Cushman Model Year 2018-2020 Hauler 800X Electric Manual

OWNER’S GUIDE
HAULER 800X ELECTRIC
663437 C
ISSUED OCT 2017
REVISED JAN 2019
Read and comply with all of the instructions and safety precautions in this manual and on all
product labels.
Failure to follow the safety precautions could result in serious injury or death.
California Proposition 65
WARNING
Operating, servicing and maintaining a passenger vehicle or off-road vehicle
can expose you to chemicals including phthalates and lead, which are known to
the State of California to cause cancer and birth defects or other reproductive
harm. To minimize exposure, wear gloves and wash your hands frequently
when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle,
decrease it’s stability or increase the speed beyond the factory-set speed. Such modifications
can cause serious personal injury or death. The manufacturer of this vehicle, TEXTRON
SPECIALIZED VEHICLES (TSV Augusta), prohibits and disclaims responsibility for any such
modifications or any other alteration which would adversely affect the safety of the vehicle.
OWNER’S GUIDE
48V ELECTRIC
HAULER 800
Starting MODEL YEAR 2018
CONTACT INFORMATION
Textron Specialized Vehicles, Inc.
1451 Marvin Griffin Road
Augusta, Georgia, USA 30906-3852
North America:
Technical Assistance & Warranty PHONE: 1-800-774-3946, FAX: 1-800-448-8124
Service Parts PHONE: 1-800-438-3946, FAX: 1-800-752-6175
International PHONE: 001-706-798-4311, FAX: 001-706-771-4609
[email protected]
1
WELCOME
Thank you for purchasing this vehicle. Before driving your new vehicle, read this owner’s manual to familiarize yourself with safe driving practices, operation, features and controls.
This manual contains instructions for minor maintenance only. Information about major repairs can be found in the
repair manual. Your dealer has thorough knowledge of your vehicle and wants your total satisfaction with your purchase. We recommend you return to your dealership for all of your service needs during, and after the warranty
period.
Repair or replacement parts can be purchased from your dealer or through the manufacturer’s parts and accessories
department.
These are original instructions as defined by 2006/42/EC.
Textron Specialized Vehicles, Inc. maintains the right to change the design of the vehicle without responsibility to
make the changes on units purchased before changes were made. The information in this manual can change without
notice.
All information in this owner’s manual is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some discrepancies may be found between
your vehicle and the information presented in this publication. The content in this publication is intended for reference
use only. The manufacturer is not liable for omissions or inaccuracies. Any reprinting or reuse of the content in this
publication, whether whole or in part, is expressly prohibited.
Printed in USA
2
TABLE OF CONTENTS
INTRODUCTION
MANUFACTURER’S INTENDED USE ..................................................................................................................... 7
WARRANTY AND REGISTRATION ......................................................................................................................... 7
BATTERY PROLONGED STORAGE ....................................................................................................................... 7
BATTERY DISPOSAL ............................................................................................................................................... 7
VEHICLE IDENTIFICATION NUMBERS ................................................................................................................. 8
REPAIR AND PARTS MANUALS ............................................................................................................................. 8
SAFETY
SAFETY LABELS ...................................................................................................................................................... 9
Operation (P/N 651654) .................................................................................................................................... 9
Operation (P/N 664789) (If equipped with card holder) .................................................................................. 10
Bed Latch Warning (P/N 74099G01) .............................................................................................................. 10
Load Bed (P/N 74821G08) .............................................................................................................................. 11
Located on the truck bed. ............................................................................................................................... 11
Pinch Warning (P/N 651671) .......................................................................................................................... 11
Run/Tow Switch Operation (P/N 665229) ....................................................................................................... 11
MAXIMUM CARGO LOAD / MAXIMUM WEIGHT CAPACITY ............................................................................... 11
TIRE PRESSURE ................................................................................................................................................... 12
OPERATOR SAFETY ............................................................................................................................................. 12
Unauthorized Operation .................................................................................................................................. 13
Operating without Instruction .......................................................................................................................... 13
Alcohol or Drugs .............................................................................................................................................. 13
Passenger ....................................................................................................................................................... 13
Before Operating ............................................................................................................................................. 13
Load Operation ............................................................................................................................................... 13
Driving in Reverse ........................................................................................................................................... 13
Driving a Damaged Vehicle ............................................................................................................................. 14
Driving at Maximum Speeds ........................................................................................................................... 14
Driving on Pavement ....................................................................................................................................... 14
Driving on Public Roads .................................................................................................................................. 14
Turning ............................................................................................................................................................ 14
Driving Uphill ................................................................................................................................................... 14
Driving Downhill .............................................................................................................................................. 14
Stalling on a Hill .............................................................................................................................................. 14
Tires ................................................................................................................................................................ 14
Slippery Terrain ............................................................................................................................................... 14
BATTERY CHARGING ........................................................................................................................................... 14
VEHICLE LIFTING .................................................................................................................................................. 15
VEHICLE MODIFICATION ...................................................................................................................................... 15
MAINTENANCE SAFETY ....................................................................................................................................... 15
FEATURES AND CONTROLS
KEY SWITCH .......................................................................................................................................................... 17
HEADLIGHT SWITCH ............................................................................................................................................. 17
Halogen ........................................................................................................................................................... 17
LED (If Equipped) ............................................................................................................................................ 17
ELECTRIC BED LIFT SWITCH (IF EQUIPPED) .................................................................................................... 17
3
TABLE OF CONTENTS
STATE OF CHARGE METER .................................................................................................................................17
HORN ......................................................................................................................................................................17
CUP HOLDER .........................................................................................................................................................17
12V OUTLET (IF EQUIPPED) .................................................................................................................................17
USB PORT (IF EQUIPPED) ....................................................................................................................................18
HOUR METER (IF EQUIPPED) ..............................................................................................................................18
STEERING WHEEL ................................................................................................................................................18
TURN SIGNAL/HORN (IF EQUIPPED) ..................................................................................................................18
RUN/TOW SWITCH ................................................................................................................................................18
BRAKE PEDALS .....................................................................................................................................................18
Brake Pedal .....................................................................................................................................................19
Parking Brake Pedal ........................................................................................................................................19
ACCELERATOR PEDAL .........................................................................................................................................19
DIRECTION SELECTOR .......................................................................................................................................19
SEAT BOTTOM .......................................................................................................................................................19
GLOVE BOX / STORAGE COMPARTMENTS .......................................................................................................19
TRUCK BED ...........................................................................................................................................................20
CANOPY TOP AND WINDSHIELD .........................................................................................................................20
OPERATION
SAFETY ..................................................................................................................................................................21
BEFORE INITIAL USE ............................................................................................................................................21
PRE-RIDE INSPECTION ........................................................................................................................................21
ENVIRONMENTAL AWARENESS .........................................................................................................................22
CHARGER ..............................................................................................................................................................22
