep them maintained and prevent discharge.
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
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. 33 on page
25). A fully charged battery will not freeze in temperatures above -75° F (-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. For portable chargers,
disconnect the charging plug from the vehicle receptacle.
For on-board chargers, disconnect the charging harness
from the batteries. 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
T
E
M
P
E
R
A
T
U
R
E
O
F
+15
O
C
-9
+5 -15
-5 -21
-15 -26
-25 -32
-35 -37
-45 -43
-55 -48
-65 -54
-75 -60
-85 -65
-95 -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
Ref Fpe 1
Fig. 33 Freezing Point of Electrolyte
In high temperatures the chemical reaction is faster,
while low temperatures cause the chemical reaction to
slow down. A vehicle that is stored at 90° F (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.
Owner’s Manual and Service Guide
Page 25
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Page 26
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Owner’s Manual and Service Guide
Page 27
GENERAL SPECIFICATIONS
ST MODEL SPORT 2+2
STANDARD EQUIPMENT:
CHASSIS
BODY
BATTERIES
SPEED CONTROLLER
MOTOR
TRANSAXLE
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
STANDARD COLORS
DASH PANEL
LIGHTING/HORN
TIRES
TIRE PRESSURE
WEIGHT (Without batteries)
BED
OPERATING CONTROLS &
INSTRUMENTATION
BATTERY CHARGER
Welded Tubular Steel; Powder Coated (DuraShield™)
Flexible, Impact Resistant DuraShield™ Injection Molded TPE
(Thermoplastic Elastomer) with Base Coat/Clear Coat
36 VDC, six 6 volt deep cycle (105 Minute Minimum, 220 Amp-Hour @ 20 Hour Discharge Rate)
Solid State, 300 Amp Capacity with Non-Contact Inductive Throttle Sensor
36 VDC High Efficiency Series Wound, Brazed Armature, Solid Copper Windings, 2.5 hp (1.9 kw)
@2700 rpm (1hour)
12.44:1 Helical Geared with Input Pinion Shaft Directly Connected to Motor Shaft
Dual Rear Wheel, Self-Adjusting Mechanical Drum Brakes
Automatic Parking Brake Release with Self-Compensating System
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion
Dual Handgrips, Pencil Holder & Clipboard
Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold
Operator & 3 Passengers
800 lbs (360 kg) Including Operator, Passenger, Accessories & Cargo
12 - 14 mph (19 - 23 kph)
Hunter Green
Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 4 Drink Holders
Dual Halogen, Horn
Trail Wolf AT 20 x 11 x 10 (Uni-directional)
20 psi (135 kpa)
610 lbs (280 kg)
Convertible Carrier
Removable Key, ‘Deadman’ Accelerator Control, Direction
Selector, Audible Reverse Warning, State of Charge Meter
PowerWise™ Portable,36 VDC, 110-120 VAC< Fully Line Compensating, 21 Amp DC Input, 60 Hz.
UL Listed, CSA Certified
-orRefer to specifications of charger supplied with vehicle. For locations outside of US and Canada,
refer to charger manufacturer for specifications and recommendations.
Specifications subject to change without notice
Page 28
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
49 in
(124 cm)
6 in
(15 cm)
81.5 in
(207 cm)
65.5 in (166 cm)
107 in (272 cm)
Rear
38 in (96 cm)
46.5 in
(118 cm)
Front
38.5" (97 cm)
ST SPORT 2+2
RECOMMENDED MAX SIDE TILT
25% or 14o MAX
RECOMMENDED MAX RAMP GRADE
25% or 14o MAX
Fig. 33 Vehicle Dimensions and Incline Specifications
Owner’s Manual and Service Guide
Page 29
GENERAL SPECIFICATIONS
TURNING CLEARANCE DIAMETER
ST SPORT 2+2
Fig. 34 Turning Clearance Diameter
Page 30
Owner’s Manual and Service Guide
20.5 ft (6.3 m)
VEHICLE WARRANTIES
VEHICLE WARRANTIES
Owner’s Manual and Service Guide
Page 31
VEHICLE WARRANTIES
DOMESTIC WARRANTY
(U.S. AND CANADA)
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch
or the Warranty Department with vehicle serial number and manufacturer date code.
