1200 X Electric Manual

1200 X Electric Manual
Owner’s Guide
623525
ISSUED JULY 2011
REVISED JANUARY 2012
WELCOME
Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this
Owner’s Guide. This guide contains the information that will assist you in maintaining this highly reliable vehicle.
Some illustrations may show items that are optional for your vehicle. This guide covers the operation of several vehicles; therefore, some illustrations may not represent your vehicle. Physical differences in controls will be illustrated.
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.
Repair or replacement parts are available through your E-Z-GO retailer or E-Z-GO Genuine Service Parts.
The following information is needed when contacting E-Z-GO concerning service or parts for your vehicle:
Vehicle Model ____________________________________________________________________________
SERIAL/VIN Number ______________________________________________________________________
FOREWORD
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
OWNER’S GUIDE
ELECTRIC POWERED VEHICLE
HAULER 1200X E
STARTING MODEL YEAR 2012
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 specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron, Inc. prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
E-Z-GO Division of Textron, Inc. reserves the right to incorporate engineering and design changes to products in this manual, without
obligation to include these changes on units sold previously.
The information contained in this manual may be revised periodically by E-Z-GO Division of Textron, Inc., and therefore is subject to
change without notice.
E-Z-GO Division of Textron, Inc. DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
These are the original instructions as defined by 2006/42/EC.
TO CONTACT US
E-Z-GO Division of Textron Inc.
1451 Marvin Griffin Road.
Augusta, Georgia, USA 30906-3852
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: 001-706-798-4311 FAX: 001-706-771-4609
Page i
FOREWORD
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
This vehicle has been designed and manufactured in the United States of America (USA).
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.
Failure to properly maintain batteries may void the warranty. Refer to the battery manual for
instructions on the proper maintenance and care of the batteries.
BATTERY PROLONGED STORAGE
All batteries will self-discharge over time. The rate of self-discharge varies depending on the
ambient temperature, 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 may be left connected to the vehicle to maintain a full charge on the batteries, provided the charger is plugged into an active electrical source. If power to the electrical source is disconnected or interrupted the battery charger will continue to check the
charge on the battery pack, this will draw power from the battery pack and eventually drain
the batteries if power is not restored in a timely manner.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
Page ii
TABLE OF CONTENTS
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SECTION
PAGE NO.
SAFETY............................................................................................................................................................................... 1-1
GENERAL SPECIFICATIONS............................................................................................................................................. 2-1
INTRODUCTION.................................................................................................................................................................. 3-1
OPERATING PROCEDURES.............................................................................................................................................. 4-1
MAINTENANCE................................................................................................................................................................... 5-1
DELCARATION OF CONFORMITY ................................................................................................................ APPENDIX A-1
Page iii
TABLE OF CONTENTS
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Notes:
Page iv
SAFETY
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TITLE
PAGE NO.
SAFETY................................................................................................................................................................. 1-3
NOTICES, CAUTIONS, WARNINGS, AND DANGERS......................................................................................... 1-3
GENERAL ............................................................................................................................................................. 1-4
GENERAL OPERATION ....................................................................................................................................... 1-5
MAINTENANCE .................................................................................................................................................... 1-5
VENTILATION ....................................................................................................................................................... 1-6
LABELS AND PICTOGRAMS ............................................................................................................................... 1-7
1- 1
1
SAFETY
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1
Notes:
1- 2
SAFETY
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SAFETY
1
For any questions on material contained in this manual, contact an authorized representative for clarification.
Read and understand all labels located on the vehicle. 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 drivetrain 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.
For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”
Vehicles equipped with Precision Drive System™ (PDS) must be towed with the Run-Tow/Maintenance switch, located
under the passenger seat, in the ‘Tow/Maintenance’ position.
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.
WASH HANDS
AFTER HANDLING!
BATTERIES
CONTAIN LEAD
AND RELATED PARTS
!
< 14˚ 25%
DO NOT
DRIVE ACROSS
SLOPES IN
EXCESS OF 14˚
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 sold.
Observe these NOTICES, CAUTIONS, WARNINGS and DANGERS; 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.
Throughout this guide NOTICE, CAUTION, WARNING, and DANGER will be used.
NOTICE
A NOTICE indicates a condition that should be observed.
A CAUTION indicates a condition that may result in damage to the vehicle.
.Battery posts, terminals and related accessories contain lead and lead compounds. Wash
hands after handling.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
1- 3
SAFETY
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1
This manual has been designed to assist 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 or property damage, the following 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 20 mph. 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
FEDERAL 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 EZGO, 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 can be 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 warning can take
replace 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 all users and maintenance personnel read this
entire manual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.
If you have any questions regarding this vehicle, contact your E-Z-GO dealer or write to the address on the back cover
of this publication, Attention: Customer Care Department.
The Manufacturer reserves the right to make design changes without obligation to make these changes on units previously sold. The information contained in this manual is subject to change without notice.
THE MANUFACTURE IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL
OR CONSEQUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL.
This vehicle conforms to the current applicable standard(s) 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 of the United States of America (USA) 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.
1- 4
SAFETY
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
1
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.
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.
Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).
GENERAL OPERATION
ALWAYS:
• use the vehicle in a responsible manner and maintain the vehicle in safe operating condition
• read and observe all warnings and operation instruction labels affixed to the vehicle
• follow all safety rules established in the area where the vehicle is being operated
• Leave the vehicle when there is a risk of lightning.
• reduce speed to compensate for poor terrain or conditions
• apply service brake to control speed on steep grades
• maintain adequate distance between vehicles
• reduce speed in wet areas
• use extreme caution when approaching sharp or blind turns
• use extreme caution when driving over loose terrain
• use extreme caution in areas where pedestrians are present
MAINTENANCE
ALWAYS:
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule
• nsure that repairs are performed by trained and qualified personnel
• Follow the manufacturer’s maintenance procedures for the 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.
• Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting
thebattery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating
material.
• Check the polarity of each battery terminal and be sure to rewire the batteries correctly
• Use specified replacement parts, NEVER use replacement parts of lesser quality
• Use recommended tools
• 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
1- 5
SAFETY
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1
• Support the vehicle using wheel chocks and jack stands, NEVER get under a vehicle that is supported by a jack,
lift the vehicle in accordance with the manufacturer’s instructions
• Maintain the vehicle in an area away from exposed flame or persons who are smoking
• Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated
• Test drive the vehicle after any repairs or maintenance in a safe area that is free of both vehicular and pedestrian
traffic•
• Replace damaged or missing warning, caution or information labels.
• Keep complete records of the maintenance history of the vehicle
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.
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
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).
1- 6
SAFETY
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LABELS AND PICTOGRAMS
1
614121
I
ON
R
F
cm
I
ON
O
OFF
R
F
I
ON
R
O
OFF
F
O
OFF
MIN 150
< 14° 25%
I
ON
< 14° 25%
O
OFF
I
ON
F
O
OFF
F
I
ON
O
OFF
R
614121
!
!
P
F
!
< 14° 25%
R
< 14° 25%
F
35962-G01
601781
OFF
ON
74322G01
74322G01
AUTHORIZED REPRESENTATIVE IN EC IS:
RANSOMES JACOBSEN LTD.
WEST ROAD, IPSWICH,
SUFFOLK, IP3 9TT, UK
601783
601783
71489G01
614068
614068
On Battery Under Seat
35493-G01
35493G01
74099G01
28203-G01
28203G01
MAX
500 lbs.
