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OWNER’S MANUAL
RECOIL iS CREW
ISSUED SEPTEMBER 2014
632441
REVISED APRIL 2015
WELCOME
Thank you for purchasing this vehicle. Before driving the vehicle, please take time to read and understand this entire
Owner’s Manual. This manual contains important safety information, as well as information that will assist in maintaining the vehicle for optimum performance.
This manual may cover the operation of several different models or show items that are optional; therefore, some illustrations/images may not be representative of all models.
Most service procedures can be accomplished using common tools. Perform service procedures at intervals shown in the
Periodic Service Schedule located elsewhere in this manual.
Repair or replacement parts are available through your BAD BOY BUGGIES retailer.
The following information is needed when contacting us concerning service or parts for your vehicle:
Vehicle Model: ___________________________________________________________
PIN or Serial Number: _________________________________________________
Manufacture Date Code: ___________________________________________________
OWNER’S MANUAL
ELECTRIC POWERED VEHICLE
RECOIL iS CREW
STARTING MODEL YEAR 2015
CALIFORNIA Proposition 65 Warning
WARNING:
Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead and lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes, and particulates, all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.
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. Bad Boy Buggies prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Bad Boy Buggies 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 Bad Boy Buggies, and therefore is subject to change without notice.
Bad Boy Buggies 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.
CONTACT US:
Bad Boy Buggies
1451 Marvin Griffin Rd.
Augusta, GA, USA 30906
FAX: 855-256-9900
E-mail: [email protected]
For parts and repair, contact local dealer. Dealers can be located at www.BADBOYBUGGIES.com
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ii
FORWARD
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.
BATTERY PROLONGED STORAGE
Batteries self-discharge over time. The rate of self-discharge varies depending on the ambient temperature, the age and condition of the batteries.
Fully charged batteries 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.
Check and maintain the proper fluid level in all battery cells during the storage period.
Proper fluid level is required for maximum battery performance.
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.
WARRANTY
Separate inserts supplied in packaging with the vehicle provide information on Product
Warranty and Emissions Warranty. Failure to follow instructions for emission parts replacement may violate Federal Law (40 CFR part 1068.105 (b)) and be subject to fines and other penalties as described in the Clean Air Act.
Owner’s Manual
TABLE OF CONTENTS
SAFETY
NOTICES, CAUTIONS, WARNINGS, AND DANGERS ................................................... 1
GENERAL SPECIFICATIONS
VEHICLE DIMENSIONS AND INCLINE INFORMATION ................................................. 8
INTRODUCTION
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Owner’s Manual
TABLE OF CONTENTS
B
OPERATING PROCEDURES
WINCH OPERATION (IF EQUIPPED WITH WINCH) ..................................................... 25
MAINTENANCE
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Owner’s Manual
TABLE OF CONTENTS
BATTERY CHARGING AND MAINTENANCE ............................................................... 37
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Owner’s Manual
TABLE OF CONTENTS
PERIODIC SERVICE SCHEDULE
B
APPENDIX A
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Owner’s Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SAFETY
GENERAL
For any questions on material content in this manual, contact an authorized representative for clarification.
Read all labels located on the vehicle. Always replace any damaged or missing labels.
On steep hills, it is possible for vehicle to obtain higher speeds than possible on flat ground. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum level ground speed. See
GENERAL SPECIFICATIONS. Limit speed by applying the 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.
NOTICES, CAUTIONS, WARNINGS, AND DANGERS
Throughout this guide
NOTICE, CAUTION, WARNING,
and
DANGER
will be used. Please 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.
Address practices not related to personal injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
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-Z-GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph. When an E-Z-GOmanufactured vehicle is modified in 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.
Owner’s Manual
1
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company 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.
All customers should adhere to this SAFETY RESTRICTION, in connection with the use of all E-Z-GO 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 web site for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
All 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 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. E-Z-GO strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.
For questions regarding this vehicle, contact your BAD BOY BUGGIES dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.
E-Z-GO 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.
E-Z-GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL OR CONSE-
QUENTIAL 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.
Vehicle is designed and manufactured for off-road use. It DOES NOT conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and is not equipped for operation on public streets.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease it’s stability, or increase the speed or extend the stopping distance beyond the factory specification. Such modifications can result in serious personal injury or death.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease it’s stability, or increase the speed or extent the stopping distance beyond the factory specification. E-Z-GO prohibits and disclaims responsibility for all such modifications which would adversely affect the safety of the vehicle.
Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).
GENERAL OPERATION
Read the following warnings before attempting to operate the vehicle.
2
To prevent personal injury or death, observe the following:
When vehicle is to be left unattended, turn key to OFF position and remove key from switch.
Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain
Owner’s Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
and traffic conditions. Consider environmental factors which affect the terrain and the ability to control the vehicle.
Avoid driving fast downhill. Sudden stops or change of direction may result in a loss of control. Use brake to control speed when traveling down an incline.
Use extra care and reduced speed when driving in poor conditions or on poor surfaces.
Stay in designated areas where provided and avoid steep slopes.
Keep feet, legs, hands, and arms inside vehicle at all times.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in reverse.
Ensure direction selector is in desired position before pressing the accelerator pedal.
Slow down before and during turns.
Always bring vehicle to a complete stop before changing direction.
See GENERAL SPECIFICATIONS for vehicle load and seating capacity.
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Read the following text and warnings before attempting to service vehicle.
In any product, components may eventually fail to perform properly as the result of normal use, age, wear, or abuse.
It is impossible to anticipate all possible component failures or the manner in which each component may fail.
A vehicle requiring repair is no longer functioning as designed and therefore could be potentially hazardous. Therefore, use extreme care when working on any vehicle. When diagnosing, removing, or replacing any components that are not operating correctly, take time to consider the safety of yourself and others around you.
Some components are heavy, spring-loaded, highly corrosive, explosive, may produce high amperage, or reach high temperatures. Exposure to battery acid and hydrogen gas could result in serious bodily injury. Be careful to protect hands, face, feet, and body from injury.
Always use the appropriate tools listed in the tool list and wear approved safety equipment.
Before working on the vehicle, remove all jewelry.
Be sure no loose clothing or hair can contact moving parts.
Use care not to touch hot objects.
Wear eye protection when working on or around the vehicle. In particular, use care when working around batteries, using solvents or compressed air.
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 and seek shelter 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.
Owner’s Manual
3
4
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
• Maintain adequate distance between vehicles.
• Reduce speed and use extreme caution in wet areas.
• Reduce speed and use extreme caution when approaching sharp or blind turns.
• Reduce speed and use extreme caution when driving over loose terrain.
• Reduce speed and use extreme caution in areas where pedestrians are present.
MAINTENANCE
ALWAYS:
• Replace damaged or missing warning, caution or information labels.
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.
• Ensure that repairs are performed by trained and qualified personnel.
• Follow the manufacturer’s maintenance procedures.
• Insulate any tools used within the battery area in order to prevent sparks or battery explosion.
• 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.
• Support the vehicle using wheel chocks and jack stands. NEVER get under a vehicle that is supported by a jack
• 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.
• 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 gas water heaters and furnaces.
Operate charger in accordance with charger manufacturers recommendations and local electrical code.
ALWAYS:
• Use a dedicated circuit for battery charger. Do not permit other appliances to be plugged into the receptacle when the charger is in operation.
• Charge vehicle in an area free of flames or sparks.
• Only use battery charger provided with vehicle.
• Operate battery charger in accordance with charger manufacturers recommendations and local electrical code.