Page 32
Owner’s Manual and Service Guide
VEHICLE WARRANTIES
2005 INTERNATIONAL WARRANTY
(ALL COUNTRIES OUTSIDE THE U.S. AND CANADA)
The E-Z-GO DIVISION OF TEXTRON, INC. (“E-Z-GO”) warrants to the Original Retail Purchaser or the Original Retail Lessee that any 2005 E-Z-GO vehicle and/or Battery Charger shall be free from any defects in material or
workmanship for one year from the date of installation at the customer’s location with respect to parts and labor.
EXCLUSIONS: Specifically excluded from any E-Z-GO warranty are adjustments/repairs made due to normal wear
beyond the first 180 days, routine maintenance items, cosmetic deterioration, and electrical components which are susceptible to fluctuations in current beyond the control of E-Z-GO. 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 and all replaced parts shall become the property of E-Z-GO.
This warranty also excludes batteries, tires, and Lester battery chargers, which are warranted by their respective manufacturer.
REMEDY: The sole remedy under this warranty and E-Z-GO’s only obligation in the event of a defect in the vehicle/battery charger, is that
E-Z-GO 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 or battery charger
without assuming any responsibility to modify previously manufactured vehicles or battery chargers.
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
WILL FURTHER DISCLAIM 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/BATTERY CHARGER.
No agent, employee or representative of E-Z-GO, or any person has any authority to bind E-Z-GO to any other agreement, representation, or warranty concerning the goods sold under this warranty.
WARNING: ANY MODIFICATION OR CHANGE TO THE VEHICLE OR BATTERY CHARGER WHICH ALTERS THE
WEIGHT DISTRIBUTION OF THE VEHICLE, ITS STABILITY, INCREASES THE SPEED, OR ALTERS THE OUTPUT
OF THE BATTERY CHARGER BEYOND THE FACTORY SPECIFICATION, CAN CAUSE 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 VEHICLE OR BATTERY CHARGER.
VOIDING OF WARRANTY: THIS, AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR BATTERY CHARGER 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, ELECTRICAL 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.
FOR FURTHER INFORMATION, CALL 1-706-798-4311 OR WRITE TO E-Z-GO DIVISION OF TEXTRON, INC., ATTENTION: WARRANTY
DEPARTMENT, 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA 30906.
Owner’s Manual and Service Guide
Page 33
VEHICLE WARRANTIES
Notes:
Page 34
Owner’s Manual and Service Guide
DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
(EUROPE ONLY)
Declaration of Conformity is packaged with vehicle. For additional information, contact:
Ransomes Jacobsen Limited
West Road, Ransomes Europark,
Ipswich, England, IP3 9TT
Owner’s Manual and Service Guide
Page 35
DECLARATION OF CONFORMITY
Notes:
Page 36
Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS
LABELS AND PICTOGRAMS
Owner’s Manual and Service Guide
Appendix A - 1
LABELS AND PICTOGRAMS
Notes:
Appendix A - 2
Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS
LABELS AND PICTOGRAMS
Owner’s Manual and Service Guide
Appendix A - 1
LABELS AND PICTOGRAMS
Notes:
Appendix A - 2
Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS
35962G01 Gas
35964G01 Electric
!
!
P
R
F
!
OFF
< 14˚ 25%
< 14˚ 25%
F
ON
35962-G01
71129-G02
71129G02 Electric
Maximum weight in basket is 25 lbs. (11 kg). Excess weight may cause
injury resulting from vehicle instability and/or frame damage. 71084G01
71084G01
OFF
ON
H
71131-G01
71131G01 Gas
ORN
FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN
SEVERE PERSONAL INJURY
Pb
WARNING
Bed load limit is 250 lbs. (114 kg).
The center of gravity of the load
must not exceed 4 inches (10 cm)
above the bed floor.
The load must be as far forward as
possible and secure.
Top heavy loads may cause vehicle
instability or tip over.
35493-G01
35493G01
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN SEVERE PERSONAL INJURY.
Avoid standing in front of or behind vehicle.
No more than 2 occupants per seat.
Always remain seated and hold on while vehicle is in motion.