255 kg
PP
MAX
5 in.
12 cm
MAX
100 lbs.
45 kg
MAX
14o / 25%
74821G01
74821G01
WARNING
Keep entire body
inside car.
27653G01
WARNING
Windshields do not
provide protection
from golf balls or
other flying objects.
EGWHL14
71419G01
71417G01
71415G01
1- 7
SAFETY
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1
1.
!
WARNING
9.
2.
< 14û 25%
READ MANUAL
WARNING
READ MANUAL
FOR MAXIMUM
LOAD BED
CAPACITY.
MAXIMUM RAMP/HILL
SECURE LOAD
10.
3.
WARNING
USE CAUTION IN
INCLEMENT WEATHER
!
4.
WARNING
DO NOT OPERATE
UNDER THE INFLUENCE
OF DRUGS OR ALCOHOL
5.
MAXIMUM
CROSS HILL/RAMP
ANGLE AS SPECIFIED
MAX
14û/ 25%
< 14û 25%
1- 8
11.
DO NOT RIDE IN
LOAD BED
12.
DANGER OF EXPLOSION
DO NOT FILL GAS CAN
IN LOAD BED
WARNING
MAXIMUM CROSS
HILL/RAMP ANGLE
AS SPECIFIED
6.
8.
CAPACITY
PP
!
7.
MAX
AS FAR FORWARD
XXX lbs. AS POSSIBLE.
XXX kg MAXIMUM LOAD BED
13.
LOAD WITH
HIGH CENTER
OF GRAVITY
COULD RESULT
IN TIP OVER
MAX
XX in.
XX cm
LOAD
CENTER
OF GRAVITY,
MAXIMUM
HEIGHT
14.
MAX LOAD
XXX LBS
in
XXX KG xxx cm
WARNING
MAXIMUM LOAD
& CENTER OF
GRAVITY.
KEEP LOAD
AS FAR
FORWARD AS
POSSIBLE.
DO NOT RIDE
IN LOAD BED
KEEP HANDS &
FINGERS AWAY
FROM DUMP BED.
DO NOT STAND
BEHIND DUMP
BED
SAFETY
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
15.
PP
16.
17.
18.
PP
3
2
1
H 2O
PP
1
28.
UNLEADED
GASOLINE
DO NOT
SPILL FUEL
ON A HOT
ENGINE
PP
CLEAN UP
GASOLINE
SPILLS WITH
WATER BEFORE
STARTING ENGINE
29.
GROUND
FUEL PUMP
30.
19.
LOW OIL PRESSURE
20.
NEGATIVE
GROUND
BATTERY
31.
21.
DO NOT CONNECT
POSITIVE BATTERY
TERMINAL TO GROUND
32.
22.
SHORTING BATTERY
TERMINALS MAY
CAUSE EXPLOSION
23.
NO
TAMPERING.
KEEP HANDS
OUT
24.
WARNING
CORROSIVE
25.
WARNING
EXPLOSIVE
26.
27.
33.
34.
35.
DO NOT
DISPOSE OF
BATTERIES
IN LANDFILL
DO NOT
DRIVE ON
HIGHWAY
WINDSHIELDS
DO NOT
PROVIDE
PROTECTION
FROM
FLYING OBJECTS
BATTERIES ARE
HEAVY.
USE CARE
LIFTING
USE INSULATED
TOOLS
WEAR EYE
PROTECTION
NO SMOKING
HOT SURFACE
WARNING
LETHAL
VOLTAGE
DO NOT
EXPOSE
TO FLAME
36.
OPERATE
FROM
DRIVERS SIDE
ONLY
1- 9
SAFETY
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1
HEADLIGHTS
45.
KEEP ARMS
AND LEGS
WITHIN VEHICLE
37.
UNLOCKED
46.
38.
F
TO OPERATE VEHICLE IN FORWARD:
Q TURN KEY TO ON
Q MOVE DIRECTION SELECTOR TO
FORWARD
Q DEPRESS ACCELERATOR PEDAL
AND ACCELERATE SMOOTHLY
LOCKED
47.
48.
DIFFERENTIAL
LOCKED
49.
WARNING
KEEP ENTIRE BODY
INSIDE CAR
50.
MAXIMUM
TAILGATE
LOAD
TO OPERATE VEHICLE IN REVERSE:
Q TURN KEY TO ON
Q MOVE DIRECTION SELECTOR TO
REVERSE
Q AN AUDIBLE DEVICE WILL SOUND
Q DEPRESS ACCELERATOR PEDAL
AND ACCELERATE SMOOTHLY
39.
R
P
40.
TO LEAVE A GASOLINE POWERED
VEHICLE IN PARK:
Q APPLY PARKING BRAKE
Q TURN KEY TO OFF
Q MOVE DIRECTION SELECTOR TO
FORWARD
F
P
41.
TO LEAVE AN ELECTRIC POWERED
VEHICLE IN PARK:
Q APPLY PARKING BRAKE
Q TURN KEY TO OFF
Q MOVE DIRECTION SELECTOR TO
NEUTRAL
LEAVE VEHICLE
WHEN LIGHTNING
IS IN THE AREA
52.
N
KEEP CLEAR
HAND OR
FINGERS CAN
BE TRAPPED
42.
53.
1 - 10
WARNING
POSSIBILE ELECTRIC
ARC OR BATTERY
EXPLOSION. WEAR
EYE PROTECTION.
51.
43.
ON
ON
POSITION
44.
OFF
OFF
POSITION
cm
150
MINUMUM HEIGHT
TO OPERATE VEHICLE
SAFETY
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Notes:
1
1 - 11
SAFETY
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1
Notes:
1 - 12
GENERAL SPECIFICATIONS
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TITLE
PAGE NO.