Owner’s Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LABELS AND PICTOGRAMS
B
NO PUBLIC
ROAD USE
WARNING USE CAUTION IN
INCLEMENT WEATHER
OPERATOR MUST
BE 4 FT-11 IN
(150 CM) MIN
OPERATE FROM
DRIVERS SIDE ONLY
OCCUPANT MUST
WEAR SEAT BELTS
FOR INFORMATION
REFER TO OWNERS
MANUAL OR
WEBSITE
MIN 150 cm
NO UNATTENDED
CHILDREN
www.badboybuggies.com
638040
DRIVE IN ACCORDANCE
WITH LOCAL RULES
AND REGULATIONS
DO NOT OPERATE
UNDER DRUG/ALCOHOL
INFLUENCE
LEAVE VEHICLE
IN THREAT OF
LIGHTNING
WARNING
READ THE
MANUAL
REMAIN SEATED
KEEP ARMS / LEGS
WITHIN VEHICLE
MAY CAUSE EXPLOSION;
DO NOT FILL FUEL
CONTAINERS IN BED
SECURE LOAD
MAX BED WEIGHT
500 LBS or 255 KG
638040
NO MORE THAN
TWO OCCUPANTS
PER SEAT
HIGH CENTER OF
GRAVITY MAY CAUSE
TIP OVER
35980G02
MAX CENTER OF
GRAVITY HEIGHT
5” OR 12 CM
ABOVE FLOOR
MAX SIDE
SLOPE 14°
DO NOT RELEASE BED
LATCH WITH ANYONE
STANDING BEHIND BED
NO PASSENGERS
IN TRUCK BED
74099-G01
74099G01
WEAR SAFETY
GLASSES
RECYCLE
BATTERIES
LOCATED ON BATTERY HOLD DOWN
INFORMATION
FOUND IN
OWNERS MANUAL
DO NOT EXPOSE
TO OPEN FLAME
DO NOT DISPOSE
OF BATTERIES IN
LANDFILL
DANGER
LETHAL
VOLTAGE
WARNING
ELECTRIC
SHOCK
640561
WARNING
EXPLOSIVE
WARNING
CORROSIVE
Owner’s Manual
5
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
6
Owner’s Manual
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
GENERAL SPECIFICATIONS
MODEL: RECOIL IS CREW
TYPE: ELECTRIC OFF ROAD VEHICLE
MODEL YEAR: 2015
Part No: 630348G01
PRODUCT SPECIFICATION
CONFIGURATION HIGHLIGHTS
Programmable AC Drive System:
Factory programmable to application z z z
Solid State variable frequency AC speed controllers
Drive-by-wire electronic throttle control
Dash mounted direction selector switch (Forward-Neutral-Reverse) z z
Descent speed control
Full-time regenerative braking z z z z z
300 Amp AC Controllers
Full torque, reduced speed reverse
Sealed Hall effect throttle sensor
Full diagnostic capability (Hand held diagnostic unit)
Dash mounted Max Speed/Max Range speed selector switch
Motor:
Two 72 Volt AC induction motors, solid copper windings. 19 hp (17.3 kW) peak. AC system reads motor speed for accurate speed control in all conditions. Regenerative braking for maximum economy
Battery Charger:
Remote 72 VDC DPI Charger, 120 VAC 60 Hz or optional 230VAC 50Hz unit. (U.L. Certified)
Electrical System:
72 Volt DC, nine, 8 volt deep cycle storage batteries
Drive Train:
Direct motor shaft connected to transaxle pinion shaft
Transaxle:
Differential with reverse helical gears
Brakes:
4-wheel hydraulic disc brakes and Induction motor. Manual parking brake
Body Protection:
Front Brush Guard
Dimensions
Overall Length
Overall Width
Overall Height
Wheel Base
146.0
in
53.8
in
76.3
in
107.0
in
371 cm
137 cm
194 cm
272 cm
Gnd Clearance @ Frame
Gnd Clearance @ Differential
Vehicle Power
13.8
7.8
in in
35
20 cm cm
Power Source
Motor Type
Horsepower (kW)
Electrical System
72 Volts DC
72 Volts AC
30 hp 22.4
kW
Batteries (Qty, Type)
Key or Pedal Start
Speed Controller
Drive Train
72 Volt
Nine, 8 Volt Deep Cycle
Key Start
300 amp
Transaxle
Direction Selection
Speed Selection
Rear Axle Ratio
Motor Shaft Direct Drive
Hardened Helical Gears
Dash mounted Forward-Neutral-Reverse
Dash mounted Speed/Range switch
14.87:1
Front Axle Ratio
Noise & Vibration
Noise
14.87:1
Sound pressure; continued A-weighted ч
77 db(A)
Vibration, WBV Highest RMS value of weighted acceleration is less than 1.3 m/s
Vibration, HAV Highest RMS value of weighted acceleration is less than 2.5 m/s
The uncertainty of measurement is 0.38 m/s
PRODUCT OVERVIEW
Performance
Seating Capacity & Style
Curb Weight
Vehicle load capacity
Bed load capacity
Gross Axle Weight Rating- F
Gross Axle Weight Rating- R
Outside Clearance Circle
Speed - Low (Level Ground)
Speed - High (Level Ground)
Speed - Reverse
Max Drawbar Pull
Towing capacity
Steering & Suspension
Steering
Front Suspension
Rear Suspension
Service Brake
Parking Brake
Front Tires
Rear Tires
Body & Chassis
Frame
Body & Finish
Standard Color
Cargo Bed
4 Persons - 2 Bench Seats
2,139 lb
1,100 lb
500 lb
1,379 lb
1,953 lb
40 ft
16.0
mph
24.5
mph
10.0
mph
1,430 lb
900 lb
Double Ended Rack & Pinion-3.69 turns to lock
MacPherson Strut
MacPherson Strut
4-Wheel Hydraulic Disc with Motor Regen
Manual w/controller cut-out
Kenda 25x8-12 Uni-Directional
Kenda 25x11-12 Uni-Directional
Welded Steel with DuraShield powder coat
Injection Molded TPO & Automotive Style Paint
Matte Black
5.9 Cu. Ft. Polyethelyne Bed
971 kg
499 kg
227 kg
626 kg
886 kg
12.2
m
25.7
kph
39.4
kph
16.1
kph
649 kg
408 kg
Owner’s Manual
7
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
VEHICLE DIMENSIONS AND INCLINE INFORMATION
52.5”
(134 cm)
76.5”
(194 cm)
43.75”
(111 cm)
107”
(178 cm)
146”
(371 cm)
53.75”
(137 cm)
8
Maximum Recommended Ramp Grade
25% or 14° Max.
Owner’s Manual
Maximum Recommended Side Tilt
25% or 14° Max.
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
Owner’s Manual
9
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
10
Owner’s Manual
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
INTRODUCTION
FEATURES
General Information
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’ position.
6
4
3 2
1
5 6
632907
632909
NOTE: Shown with steering wheel removed.
7
8
1. Key Switch / Direction Selector
Located on the dash to the right of the steering wheel, this four position switch allows the vehicle electrical system to be activated. It also determines direction of travel. It allows the operator to turn the electrical system off completely by moving the key to the OFF position; or select Reverse, Neutral, or Forward by rotating key to the right.
2. State of Charge Meter
The illuminated state of charge meter is located on the dash. It indicates the amount of usable power in the batteries, with
‘F’ indicating a full charge on the battery pack and ‘E’ indicating the batteries are low. A yellow light indicates the batteries must be charged immediately.
3. Park Brake Light
The park brake light illuminates to indicate that the park brake is engaged.
When park brake light is on, the contacts are open and there is no power being supplied to the motors.
Owner’s Manual
11
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
4. Light Switch
Located on the left side of dash, this ON/OFF switch controls the lights. In the ON position, the headlights and taillights illuminate.
5. Max Speed / Range Switch
This is a two position switch located on the dash to the right of the key switch.
S
The top position is the Max Speed setting. It allows the vehicle to travel up to 24.5 mph (39 kph). This setting diminishes distance capability for increased speed advantage.
The bottom position is the Max Range setting. It limits the top speed of the vehicle to 16 mph (25 kph), which conserves battery power in order to extend travel distance.
6. Auxiliary Switch Positions
There are three empty spaces on the dash to allow for additional switches to control added lights or accessories.
7. 12 Volt Power Outlet
Located in the lower part of the dash above the cup holder, the 12 volt outlet supplies constant power for additional equipment equipped with a 12 volt plug.
8. Cupholder
A cupholder is provided for convenience of vehicle occupants.
9. Accelerator Pedal
The accelerator pedal is located on the floorboard to the right of the brake pedal. Its function is to accelerate and control the speed of the vehicle.
10. Brake Pedal
The brake pedal is located on the floor to the left of the accelerator pedal. The brake pedal function is to slow or stop the moving vehicle.