On Board Charger ...........................................................................................................................................22
PERFORMANCE FEATURES ................................................................................................................................23
Speed Control .................................................................................................................................................23
Pedal-Up Braking ............................................................................................................................................23
Walk-Away Feature .........................................................................................................................................23
Anti-Roll Back Feature ....................................................................................................................................23
Anti-Stall Feature .............................................................................................................................................23
High Pedal Disable Feature ............................................................................................................................23
Diagnostic Mode Feature ................................................................................................................................24
STARTING AND STOPPING THE VEHICLE .........................................................................................................24
Starting on a Hill ..............................................................................................................................................24
ACCELERATING ....................................................................................................................................................24
BRAKING ................................................................................................................................................................25
Coasting ..........................................................................................................................................................25
DRIVING PROCEDURE .........................................................................................................................................25
Coasting ..........................................................................................................................................................25
DRIVING WITH A PASSENGER ............................................................................................................................25
SLIPPERY SURFACES ..........................................................................................................................................26
DRIVING UPHILL ....................................................................................................................................................26
TRAVERSING HILLSIDES ......................................................................................................................................26
DRIVING DOWNHILL .............................................................................................................................................26
STALLING ON A HILL .............................................................................................................................................27
DRIVING IN REVERSE ...........................................................................................................................................27
4
TABLE OF CONTENTS
PARKING THE VEHICLE ........................................................................................................................................ 27
HAULING CARGO .................................................................................................................................................. 28
Maximum Cargo Load / Maximum Weight Capacity .......................................................................................28
TRUCK BED OPERATION ..................................................................................................................................... 29
Load Bed (P/N 74821G08) .............................................................................................................................. 29
Located on the truck bed. ............................................................................................................................... 29
DUMPING THE TRUCK BED ................................................................................................................................. 29
Manual Bed Release Lever ............................................................................................................................. 29
Electric Lift (If Equipped) ................................................................................................................................. 29
TOWING .................................................................................................................................................................. 30
SPECIFICATIONS
VEHICLE SPECIFICATIONS .................................................................................................................................. 33
MAINTENANCE
MAINTENANCE SAFETY ....................................................................................................................................... 35
SCHEDULED MAINTENANCE ............................................................................................................................... 35
Severe Use Conditions ................................................................................................................................... 36
SCHEDULED MAINTENANCE CHART ..................................................................................................................36
RECOMMENDED LUBRICANTS AND FLUIDS .....................................................................................................37
REPLACEMENT OF MAINTENANCE ITEMS ........................................................................................................37
LIFTING THE VEHICLE .......................................................................................................................................... 38
Lifting Front .................................................................................................................................................... 38
Lifting Rear ...................................................................................................................................................... 38
Lowering Vehicle ............................................................................................................................................. 38
VEHICLE CLEANING AND CARE .......................................................................................................................... 39
Washing the Vehicle ....................................................................................................................................... 39
Polishing the Vehicle ....................................................................................................................................... 39
TIRES ...................................................................................................................................................................... 39
Tire Pressure ................................................................................................................................................... 40
Tire Repair ...................................................................................................................................................... 40
Tire Replacement ............................................................................................................................................ 40
WHEELS ................................................................................................................................................................. 40
Wheel Removal ............................................................................................................................................... 40
Wheel Installation ........................................................................................................................................... 41
LIGHTS ................................................................................................................................................................... 41
Halogen Headlight Bulb Replacement ............................................................................................................41
LED Headlight Assembly Replacement ..........................................................................................................41
Taillight ............................................................................................................................................................ 41
FUSE REPLACEMENT ........................................................................................................................................... 42
CONTROLLER SYSTEM TEST .............................................................................................................................. 42
REAR AXLE ............................................................................................................................................................ 42
Checking the Lubricant Level .......................................................................................................................... 42
LUBRICATION ........................................................................................................................................................ 42
BRAKES .................................................................................................................................................................. 43
Periodic Brake Test ........................................................................................................................................ 43
BATTERY ................................................................................................................................................................ 43
BATTERY DISPOSAL ............................................................................................................................................. 44
BATTERY CLEANING ............................................................................................................................................ 44
5
TABLE OF CONTENTS
BATTERY CHARGING AND MAINTENANCE ........................................................................................................45
At Each Charging Cycle ..................................................................................................................................45
Monthly ............................................................................................................................................................45
Electrolyte Level and Water ...........................................................................................................................45
BATTERY REPLACEMENT ....................................................................................................................................46
BATTERY STORAGE .............................................................................................................................................47
BATTERY CHARGING ...........................................................................................................................................48
AC Voltage ......................................................................................................................................................48
BATTERY FAULT DIAGNOSIS ..............................................................................................................................48
Using A Hydrometer ........................................................................................................................................50
TRANSPORTING THE VEHICLE ...........................................................................................................................51
Towing the Vehicle ..........................................................................................................................................51
Hauling the Vehicle .........................................................................................................................................51
6
INTRODUCTION
INTRODUCTION
The following symbols appear throughout this manual and on vehicle labels. Your safety is involved when these symbols are used. Become familiar with their meanings before reading the manual.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
The PROHIBITION SAFETY SIGN indicates an action NOT to take in order to avoid hazard.