HAULER 1200X E Vehicle Specifications ....................................................................................................................... 2 - 3
HAULER 1200X E Vehicle Dimensions ........................................................................................................................... 2 - 4
HAULER 1200X E Vehicle Incline Information and Turning Diameter.......................................................................... 2 - 5
2- 1
2
GENERAL SPECIFICATIONS
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2
Notes:
2- 2
GENERAL SPECIFICATIONS
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2
MODEL: HAULER 1200X
TYPE: ELECTRIC 48V POWERED TRUCK
MODEL YEAR: 2012
Part No: 619211
PRODUCT SPECIFICATION
CONFIGURATION HIGHLIGHTS
Precision Drive System™ (PDS): Factory programmable to application
Solid State continuously variable seperately excited speed controller
Diagnostic indicator
Full torque, reduced speed reverse
Dash mounted direction selector switch (Forward-Neutral-Reverse)
Anti-roll back, walkaway braking and alarm
Inductive throttle sensor
Factory selectable performance options
Anti-stall motor protection
Regenerative ’Pedal Down’ and/or ‘Pedal Up’ braking
Battery Charger: 48 VDC PowerWise™, 120/230 VAC 50/60 Hz. Underwriters Laboratories (U.L.) Listed, (C.S.A. Certified)
Motor:
Drive Train:
Electrical System:
Transaxle:
Brakes:
Cargo Bed:
48 Volt DC shunt wound, brazed armature, solid copper windings. Non vented 2.5 hp (1.9 kW) @ 2700 rpm (1 hour)
Direct motor shaft connected to transaxle pinion shaft
48 Volt DC, eight, 6 volt deep cycle storage batteries batteries (115 minute minimum, 225 amp-hour @ 20 hr. discharge rate)
Differential with helical gears
Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with
self-compensating system
Roto-molded cross-linked polyethelene. Lifts for access to powertrain. Removable hinged multi-position
tailgate requires no latch mechanism
PRODUCT OVERVIEW
Performance
Dimensions
Overall Length
111.5 in (283.0 cm)
Overall Width
49.5 in (126.0 cm)
Overall Height (No Canopy) 49.5 in (126.0 cm) (Top of Steering wheel)
Overall Height (With Canopy) 78.5 in (199.0 cm)
Wheel Base
77.0 in (196.0 cm)
Front Wheel Track
38.0 in (97.0 cm)
Rear Wheel Track
38.5 in (98.0 cm)
Gnd Clearance @ Differential 6.0 in (15.0 cm)
Cargo Box Width (inside)
44.0 in (112.0 cm)
Cargo Box Length (inside) 36.0 in (91.0 cm)
Cargo Box Depth (inside)
10.5 in (27.0 cm)
Cargo Box Capacity
9.6 cu ft (0.27 m3)
Cargo Box Material
Roto-molded polyethylene
Vehicle Power
Power Source
Motor Type
Horsepower (kW)
Electrical System
Batteries (Qty, Type)
Key or Pedal Start
Battery Charger
Speed Controller
Drive Train
Transaxle
Gear Selection
Rear Axle Ratio
48 Volts DC
Shunt Wound
2.5 hp (1.9 kW) @ 2700 rpm
48 Volt
Eight, 6 Volt Deep Cycle
Pedal Start
Seating Capacity
2 Persons
Dry Weight
820.0 lb (375.0 kg) (Without Batteries)
Curb Weight
1310.0 lb (595.0 kg)
Bed load capacity
550.0 lb (250.0 kg)
Vehicle load capacity
1000.0 lb (450.0 kg)
Outside Clearance Circle 22.0 ft (6.7 m)
Intersecting Aisle Clrnce N/A
Speed (Level Ground) 16 mph ± 0.5 mph (26 kph ± 0.8 kph)
Towing Capacity
600 lb (270 kg) max load
Steering & Suspension
Steering
Front Suspension
Rear Suspension
Service Brake
Parking Brake
Front Tires
Rear Tires
Self-compensating rack and pinion
Leaf springs with hydraulic shock absorbers
Leaf springs with hydraulic shock absorbers
Rear wheel mechanical self-adjusting drum
Self-compensating, single point engagement
Stryker 22 x 9 -10 Uni-directional
Stryker 22 x 9 -10 Uni-directional
Body & Chassis
Frame
Front Body & Finish
Standard Color
Welded steel with DuraShield™ powder coat
Injection molded TPO
Hunter Green
48 VDC PowerWise™ w/10 ft (3 m) DC cord Noise & Vibration
Noise
Sound pressure; continued A-weighted equal to or less
400 Amp Precision Drive System (PDS)
than 70 db(A)
Motor Shaft Direct Drive
Vibration, WBV Highest RMS value of weighted acceleration is 0.98 m/s2
Differential with helical gears
Vibration, HAV Highest RMS value of weighted acceleration is: less than 2.5 m/s2
Dash Mounted Forward-Neutral-Reverse
The uncertainty of measurement is 0.39 m/s2
14.7:1
Some items shown may be optional equipment
Specifications are subject to change without notice
* Field installed accessories may require installation charges
2- 3
GENERAL SPECIFICATIONS
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2
111.5 in (283.0 cm)
49.5 in
(126.0 cm)
10.5 in
(27.0 cm)
78.5 in
(199.0 cm)
77.0 in (196.0 cm)
Front
38.0 in (97.0 cm)
Rear
38.5 in (98.0 cm)
49.5 in
(126.0 cm)
HAULER 1200X E
36.0 in (91.0 cm)
2- 4
GENERAL SPECIFICATIONS
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2
RECOMMENDED MAX SIDE TILT
25% or 14o MAX
RECOMMENDED MAX RAMP GRADE
25% or 14o MAX
TURNING CLEARANCE DIAMETER
HAULER 1200X E
22.0 ft (6.7 m)
2- 5
GENERAL SPECIFICATIONS
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2
Notes:
2- 6
INTRODUCTION
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TITLE
PAGE NO.
FEATURES.......................................................................................................................................................................... 3-3
General Information .................................................................................................................................................................................... 3-3
Key Switch / Headlight Switch..................................................................................................................................................................... 3-3
State of Charge Meter................................................................................................................................................................................. 3-3
Direction Selector........................................................................................................................................................................................ 3-3
Accelerator Pedal........................................................................................................................................................................................ 3-3
Brake and Park Brake ................................................................................................................................................................................. 3-4
Horn ............................................................................................................................................................................................................ 3-5
Front Seat ................................................................................................................................................................................................... 3-5
Hip Restraint ............................................................................................................................................................................................... 3-5
Hour Meter .................................................................................................................................................................................................. 3-5
Grab Handles .............................................................................................................................................................................................. 3-5
Glove Box.................................................................................................................................................................................................... 3-5
Cup Holder .................................................................................................................................................................................................. 3-5
Steering Wheel............................................................................................................................................................................................ 3-5
Charger with DC to DC Converter............................................................................................................................................................... 3-5
Charger Receptacle .................................................................................................................................................................................... 3-5
Battery Compartment .................................................................................................................................................................................. 3-5
Ash Tray...................................................................................................................................................................................................... 3-6
Utility Bed .................................................................................................................................................................................................... 3-7
Manual Lift Bed Operation .......................................................................................................................................................................... 3-7
3- 1
3
INTRODUCTION
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Notes:
3
3- 2
INTRODUCTION
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FEATURES
General Information
NOTICE
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in
the ‘OFF’ position.
ALL accessories that do NOT use the accessory wiring harness MUST be connected to draw from the entire 48 Volt
battery pack. A DC to DC converter is required for accessories that require voltage other than 48 volts to operate
properly.
Accessories connected to this vehicle that do not use the accessory harness must be connected to the DC to DC
converter.
1. Key Switch / Headlight Switch
To reduce the possibility of component damage, the vehicle must be stopped before moving the key switch/direction
selector.
Located on the dash panel, the key switch enables the electrical system of the vehicle to be turned on and off by
turning the key and the headlight is operated by turning the key switch beyond ON position. To prevent inadvertent
operation of the vehicle when left unattended, the key should be turned to the ‘OFF’ position and removed.
2. State of Charge Meter
The vehicle is equipped with a state of charge meter located in the dash panel. The state of charge meter indicates the
amount of usable power in the batteries. The state of charge meter shows the condition of the battery pack with F indicating a full charge on the battery pack and E indicating the battery pack needs to be charged.
3. Direction Selector
To prevent loss of control, do not move Precision Drive System (PDS) vehicle directions selector
while the vehicle is in motion. Moving the selector will result in a sudden slowing of the vehicle
and the beeping of a warning device.
On PDS models, if the direction selector is shifted before the vehicle comes to a complete stop, a warning beeper will
activate.
Located on the dash panel, this switch permits the selection of either ‘F’ (forward), ‘R’ (reverse) or neutral (the position between forward and reverse). Vehicle should be left in neutral when unattended
4. 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. To stop the vehicle more quickly, depress the service brake.If key switch is ‘ON’ and park brake is set,
3- 3
3
INTRODUCTION
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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.