10
11
11. Park Brake
The hand operated park brake is located in the middle of the floorboard. The function of the park brake is to keep the vehicle from inadvertent movement when in a stationary position.
9
Park brake is engaged when handle is vertical, and disengaged when handle is almost parallel to the floor (as shown).
12. Charger Receptacle
The polarized receptacle for the batteries is located on the panel below the drivers seat. It is the receptacle for the charger cord when the batteries need to be charged.
If vehicle is equipped with optional onboard charger, receptacle is located on the back seat.
13
13. CE Charger Receptacle (If Equipped)
The (16 amp, 200-250 volt AC) CE charger receptacle for the batteries is located on the panel below the drivers seat. It is the receptacle for the charger cord when the batteries need to be charged.
12
The charger cord should be plugged into a circuit equipped with a Ground Fault Circuit Interrupt (GFCI) feature.
12
Owner’s Manual
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
14. Truck Bed Latch
A truck bed latch is located at the front of the manual lift truck bed. It is used to raise and lower the manual lift truck bed.
B
14
15. Truck Bed
A molded plastic truck bed provides space to transport cargo.
16. Taillights
The taillights are located at the rear of the truck, below the truck bed.
15
17. Head Rests
Rear seat is equipped with two head rests.
18. Side Nets
Side nets are a standard safety feature provided with the vehicle and must be properly secured before operating vehicle.
19. Seat Belts
The front seat is equipped with belts for the driver and front passenger. The rear seat is equipped with belts for two passengers. Seat belts must be worn at all times by all occupants when vehicle is in motion.
For more operational and safety information, see “Seat Belt Operation” on page 22.
16
18
19
17
Owner’s Manual
13
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
20. ROPS / Top / Windshield
The standard vehicle is equipped with ROPS (Roll Over Protection Structure) certified to ISO 3471; vehicle may be equipped with an optional top, and/or windshield.
The top provide some protection from smaller falling objects, but will not protect against large falling objects such as trees or heavy limbs.
The windshield deflects oncoming wind from occupants, but will not protect against flying objects and tree limbs.
The top and windshield provide some protection from the elements; however, they will not keep occupants dry in a downpour.
The protection of the ROPS may be compromised if it is damaged or modified.
The ROPS must be replaced after a rollover.
The ROPS is ISO 3471 certified; if it is modified or damaged in any manner, the certification is no longer valid.
Seat belts must be worn at all times when a vehicle with a ROPS is being operated.
The ROPS does not provide protection from falling objects.
The windshield does not provide protection from tree limbs or flying objects.
Remove windshield and store securely before transporting this vehicle on a trailer. The windshield is not designed to withstand highway speeds.
21. Differential Locks (If Equipped)
Differential lock controls are located on the seat wrap panel below the driver seat.
Both the front and rear drive axles are equipped with manually operated locking differentials. Differential locks are modifications to a standard differential that restrict each of the two wheels on an axle to the same rotational speed regardless of the traction available to each wheel.
21
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
OPERATING PROCEDURES
PIN AND SERIAL NUMBER LOCATION
The PIN plate is riveted to the frame below the seat wrap panel.
Two serial number and manufacture date code plates are on the vehicle. One is located on the steering column, the other is located on the chassis under the cowl on the driver’s side.
Design changes take place on an ongoing basis. In order to obtain correct components for the vehicle, the PIN number, manufacture date code, serial number and vehicle model, must be provided when ordering service parts.
V
V
Front of Vehicle
Serial Number
Part B
Serial Number
Part A
PIN Label
PIN Plate
Improper use of this vehicle could result in severe injury or death. The buggy is a light duty utility vehicle, NOT an All Terrain Vehicle (ATV).
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 affect 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 or gravel.
Maintain a safe speed when driving up or down a hill. Use 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 while the vehicle is in motion. Moving the direction selector will result in a sudden slowing of the vehicle.
Owner’s Manual
15
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Slow down before and during turns. All turns should be made at reduced speed.
B
Do not drive through water that is more than 12 inches (30 cm) deep.
To prevent inadvertent movement when the vehicle is left unattended, engage the parking brake, turn key to OFF position and remove key from switch.
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 area behind vehicle before operating in reverse.
All occupants must be seated with seat belts fastened and side nets latched. Keep entire body inside vehicle and hold on while vehicle is in motion.
This vehicle is not a toy and using it while engaging in horseplay is dangerous.
Plan carefully before using the vehicle to go significant distances over unfamiliar terrain. Remember that a one hour drive may take many hours to walk back should the batteries become discharged, or vehicle become stuck on unsuitable terrain.
Each motor has three UVW high voltage contacts that are exposed (one in front; one at rear of vehicle). These contacts should be avoided when vehicle is operational.
CE vehicles only: Do not turn on or attempt to operate vehicle without the seat locks and access cover (on cowl) in the proper locked position.
Vehicle is not equipped with an emergency stop. Turn key to OFF position to disengage power.
The vehicle is not equipped with a CV boot guard. Be aware of the possibility of sticks, rocks, etc. puncturing the CV boots. Inspect CV boots after operating vehicle over loose or rough terrain.
BEFORE INITIAL USE
Record the four digit key number and store in a safe place. Individual keys can only be replaced if the key number is known. Without a key number the entire ignition switch will have to be replaced if keys are lost.
Make a note of the key number in the event that new keys must be ordered. The key number is stamped into the key and into the face of the ignition switch. Both numbers must match.
Be sure you understand the vehicle, its equipment and how to use it safely. Read, understand and follow the safety and operation label on the dash panel. Although the vehicle has been designed to provide safe and reliable operation, maintaining good performance depends, to a large extent, on the operator.
Before a new vehicle is put into operation, the items shown in the
INI-
TIAL SERVICE CHART
must be performed.
Key Number
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Item
Battery Charger
Batteries
Seats
Brakes
Tires
Vehicle Inspection
INITIAL SERVICE CHART
Service Operation
Remove from vehicle and read operating instructions.
Charge. Batteries must be fully charged before initial use.
Remove protective plastic covering.
Check operation; adjust if necessary.
Check hydraulic fluid level; add if necessary.
Check air pressure; adjust if necessary.
See “WHEELS AND TIRES” on page 32 for inflation recommendations.
Visually inspect overall vehicle for leaks or damage that may have developed in shipping.
Inspect for loose hardware; tighten if necessary.
Visually inspect ROPS for tightness of hardware, proper installation, and damage free.
B
Hydrogen gas is generated as a natural part of the lead acid battery charging process. A 4% concentration of hydrogen gas is explosive and could cause severe injury or death. Charging must take place in an area that is adequately ventilated (minimum of 5 air exchanges per hour).
To reduce the chance of battery explosion that could result in severe injury or death, never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc.
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation.
Five air exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water heaters and furnaces.
PORTABLE CHARGER
Use charger ONLY on 72 volt battery systems. Other usage may cause personal injury and damage. Lead acid batteries may generate explosive hydrogen gas during normal operation. Keep sparks, flames, and smoking materials away from batteries. Provide adequate ventilation during charging. Never charge a frozen battery. Study all battery manufacturers’ specific precautions such as recommended rates of charge and removing or not removing cell caps while charging.
Risk of electric shock. Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances. A grounded outlet is required to reduce risk of electric shock – do not use ground adapters or modify plug.
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Do not touch uninsulated portion of output connector or uninsulated battery terminal.
B
Disconnect the DC supply before making or breaking the connections to the battery while charging. Do not open or disassemble charger. Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way – refer all repair work to qualified personnel. Not for use by children.
The portable charger is shipped with the vehicle. Prior to vehicle or charger operation, the charger
must
be removed from the vehicle.
A dedicated circuit is required for the charger.
Refer to the charger manual for appropriate circuit protection. For optimum performance and shortest charge times, place the charger in an area with adequate ventilation and relatively free of dirt, mud, or dust. If the charger is operated in an outdoor location, rain and sun protection must be provided. The charger may get hot during operation and must be placed such that risk of contact by people is reduced.
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.
An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution.
Using the Charger
Before use, read the charger manufacturer’s operation manual that is supplied with the charger.
To prevent a physical hazard that could result in an electrical shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle.