The MANDATORY ACTION SIGN indicates an action that NEEDS to be taken to avoid a hazard.
Failure to comply with the warnings in this manual can result in severe injury or death.
Read this entire manual carefully before operating this vehicle. Do not attempt to operate
this vehicle until you have thorough knowledge of the controls and features.
Regular inspections and maintenance, along with good operating techniques, will help
ensure your safe enjoyment of the capabilities and reliability of this vehicle.
This vehicle was designed and manufactured in the United States of America (USA). The standards and specifications in the following information originate in the USA unless otherwise indicated.
When servicing motors, all adjustments and replacement components must be per original vehicle specifications to
maintain the USA Federal and State emission certification applicable at the time or manufacture.
MANUFACTURER’S INTENDED USE
This vehicle is designed and manufactured for off road use only. Use on public streets, roads or highways is illegal in
most areas and increases the risk of an accident involving other vehicles and people. This vehicle does not meet
FMVSS (Federal Motor Vehicle Safety Standards) for public street, road or highway use.
Check all laws and regulations before choosing an area to operate your vehicle.
WARRANTY AND REGISTRATION
Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective.
Tampering with or adjusting the governor to allow the vehicle to operate above factory specifications will void the vehicle warranty.
All information, including coverage, limitations, exclusions and how to obtain warranty service is included in the literature package with the purchase of the vehicle. It can also be obtained from your dealer.
A registration card is included in the literature package with the purchase of the vehicle. .
BATTERY PROLONGED STORAGE
Batteries discharge over time. The rate of discharge changes according to the ambient temperature, the age and condition of the batteries.
Completely charged batteries will not freeze in winter temperatures unless the temperature is less than -75°F (- 60°C).
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return discarded batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, put residue in acid-resistant containers with absorbent material such as sand. Dispose in
accordance with local, state and federal regulations for acid and lead compounds. Contact local or state environmental authorized people for the disposal information.
7
INTRODUCTION
VEHICLE IDENTIFICATION NUMBERS
PIN
L
abel
Frame Rail Under
Passenger’s Seat
Part
PIN
C
Plat
e
Part
A
rt D
Pa
Part
B
Frame Rail Under
Driver’s Seat
Serial number and manufacture date code/PIN plates are located on the vehicle in the following locations (shown
above):
• Serial label “Part A” and “Part B” - Located on the frame rail under the driver’s seat. Lift seat to access.
• Serial label “Part C” - Located under the charger receptacle.
• Serial label “Part D” - Located on the frame tube below the driver’s side floorboard.
• PIN label - Located on the frame rail under the passenger’s seat. Lift seat to access.
• PIN plate - Located on the frame cross member below the floorboard.
Record the vehicle identification numbers in the spaces provided below. These identification numbers are required
when ordering parts from TSV.
Vehicle Model Number: _________________________________________________________________
Frame PIN: __________________________________________________________________________
REPAIR AND PARTS MANUALS
The following manuals can be purchased through a dealer:
• repair manual
• parts manual
8
SAFETY
SAFETY
For questions about your vehicle or the material in this manual, see the contact information on page 1 or the back of
this publication.
Certain replacement parts can be used independently and/or in combination with other accessories to modify a TSV
(Augusta) manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph. When a TSV-manufactured
vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess of 20 mph on public
streets or roads. 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.
Information on FMVSS 571.500 is found at Title 49 of the Code of Federal Regulations, section 571.500. For information online, go to www.ecfr.gov.
TSV will NOT approve Distributor, Dealer or customer changes that change a TSV product into a Low Speed Vehicle
(LSV).
This vehicle meets the current applicable standard for safety and performance requirements.
SAFETY LABELS
Safety and warning labels are on the vehicle for your protection. Read and comply with the instructions on the labels
carefully. If any label shown in this manual is different from the label on your vehicle, always follow the instructions on
the vehicle label.
If a label comes off or becomes illegible, contact your TSV dealer for a replacement. The part number is provided in
this manual, printed on the label, or can be obtained from your dealer.
Operation (P/N 651654)
Located on the steering wheel.
1
2 3
13 12
1 - READ THE MANUAL
I
I
R
F
F
R
O
I
N
R
O
F
O
2 - DRIVE IN ACCORDANCE WITH LOCAL LAWS AND REGULATIONS
3 - USE CAUTION IN BAD WEATHER
F
N
4 - MINIMUM HEIGHT REQUIRED TO DRIVE
5 - NO OPERATION FROM PASSENGER SEAT
R
6 - NO STANDING AND KEEP ENTIRE BODY INSIDE VEHICLE
cm
7 - REFER TO OWNER’S MANUAL FOR CARGO INFORMATION
MIN 150
8 - MAXIMUM CROSS RAMP OR HILL
9 - NO OPERATION IF USING DRUGS OR ALCOHOL
10 - NO OPERATION ON PUBLIC ROADS
< 14° 25%
9
10
11
4
5
6
11 - EXIT VEHICLE WHEN LIGHTNING IS IN AREA
12 - ELECTRIC FORWARD OPERATION REVERSE OPERATION
VEHICLE
- KEY IN F
- KEY IN R
- PRESS ACCELERATOR - PRESS ACCELERATOR
GRADUALLY
GRADUALLY
PARK VEHICLE
- STOP VEHICLE
- REMOVE FOOT
FROM ACCELERATOR
- TURN KEY TO OFF
13 - GAS
VEHICLE
PARK VEHICLE
- PUT DIRECTION
SELECTOR IN F
- TURN KEY TO OFF
- ENGAGE PARKING
BRAKE
8
< 14° 25%
651654
7
FORWARD OPERATION
- TURN KEY TO ON
- PUT DIRECTION
SELECTOR TO F
- PRESS ACCELERATOR
GRADUALLY
REVERSE OPERATION
- TURN KEY TO ON
- PUT DIRECTION
SELECTOR IN R
- PRESS ACCELERATOR
GRADUALLY
9
SAFETY
Operation (P/N 664789) (If equipped with card holder)
Located on the steering wheel.