Drive slowly straight up and down
slopes and in turns.
Keep feet, legs, hands and arms inside the vehicle
at all times.
Do not permit anyone to ride on the
platform when used as a load bed.
Do not leave children unattended on seat while
vehicle is moving.
74132G01
71093G01
71093G01
744132G01
MAX
??? lbs.
??? kg
PP
WARNING
MAX
5 in.
12 cm
MAX
100 lbs.
45 kg
MAX
14o / 25%
74821G0
Keep entire body
inside car.
74821G0* For Rotomolded Bed
27653G01
RN
HO
WARNING
Windshields do not
provide protection
from golf balls or
other flying objects.
EGWHL14
WARNING
PP
3
2
1
PP
PP
DO NOT TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE
GOVERNOR. FAILURE TO COMPLY COULD RESULT IN SERIOUS
PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY.
H2O
74093-G01
24880G01
This Label Is Located On Governor Cover At Top Of Rear Axle.
74093G01
Fig. 35 Label Locations
Owner’s Manual and Service Guide
Appendix A - 3
LABELS AND PICTOGRAMS
!
1.
WARNING
READ MANUAL
FOR MAXIMUM
LOAD BED
CAPACITY.
MAXIMUM
RAMP/HILL
WARNING
9.
< 14 ˚ 25 %
2.
READ MANUAL
MAX
xxx lbs.
xxx kg
10.
SECURE LOAD
AS FAR FORWARD
AS POSSIBLE.
MAXIMUM LOAD
BED CAPACITY
WARNING
USE CAUTION
IN INCLEMENT
WEATHER
3.
!
11.
4.
WARNING
DO NOT OPERATE
IF USING ALCOHOL
OR DRUGS
5.
MAXIMUM CROSS
HILL/RAMP ANGLE
AS SPECIFIED
MAX
14 ˚ / 25%
DO NOT RIDE IN
LOAD BED
12.
P
P
DANGER OF
EXPLOSION
DO NOT FILL
GAS CAN
IN LOAD BED
!
WARNING
MAXIMUM CROSS
HILL/RAMP
ANGLE AS
SPECIFIED
6.
13.
< 14 ˚ 25 %
8.
WARNING MAXIMUM LOAD & CENTER OF GRAVITY.
KEEP LOAD AS FAR FORWARD AS POSSIBLE.
DO NOT RIDE IN LOAD BED
LOAD WITH
HIGH CENTER
OF GRAVITY
COULD RESULT
IN TIP OVER
7.
MAX
xx in
xx cm
LOAD
CENTER
OF GRAVITY,
MAXIMUM
HEIGHT
MAX LOAD
XXX LBS
in
XXX KG xxx cm
14.
KEEP HANDS & FINGERS AWAY FROM DUMP BED.
DO NOT STAND BEHIND DUMP BED
Fig. 36 Pictogram Definitions
Appendix A - 4
Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS
1
15.
3
2
PP
H2O
26.
WARNING
LETHAL
VOLTAGE
27.
DO NOT
EXPOSE
TO FLAME
28.
DO NOT
DISPOSE OF
BATTERIES
IN LANDFILL
29.
DO NOT
DRIVE ON
HIGHWAY
30.
WINDSHIELDS
DO NOT
PROVIDE
PROTECTION
FROM
FLYING OBJECTS
31.
BATTERIES ARE
HEAVY.
USE CARE LIFTING
32.
USE INSULATED
TOOLS
33.
WEAR EYE
PROTECTION
34.
NO SMOKING
35.
HOT SURFACE
CLEAN UP GASOLINE SPILLS WITHWATER BEFORE
STARTING ENGINE
16.
17.
18.
PP
UNLEAD
GASOLINE
PP
DO NOT
SPILL FUEL
ON A HOT
ENGINE
PP
GROUND
FUEL PUMP
19.
LOW OIL PRESSURE
20.
NEGATIVE
GROUND
BATTERY
21.
DO NOT CONNECT
POSITIVE BATTERY
TERMINAL TO GROUND
22.
SHORTING BATTERY
TERMINALS MAY
CAUSE EXPLOSION
23.
NO
TAMPERING.
KEEP HANDS
OUT
24.