An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution.
The charger (DC) cord is equipped with a polarized connector that fits into a matching receptacle on the vehicle. The receptacle is located in the seat panel below the seat on the driver side of the vehicle.
Always check to be sure the receptacle is free from dirt and debris before inserting the charger cord.
Charger
Receptacle
Standard receptacle shown.
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
OPERATING THE VEHICLE
B
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.
Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline. A sudden stop or change of direction may result in loss of control.
Slow down before and during turns. All turns should be made at reduced speed.
Never drive vehicle up, down, or across an incline that exceeds 14° (25% grade).
Do not permit more occupants on the vehicle than it is designed to carry. Refer to GENERAL
SPECIFICATIONS for seating capacity.
To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings must be observed:
To prevent inadvertent movement when the vehicle is left unattended, engage the park brake, turn key to ‘OFF’ position and remove key from switch.
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 with seat belts fastened and side nets latched. Keep entire body inside vehicle and hold on while vehicle is in motion.
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Key Switch Operation
B
When key is turned to the far left, the vehicle electrical system is off and not operational. Turn right to first position, labeled R for reverse. The next position to the right, labeled N is neutral. Rotate to the far right position, labeled F, for forward.
To prevent inadvertent operation of the vehicle when left unattended, the key should be turned to the OFF position and removed from the switch.
Key Switch
Max Range/Speed Switch
To reduce the possibility of component damage, the vehicle must be stopped completely before turning the key.
Max Speed / Range Switch
Press the top of the switch to select the Max Speed setting. This setting allows the vehicle to travel up to 24.5 MPH, diminishing distance capability for increased speed advantage.
Press the bottom of the two position switch to select the Max Range setting. This setting limits top speed to 16 MPH, which conserves battery power in order to extend the range of distance the vehicle is capable of traveling before the batteries need to be recharged.
Light Switch Operation
Press the top of the two position switch to activate the headlights and taillights. Press the bottom of the switch to turn them off.
Light Switch
632907
Brake Operation
This vehicle is equipped with four wheel hydraulic brakes.
Press the brake pedal to control speed or bring vehicle to a stop.
Brake Pedal
Park Brake
Park Brake Operation
The park brake should be engaged whenever the vehicle is in a stationary position or left unattended.
Pull the hand operated park brake handle up until it stops in a vertical position to engage the park brake. Push the handle down to disengage.
Accelerator
Pedal
Accelerator Operation
With the key switch in ‘F’, ‘N’, or ‘R’ position, pressing the accelerator pedal starts the electric motor and activates the vehicle. When the pedal is released, the motor deactivates and the vehicle will decelerate. To stop the vehicle more quickly, press the brake pedal.
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Differential Lock Operation
B
To reduce the possibility of severe injury or death from loss of control while vehicle is in motion, do not engage front differential lock while turning steering wheel. Lock engagement may force steering wheel to center abruptly, causing loss of grip on wheel and control of vehicle.
Do not drive vehicle on pavement or other hard surfaces with differentials in the locked position. Sharp maneuvers and turns can cause premature wear and damage to the CV shafts and tires.
Differential locks should only be used when additional traction is required. Continued use of rear differential lock may cause excessive wear to tires. Continued use of front differential lock may increase steering effort.
Vehicle must be completely stopped before engaging or disengaging differential lock. Failure to stop may damage differential.
Front and rear differentials are equipped with manually actuated locks. A
locked
differential distributes power to both tires on the axle at all times, which greatly increases traction. Locks are not intended to be engaged at all times. Their purpose is to free, or prevent vehicle from being stuck as terrain demands, ideally for short runs at slow speeds. Always disengage differential locks as terrain and conditions allow.
Push lever(s) to the forward position to engage the differential lock(s). Pull the levers into the rear position to disengage the lock(s).
Truck Bed Latch Operation
Pull upward on the handle to release the truck bed latching mechanism, allowing the front of the bed to be raised.
Bed Latch Handle
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Seat Belt Operation
Seat belts must be worn by all occupants whenever vehicle is in motion.
Ensure seat belts are free from twists and latch securely.
Position shoulder belt across the top of the shoulder; do not place shoulder belt under the arm.
Keep belts snug and positioned low on hips. Loose fitting belts significantly reduce protection.
The vehicle is equipped with seat belts for the number of occupants it is designed to carry; do not exceed the recommended number of occupants for the vehicle.
Seat belts are designed for one occupant per belt. Do not attempt to secure more than one person in a seat belt.
Seat belts must be worn at all times by all occupants when vehicle is in motion.
To keep seat belts in proper working condition, do the following:
• Inspect the seat belt webbing and hardware periodically. Check for cuts, frays or loose parts. Replace components if excessive wear or damage is noticed.
• Keep seat belts clean and dry. To clean, use mild soap and warm water. Do not use bleach, dye or abrasive cleaners as this will weaken the belt webbing material.
• Do not insert any foreign objects into the retractor mechanism.
• Periodically check for smooth operation and replace if the mechanism is not operating properly.
To properly secure the seat belts:
1.
Pull the metal tab on the seat belt across the body toward the appropriate buckle located near the center of the seat.
2.
Insert tab into buckle. (A click will be heard when the tab is securely latched).
3.
Position the lap belt as low as possible on the hips, not at the waist.
4.
Adjust to ensure a snug fit by pulling the shoulder portion upward.
The retractor will lock the belt during sudden stops. It may also lock if occupant leans forward quickly. Slow, easy motions allow the belt to travel freely.
To release the safety belt, press the buckle release button and allow the belt to retract. If the belt does not retract, check for twisted straps.
COMMON SENSE OPERATION
22
To prevent severe injury or death, observe the following:
Never transport loaded firearms on or in vehicle.
Check that firearms are unloaded with the safety engaged and are properly secured with muzzle pointing in a safe direction before operating vehicle. Be aware of other firearms in proximity to operator and passengers.
Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
This vehicle is not a toy.
If not operated properly and responsibly, it can cause severe injury or death to the operator, passengers or bystanders. All operators should possess a valid driver’s license. Children should not be permitted to operate the vehicle. Children may not have the skill, judgement or strength to operate this or similar vehicles.
Alcohol, drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely.
Always review side effects of any medication with a doctor or pharmacist before operating vehicle.
Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when operating vehicle in rough or densely wooded terrain.
B
When driving at full speed on a dirt road, loose surfaces or wet grass, vehicle stopping distance will increase. If the vehicle is fully loaded, it requires longer to stop than with no load. When operating vehicle in wet weather conditions, remember that the brakes may need to be
lightly
applied in order to provide enough friction to dry the brake unit. If wet, the brakes lose much of their effect.
Slow down when on unfamiliar terrain. Slow down when cresting a hill in an area that is not familiar.
Some hills are too steep to climb. If attempting to climb a hill that is too steep or if unable to achieve adequate traction,
do not attempt to turn around on the hill. Slowly back straight down the hill using the brake pedal to control speed.
ENVIRONMENTAL CONCERNS
As a responsible user, practice respect for all wildlife and their habitat. Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles. To prevent severe injury or death while driving, be aware of environmental hazards such as steep slopes, overhanging limbs, etc.
STARTING AND DRIVING
• Make sure that the park brake is engaged.
• Make sure that the accelerator pedal is NOT pressed (no pressure on it).
• Place key in switch and turn to desired position.
• Release parking brake.
• Press the accelerator pedal to move the vehicle.
Make sure the park brake is engaged, the key switch is in the OFF position and the key is removed from the switch before exiting the vehicle.
This vehicle is to be operated by licensed drivers only.
Do not attempt to operate the buggy while under the influence of drugs or alcohol.
Never turn the key switch to OFF while the vehicle is in motion; doing so can cause loss of control and lead to serious injury or death.
On a downhill slope, it is possible for the vehicle to achieve speeds greater than if it were operating on flat terrain. Limit downhill speed to 5 mph (8 kph) with use of the service brake.
Caution must also be used on an uphill slope and speed should be limited to no more than 5 mph (8 kph).
If allowed to travel too fast on an uphill or downhill slope, loss of control may occur, possibly causing serious injury or death.
Use caution when traveling through water and never operate vehicle in water over 12 inches (30 cm) deep.