READ AND OBEY THE FOLLOWING WARNINGS TO
DECREASE RISK OF SEVERE INJURY OR DEATH. 664789
Pressing the accelerator pedal releases the parking brake even when the key is in the OFF position; the vehicle may
move when the accelerator pedal is pressed. Unintentional movement of the vehicle can cause injury or death. Do not
allow anyone to stand directly in front or behind the vehicle.
Driver must have a valid driver’s license.
Do not
operate vehicle until all occupants are properly seated with their backs against the seat and feet flat on the floor.
Do not leave children unattended or allow them to play on a parked vehicle.
•
•
•
SAFETY INSTRUCTIONS
BEFORE OPERATING
READ the owner’s manual and all warning labels. Contact an authorized dealer or go to the manufacturer’s website for
•replacement
manual or labels. • This vehicle is equipped for personal use in most communities; however, state law or
local rules may require additional equipment in your community.
SAFE OPERATION & PARKING
Turn key to ON, select Forward or Reverse, release the parking brake (if required), and slowly press
accelerator pedal.
Always bring vehicle to a complete stop before shifting the direction selector.
Always
remain seated in a moving vehicle.
Operate from the driver’s seat only.
Never drink alcohol or use
drugs or medications before or during operation of the vehicle.
ALWAYS engage the parking brake
and remove the key before leaving the vehicle. In an electric vehicle, put the direction selector in
OFF or Neutral; in a gasoline vehicle, put the selector in Forward.
•
•
•
•
•
•
MAINTENANCE & TOWING
This vehicle requires regularly scheduled maintenance (see the
• periodic
service schedule in owner’s manual). • ONLY qualified
personnel should service this vehicle. • Vehicle is not
to be towed; consult owner’s manual for
transport instructions.
Bed Latch Warning (P/N 74099G01)
Located on the side panel near rear fender.
KEEP HANDS AND
FINGERS AWAY FROM
DUMP BED.
DO NOT STAND
BEHIND DUMP
BED.
74099-G01
10
SAFETY
Load Bed (P/N 74821G08)
Located on the truck bed.
MAX
325 lb.
147 kg
MAX
5 in.
12 cm
PP
MAX
100 lb.
45 kg
MAX
14o / 25%
74821G08
Pinch Warning (P/N 651671)
Located on rear side panels.
PINCH WARNING
KEEP HANDS AND
FINGERS AWAY
651671
Run/Tow Switch Operation (P/N 665229)
Located on the run/tow switch.
DO NOT alter or tamper with this unit. Unauthorized modifications
can result in SERIOUS INJURY or damage to the vehicle and will
void the warranty.
To disable electrical system, turn key switch to ‘OFF’ and remove
battery wires.
ALWAYS turn key to ‘OFF’ before disconnecting or
reconnecting battery wires. ELECTRICAL ARC or
BATTERY EXPLOSION can occur if key is not in the
‘OFF’ position.
WAIT 30 seconds after reconnecting batteries BEFORE turning key
switch to ‘REVERSE’, ‘FORWARD’ or ‘NEUTRAL’ positions.
TOWING - Always select
‘TOW’ position before towing
RUN
TOW
STORAGE
665229
MAXIMUM CARGO LOAD / MAXIMUM WEIGHT CAPACITY
Exceeding the weight capacities can cause loss of vehicle control and possible injury or
death.
Maximum Cargo Load Capacity
325 lbs. (147.4 kg)
Maximum Vehicle Weight Capacity
725 lbs. (328 kg)
• Do not exceed the maximum cargo load capacity.
• Do not exceed the maximum vehicle weight capacity (includes weight of operator, passenger, cargo and accessories).
11
SAFETY
TIRE PRESSURE
Improper tire pressure or uneven tire pressure can cause loss of vehicle control and
possible injury or death.
Maintaining correct tire inflation pressure is essential for safe vehicle operation. You can vary the inflation pressure,
within the recommended range to suit the condition of the terrain.
TIRE PRESSURE RANGE
TERRAIN CONDITIONS
RECOMMENDATION
hard surfaces or pavement
Inflate to higher pressure within the range; never exceed
maximum pressure indicated.
soft terrain or turf
Inflate to lower pressure within the range to reduce
potential damage to the terrain or turf.
18 - 22 psi (124 - 152 kPa)
OPERATOR SAFETY
Safe and responsible use of this vehicle is necessary to prevent dangerous conditions for the operator, passengers
and other people in the area of operation. This section of the manual provides information on the safe operation of the
vehicle. Make sure you read, understand and comply with all of this information to decrease the risk of personal injury
or death.
Serious injury or death can occur if you do not follow the instructions and procedures
shown in this owner’s manual.
• Read this entire manual and all product labels carefully. Follow the safety information and operating procedures
described.
• Operate your vehicle responsibly to prevent dangerous conditions for the operator, passengers and other people in
the area of operation
• Operate your vehicle responsibly and keep the vehicle in safe condition of operation.
• A damaged vehicle, or a vehicle that is not functioning properly is dangerous and must not be operated until repairs
are made.
• Do not carry a passenger until you have a minimum of two hours driving experience on this vehicle.
• Keep feet, legs, hands and arms inside the vehicle at all times.
• The driver must keep both hands on the steering wheel and both feet on the floor or a pedal.
• Inspect the vehicle before each use to make sure it is in safe operating condition. Perform the pre-ride inspection
described in this manual. See page 21.
• Always have the vehicle checked by an authorized dealer if it is involved in an accident.
• Always put the direction selector in forward (F) and engage the parking brake before you exit the vehicle.
• Remove the ignition key when the vehicle is not in use to prevent accidental starting, unauthorized use by someone
below the age of 16, or someone without a driver’s license and proper training.