3
10
H
ORN
11
3
2
OFF
ON
1
7
8
5
Park
Brake Brake 4
OR
N
H
6
PARK
18
5. Brake and Park Brake
NOTICE
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in
the ‘OFF’ position. 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.
The brake pedal incorporates a park brake feature. To engage the park brake, 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.
3- 4
INTRODUCTION
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6. Horn
The horn button is located on the driver’s side floorboard; depressing the button will sound the vehicle’s horn.
7. Front Seat
The front seat is designed for two occupants, one on each side of the seat.
8. Hip Restraint - Front
The front hip restraints are designed to help keep the occupants properly positioned in the event of sudden vehicle
position changes.
9. Hour Meter
The hour meter indicates total hours of operation. If the vehicle is equipped with lights, the key switch has a position to
operate them, indicated by the light icon.
10. Glove Box
An optional lockable glove compartment is located on each side of the instrument panel.
11. Cup Holder
A cup holder is provided for convenience of both the driver and passenger.
12. Steering Wheel
The steering wheel located in front of the driver seat is used to steer the vehicle. The steering wheel is also installed
with scorecard holder assembly.
13. Charger with DC to DC Converter
Charger is used to charge battery while vehicle is parked and the DC to DC converter is used to power accessories.
14. Charger Receptacle
The charging cord is to be connected to this receptacle while the vehicle is being charged.
15. Battery Compartment
The battery compartment can be accessed by raising the front seat to perform battery maintenance and access the
Run/Tow switch.
To reduce the possibility of severe injury or death resulting from loss of vehicle control, consider
the grade of the terrain the vehicle is on and set vehicle’s park brake accordingly before switching the Run - Tow/Maintenance switch to the ‘Tow/Maintenance’ position. When in the ‘Tow/
Maintenance’ position, the Anti-Roll Back and Walk-Away safety features of the system no longer function.
Before attempting to tow vehicle, move the Run-Tow/Maintenance switch to the ‘Tow/Maintenance’ position. Failure
to do so will damage the controller or motor.
Before disconnecting or connecting a battery, or any other wiring, move the Run-Tow/Maintenance switch to the
‘Tow/Maintenance’ position.
After connecting a battery, or any other wiring, wait a minimum of 30 seconds before moving the Run-Tow/Maintenance switch to the ‘Run’ position.
3- 5
3
INTRODUCTION
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16
3
12
15
17
RUN/TOW SWITCH
14
13
NOTICE
The Run/Tow switch should always be returned to the ’TOW’ position after moving a stalled vehicle. If the switch is left in the
’RUN’ position for an extended period of time, it will drain the batteries.
The Run/Tow switch is located under the seat on the passenger side of the vehicle.
With the switch in ‘TOW/MAINTENANCE’ position:
•
•
•
the controller is deactivated
the electronic braking system is deactivated which allows the vehicle to be towed or roll freely
the warning beeper is deactivated
With the switch in ‘RUN’ position:
•
•
the controller is activated
the electronic braking system and warning beeper features are activated.
16. Ash Tray
The vehicle is equipped with ash tray as an option.
3- 6
INTRODUCTION
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17. Utility 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.
Never fill a gas can in the bed of a vehicle. Static discharge could ignite gasoline vapor and
cause an explosion.
MAX
400 lbs.
180 kg
PP
MAX
4 in.
10 cm
MAX
100 lbs.
45 kg
MAX
14o / 25%
74821G06
A load bed warning label is affixed to the front of the bed. 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. Do not drive the
vehicle with the load bed raised or with the tailgate unsupported. 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. 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.
18. Manual Lift Bed Operation
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 raise the manual lift bed, pull back on the latch release handle immediately behind the driver seat. Raise the bed
using the handle on the side of the bed.
To lower the manual lift bed, grasp the bed handle and lower the bed to the rest position. Be sure hands are not
trapped by the bed.
3- 7
3
INTRODUCTION
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Notes:
3
3- 8
OPERATING PROCEDURES
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TITLE
PAGE NO.
SERIAL NUMBER LOCATION ............................................................................................................................................ 4-2
BEFORE INITIAL USE ........................................................................................................................................................ 4-3
PORATABLE CHARGER INSTALLATION ......................................................................................................................... 4-3
Plastic Loadbed........................................................................................................................................................................................... 4-5
Manual Lift Bed Operation .......................................................................................................................................................................... 4-5
OPERATING THE VEHICLE ............................................................................................................................................... 4-6
General ....................................................................................................................................................................................................... 4-6
PRECISION DRIVE SYSTEMTM .......................................................................................................................................... 4-7
Regenerative Braking.................................................................................................................................................................................. 4-7
Pedal-Up Braking ........................................................................................................................................................................................ 4-7
Terrain......................................................................................................................................................................................................... 4-8
Walk-Away Feature..................................................................................................................................................................................... 4-8
Anti-Roll Back Feature ................................................................................................................................................................................ 4-8
Anti-Stall Feature ........................................................................................................................................................................................ 4-8
High Pedal Disable Feature ........................................................................................................................................................................ 4-8
Diagnostic Mode Feature ............................................................................................................................................................................ 4-8
STARTING AND DRIVING .................................................................................................................................................. 4-9
Starting Vehicle on a Hill ............................................................................................................................................................................. 4-9
Coasting ...................................................................................................................................................................................................... 4-9
Labels and Pictograms.............................................................................................................................................................................. 4-10
Sun Top And Windshield........................................................................................................................................................................... 4-10
Towing A Trailer ........................................................................................................................................................................................ 4-10
4- 1
4
OPERATING PROCEDURES
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SERIAL NUMBER LOCATION
The serial number and manufacture date code plates are on the vehicle. One (PART C) is placed on the body below
the front, driver side of the seat, PART D is placed on the frame weld tube. The other (PART A and PART B) is
located on the crossmember section of the chassis on the driver side (seat back support). To access it, raise the seat
and lift up the flap on the access panel.
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 mustacture date code, serial number and vehicle model must be
provided when ordering service parts.
4
PART B
PART A
V
PART C/D
V
Part A
Part D
Lift Flap on Access Panel
Part B
Serial Number
Labels
Part C
4- 2
OPERATING PROCEDURES
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BEFORE INITIAL USE
Read, understand and follow the safety label on the instrument panel. Be sure you understand how to operate the
vehicle, its equipment as well as how to use it safely. Maintaining good performance depends to a large extent on the
operator.
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. Chargingmust take place in an area that is adequately ventilated (minimum of 5 air exchanges perhour).
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 thatcould 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.
The vehicle batteries must be fully charged before initial use.
Check for leaks that could have developed in shipment from the factory.
Check for correct tire inflation. See GENERAL SPECIFICATIONS.
Determine and record the braking distance required to stop the 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.
ITEM
SERVICE OPERATION
Batteries
Charge batteries
Seats
Remove protective plastic covering
Brakes
Check operation
Establish acceptable stopping distance
Tires
Portable
Charger
Check air pressure (see SPECIFICATIONS)
Remove from vehicle and properly mount
INITIAL SERVICE CHART
.
PORTABLE CHARGER INSTALLATION
To reduce the possibility of 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.
4- 3
4
OPERATING PROCEDURES
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Provide Protection From Elements
4
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
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. 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
NOTICE
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.
To reduce the possibility of 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.