WARNING
CORROSIVE
25.
WARNING
EXPLOSIVE
Fig. 37 Pictogram Definitions
Owner’s Manual and Service Guide
Appendix A - 5
LABELS AND PICTOGRAMS
OPERATE
FROM
DRIVERS SIDE
ONLY
36.
KEEP ARMS
AND LEGS
WITHIN VEHICLE
37.
TO OPERATE VEHICLE IN FORWARD:
✱ TURN KEY TO ON
✱ MOVE DIRECTION SELECTOR TO
FORWARD
✱ DEPRESS ACCELERATOR PEDAL
AND ACCELERATE SMOOTHLY
38.
F
TO OPERATE VEHICLE IN REVERSE:
✱ TURN KEY TO ON
✱ MOVE DIRECTION SELECTOR TO
REVERSE
✱ AN AUDIBLE DEVICE WILL SOUND
✱ DEPRESS ACCELERATOR PEDAL
AND ACCELERATE SMOOTHLY
39.
R
40.
P
TO LEAVE A GASOLINE POWERED
VEHICLE IN PARK:
✱ APPLY PARKING BRAKE
✱ TURN KEY TO OFF
✱ MOVE DIRECTION SELECTOR TO
FORWARD
F
KEEP CLEAR
HAND OR
FINGERS CAN
BE TRAPPED
42.
43.
ON
ON
POSITION
44.
OFF
OFF
POSITION
45.
HEADLIGHTS
46.
UNLOCKED
47.
LOCKED
48.
DIFFERENTIAL
LOCKED
49.
WARNING
KEEP ENTIRE BODY
INSIDE CAR
50.
MAXIMUM
TAILGATE
LOAD
51.
ENGINE
CRANKING
POSITION
START
P
41.
P
N
TO LEAVE AN ELECTRIC POWERED
VEHICLE IN PARK:
✱ APPLY PARKING BRAKE
✱ TURN KEY TO OFF
✱ MOVE DIRECTION SELECTOR TO
NEUTRAL
PULL HANDLE UP
TO ENGAGE PARK
BRAKE
52.
1
53.
Fig. 38 Pictogram Definitions
Appendix A - 6
Owner’s Manual and Service Guide
2
3
PULL HANDLE UP,
PUSH BUTTON IN,
PUSH HANDLE DOWN
TO RELEASE PARK BRAKE
LABELS AND PICTOGRAMS
54.
WARNING
READ OWNER'S MANUAL
BEFORE OPERATING
VEHICLE IN FORWARD
OR REVERSE
55.
WARNING
READ OWNER'S MANUAL
BEFORE PARKING
VEHICLE AND LEAVING
IT UNATTENDED
62.
AUXILIARY LIGHTS
63.
HORN BUTTON
FORWARD
56.
NEUTRAL
REVERSE
57.
58.
WARNING
READ OWNER'S MANUAL
BEFORE ENGAGING TWO
OR FOUR WHEEL DRIVE
PUSH TOP OF SWITCH
TO LOCK DIFFERENTIAL
PUSH BOTTOM OF
SWITCH TO UNLOCK
DIFFERENTIAL
59.
REAR DIFFERENTIAL
LOCK SWITCH
60.
FRONT DIFFERENTIAL
LOCK SWITCH.
WARNING
READ OWNER'S MANUAL
BEFORE ENGAGING
FRONT DIFFERENTIAL
LOCK.
DO NOT ENGAGE LOCK
WHILE FRONT WHEELS
ARE TURNED AND
VEHICLE IS AT SPEED.
PUSH TOP PART OF
SWITCH TO RAISE LOAD
BED
61.
PUSH BOTTOM PART OF
SWITCH TO LOWER LOAD
BED
Fig. 39 Pictogram Definitions
Owner’s Manual and Service Guide
Appendix A - 7
LABELS AND PICTOGRAMS
Notes:
Appendix A - 8
Owner’s Manual and Service Guide
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, 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 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 therefore 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.
!
To prevent personal
injury or death, observe
the following:
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.
!
E-Z-GO Division Of Textron, Inc.,
1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852
TO CONTACT US
North America:
Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124
Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175
International:
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
P/N 602560
ISSUED: APRIL 2005