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Starting the Vehicle on a Hill
Do not hold vehicle on hill by using accelerator and motor. This will cause premature and excessive wear to drive train components.
To reduce the possibility of permanent damage to the drive system, it is important to prevent excessive roll-back when starting the vehicle on a hill.
Place left foot on brake pedal and disengage park brake. Press accelerator with right foot while releasing brake pedal.
COASTING
To reduce the possibility of severe injury or death from coasting at above recommended speeds, limit speed with brake pedal.
On steep hills, it is possible for the vehicle to coast at greater speeds than possible on a flat surface. To reduce possible loss of vehicle control and severe drivetrain damage, speeds should be limited to no more than the maximum governed speed on level ground (see GENERAL SPECIFICATIONS). Limit speed by applying pressure to the brake pedal.
TOWING A TRAILER
There is no connection for trailer lights on this vehicle. Use caution when towing a trailer and be aware that the trailer being towed may have low visibility from behind.
The vehicle is equipped with a 2” receiver. The trailer and its load must not exceed 900 lbs (408 kg) and no more than
100 lbs (45 kg) tongue weight may be attached to the hitch. Remember that the overall capacity of the vehicle, operator, passenger, contents of load bed and accessories must be reduced to compensate for the trailer and load. Maximum payload including trailer weight must never exceed 1100 lbs (499 kg).
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 the hitch receivers. Such items will change the performance characteristics of vehicle and result in unsafe handling, possible roll over or vehicle damage.
TERRAIN
The vehicle is NOT designed for use on public roads. The vehicle may 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 that is more than 12 inches (30 cm) deep or fast moving water.
Be aware of steep slopes and overhanging limbs.
When traveling up or down steep slopes, do not attempt to turn the vehicle around on the slope.
Be aware that vehicle stopping distance increases when driving on wet grass, dirt roads or loose surfaces.
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
TRUCK BED
Do not allow passengers to ride in truck bed. Severe injury or death could result if a passenger should fall out, if vehicle is involved in an accident, or if vehicle makes a sudden maneuver.
Use caution when loading the vehicle. Secure loads to prevent shifting. Do not overload vehicle.
A bed warning label is affixed to the inside of the bed on the front panel. This label must be understood and observed at all times for safe use of the bed.
The bed is limited to a maximum load of 500 lbs. Position load in the bed as far forward as possible. Its center of gravity must not be higher than 12" (30 cm) above the bed floor, and it must be securely fastened down. Failure to follow these instructions could cause personal injury, damage to the vehicle and/or cause the vehicle to tip over. Operate the vehicle with awareness of the load.
Do not drive the vehicle with the truck bed raised or with the tailgate unsupported.
When using the optional electric dump, 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 ensure that no one is behind or close to the bed while the electric dump mechanism is being operated.
B
WINCH OPERATION (IF EQUIPPED WITH WINCH)
This vehicle may be equipped with an optional winch. Read, understand and follow all of the information supplied with the winch on the operation and use of the winch before attempting to operate it.
Winch Application
A winch may be used for a number of purposes, including pulling the vehicle if it loses traction on unsuitable terrain.
Improper use of the winch could result in a number of conditions that could cause severe injury or death to operator, occupants of vehicle or bystander.
It is impossible to predict all conditions that the winch could be used, therefore the following warnings should not be considered as complete. Before operating the winch, consider the possible dangers and take precautions to protect yourself, your passenger and any bystanders.
To prevent severe injury or death to operator, occupants or bystanders, consider the following when selecting an object to attach the cable to:
Make sure the object cannot be pulled over or otherwise damaged.
The object the winch cable is attached to could fall on the vehicle and it’s occupants.
If attaching the winch to a dead tree, a section could fall.
When pulling vehicle with winch, pull straight only. Do not permit cable to contact the side of the drum.
Owner’s Manual
25
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Do not pull vehicle at an angle. If the vehicle is pulled at an angle, it could turn over causing severe injury or death to anyone in the area. The winch cable could also become overstressed and break causing severe injury or death to anyone struck by the cable.
To prevent severe injury or death, read and understand the following warnings before attempting to use the winch:
The winch is not intended to be used in any hoisting operation.
The rolling load capacity of the winch decreases with the steepness of the slope.
The winch is designed for intermittent duty only.
The electric motor should not be allowed to become excessively hot. If the motor becomes uncomfortably hot to the touch, stop winching and allow the motor to cool.
Always wear thick leather gloves when handling the wire cable.
Replace frayed wire cable with a direct factory replacement only.
Never operate the winch with less than five (5) full turns of cable around the drum.
If the winch motor stalls from overloading, do not continue to activate the winch remote control. The wire cable may become overstressed.
Do not attempt to pull loads exceeding the manufacturers maximum load rating.
Have all persons and pets leave the area while operating winch. Never allow anyone to remain in the vehicle.
To prevent damage to the wire cable, never hook the cable to itself. Always use a nylon sling.
Damper
Nylon
Sling
Do Not Hook Cable to Itself
Use a Nylon Sling and Install a Damper when Winching
Stay clear of the winch, the cable and the cable hook. Place a heavy cloth, jacket or blanket over the cable to act as a damper should the cable break when operating the winch.
When operating the winch, keep the entire area in view.
Never release the free spool clutch while the cable is under load.
Never work around the winch drum or the winch cable while it is under tension.
Unplug the winch switch before working on the winch drum in order to prevent inadvertent operation.
When operating winch, take up slack slowly. Stop winch before cable becomes tight and inspect all winching connections. Check winch attachment, hook attachment, nylon sling (if required) and load attachment.
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Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Incorrect
Correct
Do Not Pull at Angle
Do not pull at an angle. This will cause the wire cable to pile up on one end of the winch. This may jam the winch causing damage to the cable and/or the winch. Pulling the vehicle at an angle can cause damage to the front suspension and may cause the vehicle to overturn. When pulling vehicle, pull straight only.
If the vehicle is being used as an anchor to winch a load, it should have the parking brake applied and chocks installed on all wheels.
Never use the winch to lift people or other overhead loads.
Do not use the winch to secure loads. Use a tie down designed for the job.
Do not apply shock loads to the winch.
Do not attempt to modify or weld the winch.
Owner’s Manual
27
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
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Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
MAINTENANCE
VEHICLE CLEANING AND CARE
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 and maintain a 12” minimum distance from spray nozzle to painted surface. 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 as well as 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 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 its removal, taking care not to chip or otherwise damage paint.
ROUTINE MAINTENANCE
Preventive maintenance, applied at recommended intervals, is the best guarantee for keeping the vehicle dependable.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the PERIODIC
SERVICE SCHEDULE for appropriate service intervals.
Owner’s Manual
29
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LIFTING THE VEHICLE
Tool List Qty
Floor Jack.................................................................... 1
Jack Stands ................................................................. 4
Wheel Chocks ............................................................. 4
To reduce the possibility of severe injury or death from a vehicle falling from a jack:
Always place chocks in front and behind the wheels not being raised.
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.
Use extreme care since the vehicle is very unstable during the lifting process.
To avoid damage to the ROPS, never use it as a lifting point.
When lifting the vehicle, position the jacks and jack stands at the areas indicated.
Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while lifting.
Lift Entire Vehicle
1.
Place wheel chocks in front and behind each front wheel.
2.
Center jack under rear axle tube next to differential housing or under the skid plate.
3.
Raise vehicle and position jack stands under the frame where the leaf spring mounting bracket is welded to the frame.
4.
Lower the jack and test the stability of the vehicle on the two jack stands.
5.
Place the jack under the center front of the car just behind the bumper.
6.
Raise the vehicle and position the jack stands under the frame where the instrument panel support is attached to the frame.
7.
Lower the jack and test the stability of the vehicle on all four jack stands.
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Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Lift Front of Vehicle
1.
Place wheel chocks in front and behind rear wheels.
2.
Place the jack under the center front of the car just behind the bumper.
3.
Raise the vehicle with jack and position the jack stands under the frame where the instrument panel support is attached to the frame.
4.
Lower the jack and test the stability of the vehicle on jack stands.
5.
The jack may be left under the center front of the frame while the front end of the vehicle is on the jackstands.