NOTICE
If vehicle is to be charged with a non E-Z-GO charger, refer to the instructions supplied with the
charger.
PLASTIC LOADBED
The manual lift bed is the standard bed for the vehicle. The bed may be equipped with an optional electric lift switch.
4- 4
OPERATING PROCEDURES
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Failure to follow these instructions may result in personal injury, damage the vehicle and/or cause the vehicle to tip
over. Operate the vehicle with awareness of the load. Read, understand and follow the Danger label affixed to the
front of the loadbed.
Do not permit anyone to ride in the bed.
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and
Warnings
Before operating, check to ensure no one is behind the vehicle. A loadbed warning label is affixed to the inside front
of the bed (see Appendix A). This label must be understood and observed at all times for safe operation of the vehicle. See the loadbed warning label for maximum load. The load must be positioned in the bed as far forward as possible, distributed in such a way that its center of gravity must not be higher than height noted on label, and securely
fastened down. Failure to follow these instructions may result in severe personal injury, damage the vehicle and/or
cause the vehicle to tip over. Operate the vehicle with awareness of the load.
Do not permit anyone to ride in the bed.
Do not drive the vehicle with the loadbed raised or with the tailgate unsupported.
When using the electric lift, 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.
Before operating, check to ensure no one is behind the vehicle.
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 OPERATION
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. Raise the bed
using the handle on the side of the bed.
4- 5
4
OPERATING PROCEDURES
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Front of Vehicle
4
Manual Load Bed Latch
Pull Up to Release
Manual Bed Latch
NOTICE
To lower the manual lift bed, grasp the bed handle and lower the bed to the rest position. Be sure hands are not
trapped by the bed.
TAILGATE OPERATION
To open the tailgate, lift tailgate straight up with a sharp upward pull to lift out of the closed position and pivot out for
open position. To remove the tailgate, remove the side cables from the loadbed and open tailgate until it is straight
down, move tailgate panel straight up to remove from pins and remove from the loadbed. Reassemble in reverse
order.
OPERATING THE VEHICLE
Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance.
Read 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.
To prevent loss of control, do not move the direction selector of a vehicle while the vehicle is in
motion. Moving the selector will result in a sudden slowing of the vehicle and the beeping of a
warning device.
Slow down before and during turns. All turns should be made at reduced speed.
4- 6
OPERATING PROCEDURES
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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 forward position, turn key to ‘OFF’ position and remove key.
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.
ponds to the option per the above option numbers.
C
PRECISION DRIVE SYSTEM™
Regenerative Braking
To prevent the possibility of loss of control that could cause severe injury or death, use service
brake to control speed. The PDS system is not a substitute for the service brake.
PDS models are equipped with a regenerative motor control system.
Example: If all of the following events occur...
a) the vehicle is being driven down a slope
b) the vehicle attempts to exceed the specified top speed with the accelerator pedal depressed or released
the regenerative braking will limit the speed of the vehicle to the specified top speed (the warning beeper will not
sound). When the regenerative braking system is activated by this sequence of events, the motor generates power
which is returned to the batteries.
If the operator attempts to override the regenerative braking feature by moving the direction selector or key switch to
another position, the warning beeper will sound and the vehicle will brake rapidly until it reaches the speed of
approximately 2 mph (3 kph).
Pedal-Up Braking
Pedal-up braking is regenerative braking that occurs when the accelerator pedal is released while the vehicle is
moving between 8 mph (13 kph) and the vehicle’s top speed.
Example: If all of the following events occur...
a) the vehicle is being driven down a slope
b) the accelerator pedal is released for more than one second
4- 7
4
OPERATING PROCEDURES
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the pedal-up braking will slow the vehicle (the warning beeper will not sound) until either the vehicle speed is
reduced to 8 mph (13 kph), at which it freely coasts between 8 and 3 mph (5 kph), or the accelerator pedal is applied.
When pedal-up braking system is activated by this sequence of events, the motor generates power which is returned
to the batteries.
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.
4 Walk-Away Feature
Walk-Away limits vehicle movement without driver input, slowing the vehicle to 2 mph (3 kph) and sounding an audible alarm (reverse beeper).
Example: If all of the following events occur...
a) the vehicle has been stopped for more than 1.5 seconds
b) the accelerator pedal has been released for more than one second
c) the vehicle begins to roll above 2 mph (3 kph)
the electronic braking will limit speed to approximately 2 mph (3 kph) and the warning beeper will sound. When the
accelerator pedal is depressed, the electronic braking and warning beeper will be overridden and normal vehicle
operation resumes. Any unusual situation sensed by the PDS system will cause a similar response. The system
functions in all key switch positions.
Anti-Roll Back Feature
Anti-Roll Back, like Walk-Away, limits backward motion of the vehicle down an incline to less than 2 mph (3 kph). See
‘Walk-Away Feature’ above.
Anti-Stall Feature
Anti-Stall protection prevents motor damage from stalling the vehicle against an object or on a hill.
Example: If all of the following events occur...
a) the system senses that the accelerator pedal is depressed (power applied to motor)
b) the motor is stalled long enough that any more time may cause motor damage
the PDS system will momentarily interrupt power to the motor. This brief interruption will permit the car to roll backwards slightly before again stopping in the stalled condition. This process will repeat itself periodically until the car is
moved from the stalled condition.
Example: If all of the following events occur...
a) the system senses that the accelerator pedal is depressed (power applied to motor)
b) the brake is engaged so as to prevent vehicle motion
the PDS system will sense a stalled motor condition and remove power from the motor. When the brake pedal is
released, the car will roll backwards slightly before power is returned to the motor.
High Pedal Disable Feature
High pedal disable prevents undesired acceleration if the direction selector lever is changed, or the key is turned on
while the accelerator is depressed.
Diagnostic Mode Feature
In the unlikely event of certain electrical system failures, the PDS controller will default to a mode that will permit the
vehicle to operate, but at a very reduced speed.
This feature allows the vehicle to be driven back to its storage facility where the problem can be diagnosed.
4- 8
OPERATING PROCEDURES
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The controller can be put in diagnostic mode by the technician and the controller will report the failure mode.
STARTING AND DRIVING
To reduce the possibility of roll - back which could result in severe injury or vehicle damage, do
not release the service brake until motor has started.
All vehicles are equipped with an interlock system that disables the controller and prevents the vehicle from being
operated or towed while the charger is connected. Remove the charger plug from the vehicle receptacle and properly store the cable prior to moving the vehicle.
To operate the vehicle:
•
•
•
•
•
Apply the service brake, place the key in the key switch and turn it to the ‘ON’/’N’ position.
Move the direction selector to the direction desired.
Release the park brake by depressing the service brake pedal until the park brake releases.
Slowly depress the accelerator pedal to start the motor.
When the accelerator pedal is released, the motor controls the deceleration. To stop the vehicle more quickly,
depress the service brake pedal.
NOTICE
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 Vehicle On A Hill
To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do
not release the service brake until motor has started
.
Do not hold vehicle on hill by using accelerator and motor. Leaving motor in a stalled condition for more than 3 - 4
seconds will cause permanent damage to motor.
To reduce the possibility of permanent damage to the drive system, it is important to prevent excessive roll-back
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 the left foot.
Coasting
To reduce the possibility of severe injury or death from coasting at above recommended speeds,
limit speed with service brake.