• Drive the vehicle at appropriate speeds for the terrain and conditions. Be aware of environmental conditions that
change the terrain and your ability to control the vehicle.
• Do not drive on excessively steep hills. Evaluate the terrain before descending a hill. Drive slowly and deliberately.
Use the brake to limit speed and maintain control. Sudden braking or turning can cause loss of vehicle control.
Drive straight down the hill; do not drive across the hill.
• Operate only in approved areas. Follow all applicable safety rules for the area.
• Avoid driving on terrain that is too rough for your vehicle’s capabilities and your driving skills.
• Before you drive in the reverse direction, make sure the area behind the vehicle is clear. Accelerate slowly and
avoid making sharp turns.
• Make sure the direction selector is in the correct position before you press the accelerator pedal.
• Decrease speed before and during turns.
• Decrease speed when driving on wet or slippery surfaces.
• Bring the vehicle to a complete stop before you move the direction selector.
• Do not exceed the cargo or vehicle weight capacities. Do not exceed the occupant capacity. See SPECIFICATIONS on page 53 for the vehicle load and seat capacity.
• If there is a risk of lightning, leave the vehicle and look for a safe location to wait until the lightning has stopped.
Additional information about safety is included throughout this manual or can be obtained from your local TSV dealer.
12
SAFETY
Failure to operate this vehicle as instructed can cause collision, loss of control or rollover resulting in severe injury or death. Follow all safety warnings in this section of the
owner’s manual. See the OPERATION section of the owner’s manual for operating procedures and additional safety information.
Unauthorized Operation
This vehicle is for adult use only. Any person below the age of 16 is not permitted to operate the vehicle.
Any person who does not have a valid driver’s license is not permitted to operate the vehicle.
Any person who is be below the height of 59 in. (150 cm) is not permitted to operate the vehicle.
Leaving the keys in the ignition allows unauthorized operation of the vehicle by someone under 16
years of age, an unlicensed driver or someone who does not meet the height requirement. Always
remove the ignition key when the vehicle is not in operation.
Operating without Instruction
Operation of this vehicle without proper instruction increases the risk of an accident. The operator
must understand how to operate the vehicle correctly in different situations and on different types of
terrain.
All operators must read, understand and comply with the owner’s manual and all warning and instruction labels before operating the vehicle.
Alcohol or Drugs
Operation of the vehicle during or after consuming alcohol or drugs can adversely affect operator judgment, reaction time, balance and perception.
Never drink alcohol or use drugs or medications before or during operation of the vehicle.
Passenger
All passengers must be at least 59 in. (150 cm) tall. Passengers must be able to sit with their back against the seat,
and both feet on the floor.
For additional safety and operational information, see Driving with a Passenger on page 25.
Before Operating
Perform the PRE-RIDE INSPECTION on page 21 before each use to make sure the vehicle is in safe operating condition. Failure to inspect and confirm that the vehicle is safe to operate increases the risk of an accident.
Follow all inspection and maintenance procedures and schedules described in this owner’s manual. See SCHEDULED MAINTENANCE CHART on page 36.
Load Operation
The weight of cargo and occupants affects vehicle operation. Carefully calculate how the vehicle is loaded and how to
safely operate it. Follow the instructions in this manual for loading guidelines and tire pressure.
Do not exceed weight capacities specified for your vehicle. Capacities are listed in Maximum Cargo Load / Maximum
Weight Capacity on page 11 of this manual, and also on the label affixed to the truck bed. As passenger weight
increases, cargo weight needs to be adjusted to ensure the maximum vehicle weight capacity is not exceeded.
Tire pressure must be adjusted to accommodate the load being carried. See Tire Pressure on page 12 for pressure
specifications.
Verify tire pressure, and drive slowly and carefully to maintain control of the vehicle if driving under any of the following
conditions:
• passenger and/or cargo exceeds half the maximum weight capacity
• driving over obstacles
• towing
• climbing a hill
Driving in Reverse
Make sure the area behind the vehicle is clear before operating in reverse. After making sure it is clear and safe to
operate in reverse, accelerate slowly. Avoid making sharp turns in reverse. Refer to Driving in Reverse on page 27 for
operational information.
13
SAFETY
Driving a Damaged Vehicle
Driving a damaged vehicle is not safe.
If your vehicle has been involved in any type of accident, have it inspected by a qualified service dealer to verify that it
is safe for operation.
Driving at Maximum Speeds
Maximum speed operation increases risk of loss of control. Always drive at a speed that is appropriate for the terrain,
visibility, operating conditions and your skill and experience level. Use the brake to control speed and maintain control
of the vehicle.
Driving on Pavement
Driving the vehicle on paved surfaces can affect handling characteristics and increase tire wear.
If possible, avoid driving on paved surfaces. If unavoidable, drive slowly, travel short distances and avoid sudden turns
or stops.
Driving on Public Roads
Driving this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never drive this
vehicle on any public street, road or highway, including dirt and gravel roads, unless they are designated for off road
use. Most areas prohibit the operation of this vehicle on public streets, roads or highways, and can result in traffic violations and fines.
Turning
Improper or careless turning can cause loss of traction, loss of control, accident or rollover. Do not turn quickly or at
sharp angles. Do not turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.
Driving Uphill
Do not climb hills that are too steep for the vehicle or your driving abilities. Loss of vehicle control or rollover can result
from climbing hills incorrectly. Refer to Driving Uphill on page 26 for operational information.
Driving Downhill
Inspect the terrain before descending a hill. Avoid driving across hills. Use the brake to limit speed and maintain control. Loss of vehicle control or rollover can result from driving downhill incorrectly. Refer to Driving Downhill on page 26
for operational information.
Stalling on a Hill
A rollover can result from stalling or rolling backward while climbing a hill. Drive uphill at a constant speed. See procedure on page 27 for maintaining control of your vehicle if it stalls on a hill.