B
Lift Rear of Vehicle
1.
Place wheel chocks in front and behind front wheels.
2.
Center jack under rear axle tube next to differential housing or under the skid plate.
3.
Raise vehicle with jack and position jack stands under the frame where the leaf spring mounting bracket is welded to the frame.
4.
Lower the jack and test the stability of the vehicle on the two jack stands.
5.
The jack may be left under rear axle tube while the rear end of the vehicle is on the jackstands.
Lower Vehicle
Lower the vehicle by reversing the lifting sequence.
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.
Headlight Bulb
Turn key switch to OFF and remove key from switch.
Locate the headlight bulb socket on the backside of the light assembly.
Turn bulb socket a quarter turn counterclockwise to unlock.
Pull out bulb and socket, remove old bulb from the socket.
Insert new bulb in socket and position bulb socket into headlight housing and rotate socket a quarter turn clockwise to secure.
Inside of Cowl
Headlight
Bulb
Taillight Bulb
The taillight contains an LED light board rather than a light bulb, if the LEDs burn out the whole light will have to be replaced.
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Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
WHEELS AND TIRES
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.
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.
To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for impact wrench use.
Tire Repair
Tool List Qty.
Lug Wrench, 3/4” (for steel rims)................................. 1
Lug Wrench, 17mm (for aluminum rims) ..................... 1
Impact Wrench ............................................................ 1
Tool List Qty.
Impact Socket, 3/4” (for steel rims) ............................. 1
Impact Socket, 17mm (for aluminum rims) ................. 1
Torque Wrench, ft. lbs. ................................................ 1
Generally, the most cost effective way to repair a flat tire resulting from a puncture in the tread portion is to use a commercial tire plug.
If the tire is flat, raise vehicle and remove wheel. Refer to ‘Lifting the Vehicle’ for proper lifting procedure and safety information. Inflate tire to the maximum recommended pressure, immerse tire in water to locate the leak and mark the leak with chalk. Insert tire plug in accordance with manufacturer’s specifications.
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.
Recommended tire inflation pressure is 12 psi. 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 volume tubeless tires mounted on one piece rims.
32
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Wheel Installation
B
Ro t a t io
Front of
Vehicle
To reduce the possibility of component damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.
1
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.
Tire style may vary
Valve Stem Cap
1
Cross Sequence
Unidirectional Tires
Unidirectional tires may be identified by a directional arrow on the sidewall. Be sure to position the wheel on the hub correctly with the arrow indicating the direction of rotation when moving forward.
WHEEL ALIGNMENT
Driving over rough terrain may cause misalignment of the wheels. With four wheel independent suspension both front and rear wheels may need to be aligned.
Wheel Alignment
Tool List Qty.
Tape Measure.............................................................. 1
Open End Wrench, 17 mm.......................................... 1
Tool List Qty.
Open End Wrench, 12 mm.......................................... 1
Open End Wrench, 19 mm.......................................... 1
Park the vehicle on a level surface, set the front wheels straight ahead. Turn the key switch to OFF, remove the key from switch and set the park brake.
With vehicle empty (no passengers or payload), measure distance between center of both the front and the rear sets of tires. Measure both in front and behind each tire set, keeping tape measure parallel to the ground. The measurement behind the tires should be 1/4” more than the measurement taken at the front of the tires to produce a toe-in condition.
33
Owner’s Manual
MAINTENANCE
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Adjust both tie rods equally to obtain the correct toe-in. Hold tie rod (2) with an open end wrench, loosen the jam nut (1) and turn the adjustment shaft (3) to move the wheel in the desired direction.
Recheck the measurement at the front and at the rear of the front tires, if the 1/4” toe-in has been achieved tighten the lock nut (1) on each tie rod.
3
1
2
BRAKES
This vehicle is equipped with four wheel hydraulic disc brakes and a hand operated park brake. Check the fluid level at intervals specified in the PERIODIC SERVICE SCHEDULE; if fluid leaks are noticed or the brake pedal seems soft, check the fluid level immediately. If the brake pedal is soft, the brake system should be bled to remove air from the brake
lines. Refer to “Bleeding Brakes” on page 34 for procedure.
Master Cylinder
The master cylinder is located behind the driver side front wheel, mounted to the frame. Before removing the reservoir cap, clean any dirt or debris from around the reservoir and cap.
Check fluid level in the reservoir. The fluid level should be between the
MAX and MIN lines. Use fresh DOT 3 brake fluid only.
To fill the reservoir, remove the cap to expose the rubber diaphragm, remove the diaphragm, making sure to keep it clean. Add enough brake fluid to bring the level up to the MAX line. Collapse and replace the diaphragm and install the reservoir cap. Clean any spilled brake fluid from the area.
Bleeding Brakes
Tool List Qty. Tool List
Hose ........................................................................ A/R
Brake Fluid, DOT 3.................................................. A/R
Qty.
Clean Container .......................................................... 1
Wrench, 1/4” box end .................................................. 1
The hydraulic brake system must be free of air to operate properly. Air can enter the system when hydraulic parts are disconnected for servicing or replacement, or when the fluid level in the master cylinder reservoir is very low. Air in the system will give the brake pedal a spongy feeling when pressed.
An assistant is necessary to perform this procedure.
34
Owner’s Manual
MAINTENANCE
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1.
Use a clean cloth to wipe off the master cylinder reservoir and wheel cylinder bleeder valves. Clean each fitting before opening to prevent contaminating the system.
2.
Open the master cylinder reservoir and top off with standard automotive DOT 3 brake fluid.
B
Never return brake fluid to the original container or reuse brake fluid due to the possibility of contamination by dirt, grease, moisture. Contaminated brake fluid could cause failure of the braking system. Dispose of brake fluid in accordance with Federal, state and local codes.
3.
Attach a short length of clear hose to the caliper bleed valve and insert the other end into a suitable clean container containing fresh, clean brake fluid.
Check the fluid level in the master cylinder frequently during this operation to prevent air from entering the lines.
Bleeder
Hose
4.
Start with the passenger side rear brake, then driver side rear brake, passenger side front brake and finish with driver side front brake. Bleeding the brakes requires an assistant to pump the brake pedal and keep pressure on the pedal. Bleed the brakes using the following procedure: a.
Build pressure in the brake system, if possible, by slowly pumping the brake pedal.
b.
Open the bleeder valve while an assistant holds pressure on the brake pedal as the pedal slowly goes through the full stroke.
c.
Close the bleeder valve and have the assistant slowly release the brake pedal. d.
Repeat the process until no bubbles can be seen leaving the bleeder valve. e.
Close the valve and move to the next brake.
f.
Park Brake Adjustment
The floor mounted park brake has an adjustment knob on the end of the handle. If the vehicle starts to roll when the park brake is engaged on a hill, place one foot on the service brake pedal, turn the adjustment knob clockwise to increase tension on the brake, release the service brake and check to see if the park brake holds.
Repeat the process if necessary.
Adjustment
Knob
Owner’s Manual
35
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
POWERTRAIN
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.
Never press the accelerator pedal with drive wheels off the ground.
Any servicing requiring adjustments to the powertrain while the motor is running must be made with all four 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.
Reduce the possibility of accidental starting by disconnecting battery at negative terminal before servicing.
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.
Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liter) of water and flushed with water.
Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion.
It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual. Preventative maintenance, applied at recommended intervals, is the best guarantee for keeping the vehicle both dependable and economical.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the PERIODIC
SERVICE SCHEDULE for appropriate service intervals.
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, or frequent use with maximum load.
36
Owner’s Manual
MAINTENANCE
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AXLES
Front and Rear Axles
The only maintenance required for the first five years is the periodic inspection of the axles 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.
Check/Fill
Plug
B
Checking the Lubricant Level
Clean the area around the check/fill plug and remove the 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 it starts to seep from the hole. Install the check/fill plug.
BATTERY CHARGING AND MAINTENANCE
Battery Safety
Always observe the following warnings when working on or near batteries.
To prevent battery explosion that could result in severe personal injury or death, keep all smoking materials, open 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 to move 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.
Electrolyte in a storage battery is an acid solution which can cause severe burns to 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.