Uncontrolled coasting does not occur with PDS model vehicles because the PDS controls the top speed of the
vehicle while moving down hill. However, the PDS is not a substitute for the service brake which should be used to
control the speed of the vehicle
4- 9
4
OPERATING PROCEDURES
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NOTICE
Some PDS models are equipped with a feature (pedal-up braking) which slows the vehicle’s speed when the accelerator pedal is
released
On steep hills, it is possible for non-PDS 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
4 Vehicles may be labeled with pictograms as a method of conveying information or warnings. The SAFETY Section of
this manual explains the labels that are used on this vehicle.
Sun Top And Windshield
The sun top does not provide protection from roll-over or falling objects.
The windshield does not provide protection from tree limbs or flying objects.
The sun top and windshield provide some protection from the elements; however, they will not keep the operator and
passenger dry in a downpour. This vehicle is not equipped with seat belts and the sun top has not been designed to
provide roll-over protection. In addition, the sun top does not protect against falling objects nor does the windshield
protect against flying objects and tree limbs. Keep arms and legs inside of the vehicle while it is moving.
TOWING A TRAILER
The vehicle may be equipped with a receiver that can be fitted with a standard 1 7/8" ball. The trailer and its load
must not exceed 500 lbs (227 kg) and no more than 50 lbs (23 kg) tongue weight may be attached to the hitch.
Remember that the overall capacity of the vehicle, operator, passenger, contents of loadbed and accessories must
be reduced to compensate for the trailer and load.
The range of motion of the trailer is limited by the ball and hitch. The trailer should not be used on rough trails or over
objects such as logs, large rocks, holes, etc.
Never install baskets or extensions using a hitch receiver. Such items will change the performance characteristics of
vehicle and result in unsafe handling, possible roll over or vehicle damage.
4 - 10
OPERATING PROCEDURES
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
4
4 - 11
OPERATING PROCEDURES
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
4
4 - 12
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
TITLE
PAGE NO.
VEHICLE CLEANING AND CARE ...................................................................................................................................... 5-3
Vehicle Cleaning ......................................................................................................................................................................................... 5-3
REPAIR ............................................................................................................................................................................... 5-3
Lifting the Vehicle........................................................................................................................................................................................ 5-3
WHEELS AND TIRES.......................................................................................................................................................... 5-4
Tire Repair .................................................................................................................................................................................................. 5-4
Wheel Installation........................................................................................................................................................................................ 5-5
LIGHT BULB REPLACEMENT ........................................................................................................................................... 5-6
FUSE REPLACEMENT ....................................................................................................................................................... 5-6
TRANSPORTING VEHICLE ................................................................................................................................................ 5-7
Towing......................................................................................................................................................................................................... 5-7
Hauling ........................................................................................................................................................................................................ 5-7
SERVICE AND MAINTENANCE ......................................................................................................................................... 5-7
ROUTINE MAINTENANCE.................................................................................................................................................. 5-8
Tire Inspection............................................................................................................................................................................................. 5-8
Brakes ......................................................................................................................................................................................................... 5-8
PERIODIC BRAKE TEST FOR MECHANICAL BRAKES ................................................................................................... 5-9
REAR AXLE ........................................................................................................................................................................ 5-9
Checking the Lubricant Level...................................................................................................................................................................... 5-9
LUBRICATION .................................................................................................................................................................. 5-10
PDS SYSTEM TEST .......................................................................................................................................................... 5-10
HARDWARE...................................................................................................................................................................... 5-10
CAPACITIES AND REPLACEMANT PARTS.................................................................................................................... 5-11
PERIODIC SERVICE SCHEDULE..................................................................................................................................... 5-12
BATTERY CHARGING AND MAINTENANCE .................................................................................................................. 5-13
Safety ........................................................................................................................................................................................................ 5-13
Battery....................................................................................................................................................................................................... 5-14
Battery Maintenance ................................................................................................................................................................................. 5-14
At Each Charging Cycle ............................................................................................................................................................................ 5-14
Monthly...................................................................................................................................................................................................... 5-14
Electrolyte Level and Water ...................................................................................................................................................................... 5-14
Battery Cleaning........................................................................................................................................................................................ 5-16
Battery Replacement................................................................................................................................................................................. 5-17
Battery Charging ....................................................................................................................................................................................... 5-18
5- 1
5
MAINTENANCE
AC Voltage ................................................................................................................................................................................................ 5-18
Troubleshooting......................................................................................................................................................................................... 5-18
HYDROMETER ..................................................................................................................................................................5-19
Using Hydrometer...................................................................................................................................................................................... 5-20
PROLONGED STORAGE ..................................................................................................................................................5-22
5
5- 2
MAINTENANCE
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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. 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 to wash exterior of vehicle.
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.
REPAIR
Lifting The Vehicle
Tool List
Qty.
Floor jack .................................................................... 1
Wheel Chocks ............................................................. 4
Tool List
Qty.
Jack stands ............................................................. 4
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.
Use extreme care since the vehicle is extremely unstable during the lifting process.
5- 3
5
MAINTENANCE
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When lifting the vehicle, position the jacks and jack stands at the areas indicated only.
Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while
lifting.
To raise the entire vehicle, install chocks in front and behind each front wheel. 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.
5 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.
Lifting The Vehicle
Flat Portion
of Frame
Center of
Front Axle
Outside End
of Rear Axle
View from Underside of Vehicle
WHEELS AND TIRES
Tire Repair
Tool List
Qty.
Lug wrench, 3/4" ..........................................................1
Impact wrench, 1/2" drive ............................................1
Tool List
Qty.
Impact socket, 3/4", 1/2" drive ................................ 1
Torque wrench, 1/2" drive ....................................... 1
A tire explosion can cause severe injury or death. Never exceed the inflation pressure rating on
the tire sidewall.
To reduce the possibility of tire explosion, pressurize tire with small amounts 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 a valve core.
To reduce the possibility of severe injury caused by a broken socket when removing wheels, use
5- 4
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
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.
Do not use low inflation pressure tires on any E-Z-GO vehicle. Do not use any tire which has a
recommended inflation pressure less than the inflation pressure recommended in Owner’s
Manual.
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 stem 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.
NOTICE
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.
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.
To reduce the possibility of severe injury, be sure the 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.
Wheel Installation
To reduce the possibility of component damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.
NOTICE
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 the lug nuts (1) in a
‘cross sequence’ pattern. Tighten the lug nuts to 50 to 85 ft. lbs. (68 to 115 Nm) torque in 20 ft. lbs. (27 Nm) increments following the ‘cross sequence’ pattern.
5- 5
5
MAINTENANCE
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Tire/wheel style
may vary
'Cross Sequence'
1
'Cross Sequence'
1
3
3
4
5
2
4
5
2
Wheel Installation
LIGHT BULB REPLACEMENT
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.
Inside
of Cowl
Headlight
Casing
Screw
Headlight
Bulb
For vehicles equipped with lights mounted in the cowl,
locate bulb socket on backside of light and turn bulb
socket a quarter turn counterclockwise to unlock and pull
out bulb and socket. Insert new bulb and rotate socket a
quarter turn clockwise to secure.
Similarly replace the turn signal light bulb, locate bulb socket on backside of light
bar and turn bulb socket a quarter turn counterclockwise to unlock and pull out
bulb and socket. Insert new bulb and rotate socket a quarter turn clockwise to
secure.
Roll Rubber
Bezel Away
From Body
To replace the tail and brake light bulb, roll the rubber bezel from around the
edge of the taillight and remove lens. Install replacement bulb and replace
lens.