Tires
Operating the vehicle with incorrect tires or with incorrect or uneven tire pressure can cause loss of control or an accident. Always use the size and type tires specified for the vehicle. See VEHICLE SPECIFICATIONS on page 53.
Always maintain correct tire pressures as specified in Tire Pressure on page 12.
Slippery Terrain
Driving on rough, wet or loose terrain increases the risk of loss of traction or control, accident or rollover. Drive slowly
and use correct turning procedures when operating on slippery surfaces.
Tires that have lost traction, and then regain traction suddenly, can cause loss of vehicle control or rollover.
Refer to Slippery Surfaces on page 26 for operational information.
BATTERY CHARGING
Explosive hydrogen gas is created during the charge cycle of the batteries. Good ventilation is necessary to remove
gas from enclosed spaces. The air must change every 12 minutes.
Never charge a vehicle near flammable materials, open flame or sparks. Never charge a vehicle near gas water heaters and furnaces.
14
SAFETY
VEHICLE LIFTING
The vehicle must be on a firm and level surface for lifting. Remain constantly aware that the vehicle is not stable
during the lifting process. Do not get under a vehicle until you verify that it is stable on the jack stands. Never get
under a vehicle while it is on a jack only. Put wheel chocks in front and behind the wheels that are not being lifted. Do
not allow anyone to remain or get on the vehicle at any time during the lifting process.
Read and comply with all warnings and follow the lifting procedures described on page 38.
VEHICLE MODIFICATION
Do not install any accessory not approved by TSV. Do not modify the vehicle to increase speed or power. Any modifications or installation of accessories not approved by TSV can create a safety hazard and increase the risk of injury.
The warranty will be terminated if the vehicle is modified to increase vehicle speed or power.
The warranty may be terminated if original (or equivalent) replacement parts are not installed on the vehicle.
The addition of some accessories can change the handling characteristics of the vehicle. Use only TSV approved
accessories, and familiarize yourself with their function and effect on the vehicle.
MAINTENANCE SAFETY
Routine and scheduled maintenance of this vehicle is necessary to keep your vehicle in safe and reliable condition.
This section of the manual provides safety information for performing maintenance on your vehicle. Make sure you
read, understand and comply with all of this information to decrease the risk of personal injury or death.
Serious injury or death can occur if you do not follow the instructions and procedures
shown in this owner’s manual.
• Read this entire manual and all product labels carefully. Follow the procedures and comply with the safety information in this manual while performing vehicle service or maintenance.
• Use the tools shown in the tool list and wear the specified safety equipment when performing vehicle service or
maintenance.
• Remove all jewelry before you service the vehicle.
• Do not allow loose clothing or hair to contact the moving parts.
• Do not touch hot objects.
• The drive wheels must be lifted and supported on jack stands before you perform any service to the powertrain
while the motor is in operation.
• Use wheel chocks and support the vehicle on jack stands. NEVER get under a vehicle that is supported by a jack.
Lift the vehicle following instructions. See LIFTING THE VEHICLE on page 38.
•When you service the vehicle, always wear eye protection. Be careful when working around batteries, using solvents or compressed air.
•Use insulated tools within the battery area to prevent sparks or battery explosion.
•To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks away
from the battery.
• Hydrogen gas is produced as batteries are charged. Charge the battery pack only in well-ventilated areas.
• Maintain constant awareness that some components are heavy, spring loaded, corrosive, explosive, can cause
high amperage or get extremely hot. Battery acid and hydrogen gas can cause bodily injury. Keep your hands, face,
feet and body away from any area that can expose them to injury if an unexpected situation occurs.
• After you make repairs or do maintenance, test the vehicle in a safe area that is free from vehicle and person traffic.
15
SAFETY
16
FEATURES AND CONTROLS
FEATURES AND CONTROLS
NOTICE: Some accessories continue to operate with the key in the OFF position. Leaving these accessories
activated after the vehicle is shut down can cause the battery to discharge.
12V accessories must be connected to the DC to DC converter. Converter is rated for 390 Watt output. Exceeding this power rating may result in unintended accessory operation or failure.
KEY SWITCH
The key switch is a four-position switch.
• OFF; vehicle is disabled.
• REVERSE; activates vehicle electronics and accessory
power, and allows driving in reverse direction.
• NEUTRAL; activates vehicle electronics and accessory
power.
• FORWARD; activates vehicle electronics and accessory
power, and allows driving in forward direction.
State of
Key
Charge Meter Switch
Light LED
Switch Light
Switch
Horn
Switch
HEADLIGHT SWITCH
Halogen
The Halogen headlight switch is a two-position switch.
Two-position:
• upper – on
• lower – off
LED (If Equipped)
The LED headlight switch is a three-position switch.
Three-position:
• upper – high beam
• middle - low beam
• lower – off
Cup Holder
ELECTRIC BED LIFT SWITCH (If Equipped)
If the vehicle is equipped with an electric bed lift, the switch is last toggle switch on the right on the console.
Press and hold the top of the switch to raise the bed. Press and hold the lower part of the switch to lower the bed.
STATE OF CHARGE METER
The state of charge meter is on the dash panel beside the key switch. It indicates the amount of usable power in the
batteries, with F indicating a full charge on the battery pack and E indicating low charge. The yellow light indicates the
batteries must be charged immediately.
HORN
The horn switch is the red switch on the dash panel, press the top of the switch to activate the horn.
CUP HOLDER
The vehicle has a center cup holder that will accommodate two beverage containers. Another cup holder is located to
the left of the steering column and will accommodate a larger beverage container.
12V OUTLET (If Equipped)
Excessive use of accessories that are connected to the outlet can drain the battery.
17
FEATURES AND CONTROLS
A 12V auxiliary outlet is located on the center console.
With the key switch in the ON position, the auxiliary outlet supplies power for any lights and accessories that have a
12V plug.
USB PORT (If Equipped)
A USB port is located on the center console.
With the key switch in the ON position, the USB port supplies power to electronic devices via a USB cable.