Neutralize electrolyte spills with a solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1-1/2 gallons (6 liters) of water and flush 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 metal container to prevent can from contacting battery terminals which could result in an explosion.
Owner’s Manual
37
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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 Disposal
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling.
For neutralized spells, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.
Battery
A battery is defined as two dissimilar metals immersed in an acid. If the acid is absent or if the metals are not dissimilar, a battery has not been created. The batteries most commonly used in these vehicles are lead acid.
A battery does not store electricity, but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy. The chemical reaction takes place faster in warm conditions and slower in cold conditions. Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences.
As a battery ages, it continues to perform 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
Battery Protective Spray.............................................. 1
Tool List Qty.
Battery Carrier............................................................. 1
Battery Maintenance Kit P/N 25587-G01 .................... 1
There are two batteries under the cowl; the remaining batteries are located under the seat. The batteries under the cowl are equipped with a battery fill system tube that is located in the passenger side glove box. The batteries under the seat may have an optional fill system, and can be accessed by raising and removing the seat bottom.
At Each Charging Cycle
To reduce the possibility of fire, never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle. Overcharging could cause damage to the vehicle batteries and result in extreme overheating. The charger should be checked after 24 hours and unplugged after the charge cycle is complete.
Before charging the batteries, inspect the plug of the battery charger and vehicle receptacle housing for dirt or debris.
Charge the batteries after each days use.
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.
• Torque battery terminal nuts to 95 - 105 in. lbs. (11 - 12 Nm).
38
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
• Coat battery terminals with commercially available protectant.
• Replace all terminal covers.
• Replace battery compartment cover and note service date on chart.
Temperature Affects Battery Capacity
Battery storage capacity is affected by the temperature; the colder it is, the less energy it is able to store; as temperature increases, so does the storage capacity of the battery.
The ideal battery temperature for deep cycle batteries is
77°F (25°C). At 32°F (0°C) the storage capacity of the battery will be reduced by 20%. This means in cold weather the vehicle will not travel as far as it would in warm weather.
70
65
60
55
90
85
80
75
115
110
105
100
95
50
45
40
35
F°
30
-40
C° -40
-22
-30
-4
-20
14
-10
32
0
50
10
TEMPERATURE
68
20
86
30
104
40
122 140
50 60
B
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.
Expansion
Space
Vent Cap
Gas Vent
Vent
DO NOT overfill batteries. The charging cycle will expel electrolyte and result in component damage.
If the battery electrolyte level is too high, the electrolyte will block the vent tube and the gas will force it out of the vent tube and battery cap. The water will evaporate but the sulfuric acid will remain where it can damage vehicle components and the storage facility floor. Sulfuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery.
1/4 to 3/8 inch
(6 mm to 10 mm)
Plates
1/2 inch
(13 mm)
Electrolyte level should be at least 1/2” (13 mm) above the plates and 1/4” to 3/8” (6 to 10 mm) below vent.
39
Owner’s Manual
MAINTENANCE
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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. 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.
An automatic watering gun or a battery watering jug, available from many auto parts stores may be used to fill the batteries.
These watering devices are accurate, easy to use and allow for rapid filling. They also maintain the correct electrolyte level within the battery cells.
Impurity
Color
Suspended
Total Solids
Calcium & Magnesium Oxides
Iron
Ammonia
Organic & Volatile Matter
Nitrites
Nitrates
Chloride
Water Purity Table
Parts Per
Million
Clear
Trace
100
40
5
8
50
5
10
5
Hand Held Watering Device
Valve consistently fills to a predetermined level
Electrolyte Level
Pure Water
Single Battery Cell
Automatic Watering Gun
Distilled Water
Valve consistently fills to a predetermined level
Electrolyte Level
Single Battery Cell
The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates.
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.
Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liter) of water and flushed with water.
Always wear a safety shield or approved safety goggles when adding water or charging batteries.
40
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Cleaning Batteries
When cleaning the outside of the batteries and terminals, do not use a water hose without first spraying the batteries with a solution of baking soda (sodium bicarbonate) and water to neutralize any acid deposits. Use of a water hose without first neutralizing the acid will move the acid from the top of the batteries to another area of the vehicle or storage facility, where it will attack the metal structure or the concrete/asphalt floor.
After hosing down the batteries, a residue will be left on the batteries, which is conductive and will contribute to the discharge of the batteries.
1 quart
(1 liter)
Clear Water
2 Teaspoons
(10 ml)
Sodium
Bicarbonate
(Baking Soda)
Plastic
Spray
Bottle
B
.
To prevent battery damage, be sure that all battery caps are tightly installed.
There are two batteries under the cowl; the remaining batteries are located under the seat. The batteries under the cowl are equipped with a battery fill system tube that is located in the passenger side glove box. The batteries under the seat may have an optional fill system, and can be accessed by raising and removing the seat bottom.
Clean batteries:
1.
Use a plastic spray bottle to spray the top and sides of the batteries with a solution of baking soda and water. The solution should consist of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liter) of water.
2.
In addition to the batteries, pay special attention to metallic components adjacent to the batteries. Spray these with the baking soda solution also.
3.
Allow the solution to set for at least three minutes; then use a soft bristle brush or cloth to wipe the tops of the batteries to remove any residue that could cause the batteries to self-discharge.
4.
Rinse the entire area with low pressure clear water.
To prevent battery explosion that could result in severe personal injury or death, use extreme care with aerosol containers of battery terminal protectant. Insulate the metal container to prevent the metal can from contacting battery terminals.
5.
After batteries are clean and dry, coat terminals with a commercially available protectant. See previous WARNING.
Cleaning should take place once a month or more often under extreme conditions.
41
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Battery Removal and Installation
Improper handling of high voltage wiring, batteries, or control systems could result in serious or fatal injury by electric shock. Only qualified technicians should repair or access high voltage wiring, battery packs, and associated systems.
To prevent battery explosion that could result in severe personal injury or death, use extreme care with aerosol containers of battery terminal protecting spray. Insulate the metal container to prevent the metal can from contacting battery terminals, which could result in an explosion.
If the batteries are replaced, make sure they are the exact type and model originally supplied with the vehicle.
Failure to follow this caution can result in damage to the vehicles electrical system.
Battery Fill Tube
42
To Controller B-
To Solenoid
Battery fill system at this set of batteries is optional, therefore some vehicles may not be equipped with it.
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
.
Prolonged Storage
During periods of storage, the batteries must be maintained to prevent discharge.
In winter conditions, the batteries must be fully charged to prevent the possibility of freezing. A fully charged battery will not freeze in temperatures above -75° F (-60° C). Although the chemical reaction is slowed in cold temperatures, the battery must be stored fully charged, and disconnected from any circuit that could discharge the battery.
The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge.
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.
O
F
O
C
E
R
A
T
T
E
M
P
U
R
E
T
R
O
L
E
L
E
C
Y
T
E
+15 -9
+5 -15
-5 -21
-15 -26
-25 -32
-35 -37
-45 -43
-55 -48
-65 -54
-75 -60
-85 -65
-95 -71
1.100
1.140
1.180
1.220
1.260
1.300
B
1.120
1.160
1.200
1.240
1.280
Battery Charging
SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT
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 being used.
Before charging, the following should be observed:
Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage.
• The electrolyte level in all cells must be at the recommended level and cover the plates.
• The charging must take place in an area that is well ventilated and capable of removing the hydrogen gas that is generated by the charging process. A
minimum
of five air exchanges per hour is recommended.
• The charging connector components 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 must be 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.
43
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
BATTERY TROUBLESHOOTING
In general, troubleshooting will be done for two distinct reasons:
• 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.
• 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, as the battery ages, its capacity diminishes. 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 problematic cell or cells 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.
Thermometer
Add to Float
Reading
Cylinder
Bulb Float
Subtract from Float
Reading
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.
Hydrometer
Weight
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.
44
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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.
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.
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.