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.
5- 6
Tail/Brake
Light
Rear
Fender
MAINTENANCE
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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
5
To reduce the possibility of severe injury or death while transporting the vehicle:
Secure the vehicle and contents.
Never ride on the vehicle being transported.
Always remove the windshield before transporting.
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 plus 1000 lbs. (454 kg). 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 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.
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 dropped wrench
‘shorting out’ a battery, which could result in an explosion.
The electrolyte in a 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.
5- 7
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
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.
ROUTINE MAINTENANCE
5
Before any electrical service is performed on PDS model vehicles, the ‘Run-Tow/Maintenance’ switch must be
placed in the ‘Tow/Maintenance’ position.
If a power wire (battery, motor or controller) is disconnected for any reason on the PDS model vehicle, the ‘Run-Tow/
Maintenance’ switch must be left in the ‘Tow/Maintenance’ position for at least 30 seconds after the circuit is
restored.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic
Service Schedule for appropriate service intervals Refer to Lubrication Points for appropriate lubrication locations
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.
Tire Inspection
Tire condition should be inspected per the Periodic Service Schedule. Inflation pressures should be checked when
the tires are cool. Be sure to install the valve dust cap after checking or inflating.
Brakes
To reduce the possibility of severe injury or death, always evaluate pedal travel before operating
a vehicle to verify some braking function is present.
All driving brake tests must be done in a safe location with regard for the safety of all personnel.
NOTICE
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 as an evaluation of braking system performance. It is useful as a method of identifying subtle loss of performance over time.
5- 8
MAINTENANCE
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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.
Establish the acceptable stopping distance by testing a new or
‘known to be good’ vehicle and recording the stopping location
or stopping distance. Several vehicles should be tested when
new and the range of stopping locations or distances recorded.
Drive the vehicle at maximum speed on a flat, dry, clean, paved
surface. 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 TROUBLE SHOOTING section in the Technician’s Repair and Service Manual.
Dry, Level, Clean, Paved Surface
Accelerate To
Maximum Speed
5
Latch
Parking Brake
and Take Foot
Off Pedal
Line or Marker
Line or Marker
Acceptable
Stopping 4 ft. (1.2 m)
Distance
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
Typical Brake Performanace Test
REAR AXLE
The only maintenance required for the first five years is the periodic inspection
of the rear axle for lubricant leakage. Unless leakage is evident, the lubricant
need only be replaced after five years. Refer to the Service and Repair Manual
for the fluid replacement procedure.
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.
Check/Fill Plug
5- 9
MAINTENANCE
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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.
Lubrication Points
5
Rack
Ball
Joint
View from Underside of Vehicle
Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure.
PDS SYSTEM TEST
At monthly intervals, test the PDS system by allowing the vehicle to roll down an incline with the accelerator pedal
released. Braking force should be felt at approximately 2 mph (3 kph) indicating that the PDS system is functioning.
If vehicle speed continues to rise, apply the service brake and have vehicle inspected by a trained mechanic.
Hardware
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)
Torque Specifications and Bolt Grades
5 - 10
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with
the Torque Specifications table.
Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific torque values.
Generally, three classes of standard hardware and two classes of metric 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. Metric hardware is marked on the head with 8.8 or 10.9. Unmarked hardware is Grade 2.
CAPACITIES AND REPLACEMENT PARTS
Rear Axle Oil
40 oz (1.2 liters) / SAE 30
Fuse
15 amp (P/N 18392-G1)
Headlight Bulb
(P/N 619100)
LED Bulb
(P/N 619101)
Turn Signal Bulb
(P/N 619102)
Tail Light Bulb
#1157 (P/N 21759-G1)
5
Capacities and Replacement Parts
5 - 11
MAINTENANCE
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PERIODIC SERVICE SCHEDULE
 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
5
WEEKLY
TIRES
 Examine for cuts, excessive wear and pressure
WHEELS
 Check for bent rims, missing or loose lug nuts
(See GENERAL SPECIFICATIONS)
MONTHLY - 20 HOURS (includes items listed in previous table & the following)
BATTERIES
WIRING
CHARGER / RECEPTACLE
ACCELERATOR
SERVICE BRAKE
(MECHANICAL BRAKES)
(HYDRAULIC BRAKES)
PARK BRAKE
DIRECTION SELECTOR
STEERING ASSEMBLY
TIE ROD/LINKAGES
CONTROLLER
REAR AXLE
 Clean batteries & terminals. See BATTERY CLEANING.
 Check charge condition and all connections
 Check all wiring for loose connections and broken/missing insulation
 Clean connections, keep receptacles free of dirt and foreign matter
 Check for smooth movement
 Conduct brake performance test
 Check brake performance and adjust if required
 Check attachment, tighten if required
 Check for abnormal play, tightness of all hardware
 Check for excessive play, bent components or loose connections
 Check for Controller braking force for proper operation of system
 Check for leakage, add SAE 30 oil as required
QUARTERLY - 50 HOURS (includes items listed in previous tables & the following)
FRONT AXLE
FRONT SHOCK ABSORBERS
FRONT SPRINGS
FRONT WHEEL ALIGNMENT
PARK BRAKE
 Check for damage to axle and loose or missing hardware
 Check for oil leakage and loose fasteners
 Check for loose hardware, cracks at attachments
 Check for unusual tire wear, align if required
 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
HARDWARE AND FASTENERS
5 - 12
 Check for oil leakage, loose mounting hardware
 Check for loose or missing hardware and components
 Tighten or replace missing hardware
MAINTENANCE
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SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)
 Check for wear and smooth movement (lubricate shaft with light oil if required)
 Check for excessive play and tightness of retaining nuts
 Check bellows and pinion seal for damage or grease leakage
 Lubricate, use wheel bearing grease
 Check for unusual noise and loose or missing mounting hardware
DIRECTION SELECTOR
KING PINS
STEERING ASSEMBLY
RACK END BALL JOINT
REAR AXLE
ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)
FRONT WHEEL BEARINGS
REAR AXLE
SERVICE BRAKES
(HYDRAULIC BRKES)
 Check and adjust as required, see Technician’s Repair and Service Manual
 Check lubricant, add lubricant (SAE 30 oil) as required
 Clean and adjust, see Technician’s Repair and Service Manual
 Check brake shoe linings, see Technician’s Repair and Service Manual
 Check brake fluid
5
BATTERY CHARGING AND MAINTENANCE
Safety
NOTICE
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 flames 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 the vehicle.
Never disconnect a circuit under load at a battery terminal.
Batteries are heavy. Use proper lifting techniques when moving them.
Always lift the battery with a commercially available battery lifting device.
Use care not to tip batteries when removing or installing them; spilled
electrolyte can cause burns and damage.
The electrolyte in a storage battery is an acid solution which can cause
severe burns to the skin and eyes. Treat all electrolyte spills to the body
and eyes with extended flushing with clear water. Contact a physician
immediately.
Always wear a safety shield or approved safety goggles when adding water
or charging batteries.
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 spilled 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
5 - 13
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
metal container to prevent can from contacting battery terminals which could result in an
explosion.
Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench
from ’shorting out’ a battery, which could result in an explosion and severe personal injury or death.
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.
5
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.
Insulated Wrench, 9/16"...............................................1
Hydrometer ..................................................................1
Tool List
Qty.