HOUR METER (If Equipped)
The hour meter is located under the driver’s seat and indicates the vehicle’s total hours of operation.
STEERING WHEEL
The steering wheel allows the driver to
control the direction of travel.
Turn Signal Switch
Steering Wheel
Cup Holder
TURN SIGNAL/HORN (If
Equipped)
The turn signal switch also controls the
hazard lights and horn. The switch is
located on the steering column.
Horn Switch
Hazard Switch
Accelerator Pedal
Run/Tow Switch
Before you
attempt to tow the vehicle, turn the key switch to N and move the Run/Tow switch to the
TOW position. Failure to do so will damage the controller or the motor.
The Run/Tow switch is located under the seat on the passenger side of the vehicle.
BRAKE PEDALS
The brake pedal is a combination brake and parking brake pedal.
18
FEATURES AND CONTROLS
Brake Pedal
The brake pedal is the bottom left pedal on the floorboard.
Press the brake pedal to slow the speed or bring the
vehicle to a complete stop.
Parking Brake Pedal
(2-Wheel)
Parking Brake Pedal
The parking brake is the upper pedal. It allows the
operator to lock the brake when the vehicle is parked
to prevent accidental movement.
To engage the parking brake, press the upper pedal
until it locks into place.
NOTICE: Vehicles equipped with the 4-wheel
mechanical brake option have a parking
brake with multiple engagement levels.
Each additional level that the latch is
engaged increases the amount of braking applied.
Parking Brake
Pedal (4-Wheel)
Brake Pedal
Accelerator
Pedal
H
TC
I LA
MULT
Quickly press and release the lower pedal to disengage the parking brake.
NOTICE: If the key switch is in the ON position
and the parking brake is engaged, the
brake will release when you press the
accelerator pedal and can cause the vehicle to move suddenly. This is a feature to make sure the
vehicle is not driven with the parking brake engaged. Pressing the accelerator pedal is not the recommended method to release the parking brake.
ACCELERATOR PEDAL
The accelerator pedal is the right pedal on the floorboard. It activates the motor and controls the acceleration of the
vehicle.
Apply slow and steady pressure to the accelerator pedal to increase vehicle speed.
DIRECTION SELECTOR
The direction selector is the key switch. The switch allows the
operator to select F (forward), N (neutral), or R (reverse).
When you leave the vehicle turn the key switch to OFF, set the
parking brake and remove the key.
Direction
Selector
SEAT BOTTOM
The bench seat is designed for two occupants.
Lift up on either hip restraint to pivot the seat bottom forward to
access the components underneath. Pivot and lift up on the seat
to completely remove it from the vehicle.
GLOVE BOX / STORAGE COMPARTMENTS
The glove box provides storage space for small items. Glove boxes may be equipped with optional shelf and/or glove
box door.
19
FEATURES AND CONTROLS
TRUCK BED
To prevent injury and property damage, follow all warnings, procedures, and weight capacities described on the label in the
truck bed as well as the ones in this owner’s manual. See
HAULING CARGO on page 28 and DUMPING THE TRUCK
BED on page 29.
The tailgate can be opened for loading and unloading cargo.
Open the tailgate latches and lower the tailgate.
Lift the tailgate and secure the latches to close the tailgate.
Max weight on tailgate is 100 lbs. (45 kg).
Truck Bed
Release Lever
Canopy Top and Windshield
The canopy top does not provide protection from rollover or falling objects.
The windshield does not provide protection from tree branches or moving objects.
To prevent damage to the vehicle, do not hold on to the canopy top struts.
The canopy top and windshield provide some protection from the elements, but do not keep the operator and passenger dry in heavy rain.
This vehicle is not equipped with seat belts, and the canopy top is not designed to provide rollover protection. In addition, the canopy top does not protect against falling objects, nor does the windshield protect against flying objects and
tree limbs.
20
OPERATION
OPERATION
SAFETY
Failure to operate the vehicle correctly can result in a collision, loss of control, accident
or rollover, and cause serious injury or death. Follow all operation procedures in this
section of the manual. Read and comply with all safety warnings in the safety section of
this owner’s manual.
BEFORE INITIAL USE
To prepare your new vehicle for operation, complete the following:
• Remove the protective plastic from the seats.
• Check for possible leaks that may have developed during shipment of the vehicle.
Explosive hydrogen gas is created during the charge cycle of the batteries. Good ventilation is necessary to remove gas from enclosed spaces. The air must change every 12
minutes.
Never charge a vehicle near flammable materials, open flame or sparks. Never charge a
vehicle near gas water heaters and furnaces.
• Charge the batteries.
• Perform the following pre-ride inspection.
PRE-RIDE INSPECTION
Inspect and verify that the vehicle is in safe operating condition before each use to decrease the risk of an accident.
Check the items in the table to help ensure safe and reliable operation.
Item
Check
Batteries
Check charge level.
Brake system/pedal travel
Check for proper operation.
Parking brake
Make sure vehicle does not roll when the parking brake is engaged.
Front suspension
Inspect. Lubricate if necessary. Check for loose or missing hardware.
Rear suspension
Inspect. Lubricate if necessary. Check for loose or missing hardware.
Steering
Check for smooth and free operation.
Tires
Check condition and pressure.
Wheel hardware
Check for loose or missing hardware.
Frame hardware
Check for loose or missing hardware.
Fluid leakage
Inspect shocks, differential, and vehicle for leaks.
Page
43
39
Switches
Check operation.
Reverse warning alarm
Check operation.
Headlights
Check operation.
41
Brake light / taillights
Check operation.
41
21
OPERATION
ENVIRONMENTAL AWARENESS
When driving the vehicle, be careful of potential environmental hazards like steep
slopes, rocks, tree branches, etc. that could cause an incident that could result in vehicle
damage, personal injury or death.
There is a risk of fire when the vehicle is operated near combustible material.
Always be respectful of the environment.