ELECTROLYTE
TEMPERATURE
°F °C
160 71
150 65
140 60
130 54
120 49
110 43
100 37
90 32
80 26
70 21
60 15
50 10
40 4
30 -1
20 -6
10 -12
+.008
+.006
+.004
+.002
0
-.002
-.004
-.006
-.008
-.010
-.012
-.014
-.016
-.018
-.020
-.022
-.024
-.026
+.032
+.030
+.028
+.026
+.024
+.022
+.020
+.018
+.016
+.014
+.012
+.010
-.028
EXAMPLE #1
ELECTROLYTE TEMPERATURE
Above 80 °F (27 °C)
AMBIENT TEMPERATURE
Above 80 °F (27 °C)
ELECTROLYTE TEMPERATURE
Above 90 °F (32 °C)
HYDROMETER READING 1.250
1.250 + .004 = 1.254
CORRECTED SPECIFIC GRAVITY
READING
EXAMPLE #2
ELECTROLYTE TEMPERATURE
Above 80 °F (27 °C)
AMBIENT TEMPERATURE
Above 80 °F (27 °C)
ELECTROLYTE TEMPERATURE
Above 70 °F (21 °C)
HYDROMETER READING 1.250
1.250 - .004 = 1.246
CORRECTED SPECIFIC GRAVITY
READING
3.
Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float.
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 Hydrometer Temperature Correction 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).
B
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.
45
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
HARDWARE
Periodically, the vehicle should be inspected for loose fasteners. Use care when tightening fasteners, 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 hex head and grade 8 hardware is identified by six marks on the head. metric hardware is marked on the head with 8.8 or 10.9. Unmarked hardware is Grade 2.
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
Grade 2
Grade 5
Grade 8
1/4"
4
(5)
6
(8)
6
(8)
5/16"
8
(11)
13
(18)
18
(24)
3/8"
15
(20)
23
(31)
35
(47)
7/16"
24
(33)
35
(47)
55
(75)
1/2"
35
(47)
55
(75)
80
(108)
9/16"
55
(75)
80
(108)
110
(149)
5/8"
75
(102)
110
(149)
170
(230)
3/4"
130
(176)
200
(271)
280
(380)
7/8"
125
(169)
320
(434)
460
(624)
1"
190
(258)
480
(651)
680
(922)
BOLT SIZE
Class 5.8
(Grade 2)
5.8
Class 8.8
(Grade 5)
8.8
Class 10.9
(Grade 8)
10.9
M4
1
(2)
2
(3)
3
(4)
M5
2
(3)
4
(6)
M6
4
(6)
7
(10)
M8
10
(14)
18
(24)
M10
20
(27)
35
(47)
M12
35
(47)
61
(83)
M14
55
(76.4)
97
(131)
6
(8)
10
(14)
25
(34)
49
(66)
86
(117)
136
(184)
Torque Specifications and Bolt Grades
CAPACITIES AND REPLACEMENT PARTS
Front Axle Oil
Rear Axle Oil
Brake Fluid
CAPACITIES
13.8 oz. 90 wt. Gear Oil
13.8 oz. 90 wt. Gear Oil
DOT 3
REPLACEMENT PARTS
LED Headlight Bulb
Headlight Bulb
P/N 619101
P/N 619100
ATC Type Fuse 10 Amp
ATC Type Fuse 15 Amp
ATC Type Fuse 20 Amp
P/N 35212G07
P/N 35212G01
P/N 35212G02
46
Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
Owner’s Manual
47
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
48
Owner’s Manual
PERIODIC SERVICE SCHEDULE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE
CH
- CHECK
C&A
- CHECK & ADJUST
CL
- CLEAN
R
- REPLACE
REMARKS
Tires - pressure, condition of tires & rims
Hardware - loose or missing
ROPS - loose or missing hardware; ensure free of damage
Overall Vehicle Condition
Seat Belts - Inspect webbing for cuts, frays or any kind of damage or wear that could weaken the belt. Check latch mechanism for proper operation.
Batteries - state of charge, condition, loose terminals, corrosion, hold downs & hardware
Batteries* - check electrolyte level, fill after charging if required (if plates are exposed before charging, add only enough water to cover any exposed plates and fill after charging)
Brakes - Check fluid level in master cylinder
Brakes - smooth operation of pedal, stopping distance
CH
CH
CH
CH
CH
CH
CH
CH
CH
CH
CH
C&A
CH
CH
CH
CH
CH
CH
CH
CL
C&A
CH
CH
CH
CH
CH
CH
CH
CL
C&A
CH
CH
CH
CH
CH
CH
CH
CL
C&A
CH
CH
3000 miles/
5000 kms
CH
Park Brake - ability to hold on a hill
Accelerator - smooth operation
Wiring - loose connections, broken or missing insulation
Charger Receptacle - inspect and clean receptacle at each charge
Direction Selector - attachment and mechanism
Steering Assembly - excessive play, loose or missing hardware
Tie Rods - excessive play, bent rods, loose or missing hardware
Front and Rear Axle - oil leakage, noise, loose or missing hardware
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
Front and Rear Axle - drain and replace fluid
5000 miles/
8000 kms
Front Suspension - strut oil leakage, excessive play in hubs or kingpins, worn bushings, loose or missing hardware
Rear Suspension - strut oil leakage, worn bushings, loose or missing hardware
Front Wheel Alignment - unusual tire wear
CH CH
CH
C&A
* Use only distilled or purified water that is free from contaminates to fill batteries.
CH
CH
C&A
CH
CH
C&A
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.
Owner’s Manual
49
PERIODIC SERVICE SCHEDULE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
50
Owner’s Manual
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
APPENDIX A
DECLARATION OF CONFORMITY
Owner’s Manual
A
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Owner’s Manual
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Owner’s Manual
C
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
D
Owner’s Manual
Read the following warnings before operating vehicle:
To prevent personal injury or death, observe the following:
When vehicle is to be left unattended, engage park brake, move direction selector to neutral, turn key to OFF position and remove from key switch.
Drive vehicle only as fast as terrain and safety considerations allow. Consider environmental factors which effect the terrain and the ability to control the vehicle.
Avoid driving fast down hill. Sudden stops or change of direction may result in loss of control. Use service brake to control speed when traveling down an incline.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.
All travel should be directly up or down hills; use extra care if ever forced to drive across an incline.
Stay in designated areas and avoid steep slopes. Activate the park brake when the vehicle is parked.
Keep feet, legs, hands and arms inside vehicle at all times.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in reverse.
Make sure direction selector is in desired position before starting the vehicle.
Slow down before and during turns.
A l l t u r n s s h o u l d b e e x e c u t e d a t reduced speed.
Always bring vehicle to a complete stop before shifting direction selector.
See GENERAL SPECIFICATIONS for vehicle load and seating capacity.
Read the following information and warnings before operating vehicle:
In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible component failures or the manner in which they may fail.
A vehicle requiring repair indicates that it is no longer functioning as designed and therefore should be considered potentially hazardous.
Use extreme care when working on vehicle. When diagnosing, removing or replacing any components that are not operating properly, take time to consider the safety of yourself and others around you should the component move unexpectedly.
Some components are heavy, spring loaded, highly corrosive, explosive, may produce high amperage or reach high temperatures. Battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders if not treated with utmost caution. Be careful not to place hands, face, feet or body in a location that could expose them to injury should an unexpected situation occur.
Always use the appropriate tools listed in the tool list and wear approved safety equipment.
Before working on vehicle, remove all jewelry (rings, watches, necklaces, etc.).
Be sure no loose clothing or hair can contact moving parts.
Use care not to touch hot objects.
Raise rear of vehicle and support on jack stands before running or adjusting powertrain.
Wear eye protection when working on or around the vehicle. In particular, use care when working around batteries, using solvents, or compressed air.
Hydrogen gas forms when charging batteries.
Do not charge batteries without adequate ventilation.
Do not permit open flame or smokers in an area being used for charging batteries. A concentration of 4% hydrogen gas or more is explosive.
CONTACT US:
Bad Boy Buggies
1451 Marvin Griffin Road
Augusta, Georgia 30906-3852 USA
FAX: 855-256-9900
E-mail: [email protected]
For parts and repair, contact local dealer. Dealers can be located at www.BADBOYBUGGIES.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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Key Features
- Electric powered for quiet and environmentally friendly operation
- Rugged construction for durability and reliability
- Spacious cabin for comfortable seating and ample cargo space
- Versatile design for work and leisure activities
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