Battery Carrier ........................................................ 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 day’s use.
Monthly
•
•
•
•
Inspect all wiring for fraying, loose terminations, corrosion or deterioration of insulation.
Check that the electrolyte level is correct and add suitable water as required.
Clean the batteries and wire terminations.
Coat battery terminals with commercially available protectant.
Electrolyte Level and Water
The correct level of the electrolyte is 1/2" (13 mm) above the plates in each cell.
This 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. Also avoid filling with too much water, which will result in electrolyte being forced out of the battery due to gassing and a decrease
in volume of the electrolyte that results from the charging cycle.
5 - 14
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
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 with is lighter than air. Water and sulphuric 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 sulphuric
acid will remain where it can damage vehicle components and the storage facility floor. Sulphuric acid loss will
weaken the concentration of acid within the electrolyte and reduce the life of the battery.
5
Vent Cap
Gas Vent
Expansion
Space
Vent
1/4” to 3/8”
(6 mm to 10mm)
1/2” (13 mm)
Plates
Electrolyte level should be at least
1/2” (13mm) above the plates and 1/4”
to 3/8” (6 to 10 mm) below vent
Correct Electrolyte Level
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.
Water Purity Table
Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it does
not exceed the impurity levels specified in the table.
Automatic watering devices such as the one included in the Battery Maintenance Kit (P/N 25587-G01) can be used
with an approved water source. These watering devices are accurate, easy to use and allow for rapid filling. They
also maintain the correct electrolyte level within the battery cells.
5 - 15
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
NOTICE
The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates.
WATERING GUN SIMILAR TO THE TYPE INCLUDED
IN THE E-Z-GO BATTERY MAINTENANCE KIT
5
VALVE
CONSISTENTLY
FILLS TO A
PREDETERMINED
LEVEL
PURE WATER
ELECTROLYTE
LEVEL
SINGLE BATTERY CELL
Automatic Watering Gun
Battery Cleaning
To prevent battery damage, be sure that all battery caps 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.
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. In addition, spe-
5 - 16
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
cial attention should be paid to metal components adjacent to the batteries which should also be sprayed with the
solution.
Allow the solution to set for at
least three minutes; use a soft
bristle brush or cloth to wipe
the tops of the batteries in
order to remove any residue
that could cause the self-discharge of the battery. Rinse the
entire area with low pressure
clear water. All of the items
required for complete battery
cleaning and watering are contained in the Battery Maintenance Kit (P/N 25587-G01).
Non-Metalic Wand
1 quart
(1 liter)
Clear Water
1/4 Cup (60 ML)
Baking Soda
2 Teaspoons
(10 ml)
Sodium
Bicarbonate
(Baking Soda)
5
OR
Plastic
Spray
Bottle
1 1/2 GAL (6 Liters) Water
2 GAL (8 Liters)
Gargen Sprayer
(1 1/2 GAL (6 Liters)
Baking Soda Solution
.
Preparing Acid Neutralizing Solution
Battery Replacement
Before any electrical service is performed, the Run-Tow/Maintenance switch must be placed in the ‘Tow/Maintenance’ position.
If a power wire (battery, motor or controller) is disconnected for any reason, the Run-Tow/Maintenance switch must
be left in the ‘Tow/Maintenance’ position for at least 30 seconds after the circuit is restored.
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.
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.
5 - 17
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Use care to connect the battery wires as shown.
Tighten the battery post hardware to 90 - 100 in. lbs. (6 -8 Nm) torque. Do
not over-torque the terminal stud nut, this will cause a “mushroom” effect on
the battery post which will prevent the terminal nut from being properly
tightened.Protect the battery terminals and battery wire terminals with a
commercially available coating.
Protect the battery terminals and battery wire terminals with a commercially
available coating.
Front of Vehicle
+
+
-
-
+
BL +
-
-
BL -
Battery Charging
+
+
+
+
+
5
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.
-
-
Battery Connections
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 must be in good condition and free from dirt or debris.
The charger connector must be 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
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 the manufacturer’s
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.
5 - 18
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
HYDROMETER
A hydrometer is used to test the state of charge of a battery
cell. This is performed by measuring the density of the electrolyte, which is accomplished by measuring the specific
gravity of the electrolyte. The greater the concentration of
sulfuric acid, the more dense the electrolyte becomes. The
higher the density, the higher the state of charge.
To prevent 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.
CYLINDER BULB
THERMOMETER
FLOAT
Add to Float
Reading
Subtract
from Float
Reading
5
WEIGHT
Hydrometer
NOTICE
Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one
charge and discharge cycle in order to permit the water to adequately mix with the electrolyte.
The temperature of the electrolyte is important since the hydrometer reading must be corrected to 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.
5 - 19
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Using A Hydrometer
1. Draw electrolyte into the hydrometer several times to permit
the thermometer to adjust to the electrolyte temperature and
note the reading. Examine the color of the electrolyte. A
brown or gray coloration indicates a problem with the battery
and is a sign that the battery is nearing the end of its life.
2. Draw the minimum quantity of electrolyte into the hydrometer
to permit the float to float freely without contacting the top or
bottom of the cylinder.
3. Hold the hydrometer in a vertical position at eye level and
note the reading where the electrolyte meets the scale on
the float.
5 4.
Add or subtract four points (.004) to the reading for every 10°
F (6° 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.
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 and replaced with a good battery of the same brand, type and approximate age.
Hydrometer Temperature Correction
5 - 20
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
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.
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 loose.002 of specific
gravity each day. If a fully charged battery has a specific gravity of 1.275, and the battery is allowed to sit unused, it will
become partially discharged. When it reaches 1.240, which it
will do in less than twenty days, it should be recharged. If a
battery is left in a discharged state, sulfating takes place on
and within the plates. This condition is not reversible and will
cause permanent damage to the battery. In order to prevent
damage, the battery should be recharged. A hydrometer (P/N
50900-G1) can be used to determine the specific gravity and
therefore the state of charge of a battery.
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
5
-15 -26
-25 -32
-35 -37
-45 -43
-55 -48
-65 -54
-75 -60
In winter conditions, the battery must be fully charged to pre-85 -65
vent the possibility of freezing. A fully charged battery will not
-95 -71
freeze in temperatures above -75° F (-60° C). Although the
1.100 1.140 1.180 1.220 1.260 1.300
chemical reaction is slowed in cold temperatures, the battery
1.120 1.160 1.200 1.240 1.280
must be stored fully charged, and disconnected from any cirSPECIFIC GRAVITY ELECTROLYTE FREEZING POINT
cuit that could discharge the battery. For portable chargers,
disconnect the charging plug from the vehicle receptacle. For
Freezing Point Of Electrolyte
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.
5 - 21
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
5
5 - 22
APPENDIX A
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TABLE OF CONTENTS FOR APPENDIX A
TITLE
PAGE NO.
DECLARATION OF CONFORMITY ................................................................................................................................................................. A - 3
A- 1
APPENDIX A
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
A- 2
APPENDIX A
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
DECLARATION OF CONFORMITY
A- 3
APPENDIX A
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
DECLARATION OF CONFORMITY (CONTINUED)
A- 4
APPENDIX A
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
A- 5
APPENDIX A
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
A- 6
E-Z-GO Division of Textron Inc.,
1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA
Service Parts Manuals, as well as Repair and Service Manuals
are available from a local Distributor, an authorized Branch,
Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.
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
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