Respect all wildlife and their habitat.
Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles.
Make sure you are permitted by property owners to operate the vehicle on their property.
If operating your vehicle on private property, obtain permission from the owner prior to entering their property.
CHARGER
Both off board and on board chargers should be operated in accordance with the charger manufacturer’s instructions.
If the off board charger option has been selected, be sure to retain and follow the operation instructions supplied with
the charger. Always place the off board charger outside the vehicle before and during the charging cycle. Never
charge batteries in a hazardous environment.
Risk of electric shock. Connect the charger power cord to an outlet that is correctly
installed and connected to an electrical ground according to all codes and regulations. A
grounded outlet is necessary to decrease the risk of electric shock – do not use ground
adapters or replace the plug. Do not touch parts of output connector or battery terminals
that do not have insulation.
Disconnect the DC plug before you make or break the connections to a battery that is
charging. Do not open or disassemble the charger. Do not operate the charger if the AC
cord is damaged. Make sure qualified personnel does all repair work to the charger.
Refer to APPENDIX A for the charger manufacturer User’s Guide for operating instructions, maintenance instructions
and troubleshooting instructions.
On Board Charger
To prevent over-heating that can cause damage to the charger and possible fire, keep
the air fins clear. Install portable chargers on a platform above the ground to allow maximum air flow around and below the charger.
The power AC cord has a plug with a ground post. Do not remove, cut or bend the
ground post.
The on board charger is located under the driver side seat. It is wired directly to the batteries. Before charging the batteries, park the vehicle in a well ventilated area, engage the parking brake, turn key switch to OFF and remove key.
Plug charger cord into a dedicated 15 amp AC outlet to activate the charger. When the charging cycle is complete,
unplug the charging cord and correctly store the cord.
22
OPERATION
PERFORMANCE FEATURES
NOTICE: The vehicle operates when the Run/Tow switch is in the RUN position.
The speed of the motor is sensed and controlled by the controller.
Speed Control
The speed control system is not an alternative for the brake. Use the brake to control
speed and decrease the risk of injury.
Speed control system vehicles are equipped with a regenerative motor control system.
Example: If all of the following events occur:
• the vehicle is being driven down a slope
• the vehicle attempts to exceed the specified top speed with the accelerator pedal pressed or released
the regenerative brake will limit the speed of the vehicle to the specified top speed but the warning beeper will not
activate. When the regenerative braking system is activated by this sequence of occurrences, the motor generates
power which is returned to the batteries.
If the operator tries to override the electronic brake feature by moving the direction selector or key switch to another
position the vehicle will brake quickly until it reaches approximately 2 mph (3 kph).
Pedal-Up Braking
Pedal-up braking is regenerative braking that occurs when the accelerator pedal is released while the vehicle is moving.
Example: If all of the following events occur:
• the vehicle is being driven down a slope
• the accelerator pedal is released
the pedal-up braking decreases speed until the vehicle stops or the accelerator pedal is applied. The warning beeper
will not activate. When pedal-up braking is activated by this sequence of occurrences, the motor generates power
which is returned to the batteries.
Walk-Away Feature
Walk-Away limits vehicle movement without driver input, decreases vehicle speed to 2 mph (3 kph) and activates an
alarm.
Example: If all of the following events occur:
• the vehicle is stopped for more than 2 seconds
• the accelerator pedal is released for more than one second
• the vehicle starts to move at more than 2 mph (3 kph)
the Walk-Away feature limits speed to approximately 2 mph (3 kph) and the warning beeper activates. When the
accelerator pedal is pressed, the Walk-Away feature and warning beeper stops and normal vehicle operation continues.
Anti-Roll Back Feature
Anti-Roll Back, like Walk-Away, limits reverse motion of the vehicle down a slope to less than 2 mph (3 kph). See
Walk-Away Feature for more information. An alarm will not be activated should the anti-roll back feature engage.
Anti-Stall Feature
Anti-Stall protection prevents motor damage if the vehicle is stalled against an object or on a hill.
Example: If all of the following events occur:
• the system senses that the accelerator pedal is pressed (power applied to motor)
• the motor is stopped long enough that additional time can cause damage to the motor
the Anti-Stall feature will interrupt power to the motor. To restore power to the motor, flip the RUN/TOW switch to
“TOW” position and then return the switch to “RUN” position.
High Pedal Disable Feature
High Pedal Disable prevents acceleration of the vehicle if the direction selector is changed or the key is turned on
while the accelerator is pressed.
23
OPERATION
Diagnostic Mode Feature
Diagnostic mode helps with troubleshooting.
With some electrical system failures, the Diagnostic Mode feature defaults to a mode that allows the vehicle to operate at a decreased speed.
This feature allows you to return the vehicle to the storage facility and identify the problem.
The technician can put the controller in diagnostic mode and the controller identifies the failure mode.
STARTING AND STOPPING THE VEHICLE
Unintentional roll-back of the vehicle could cause severe personal injury or vehicle damage. To reduce the possibility of vehicle roll-back, keep the brake fully pressed until the
motor has started.
All vehicles have an interlock system that disables the controller and prevents operation of the vehicle while the charger is connected. Remove the charger plug from the receptacle and correctly store the cord before you move the vehicle.
1. Sit in the driver’s seat.
2. Press and hold the brake pedal.
3. Insert the key and turn to the desired direction.
NOTICE: When the direction selector is moved to the reverse position, a warning alarm will activate to indicate that the vehicle is ready to run in reverse.
4.
5.
6.
Slowly press the accelerator pedal to start the motor.
When the accelerator pedal is released, the motor decreases the speed of the vehicle. To stop the vehicle more
quickly, press the brake pedal.
Engage the parking brake, turn the key to OFF and remove the key from the switch before exiting the vehicle.
Starting on a Hill
Unintentional roll-back of the vehicle could cause severe personal injury or vehicle damage. To reduce the possibility of vehicle roll-back, keep the brake fully pressed until the
motor has started.
Do not use the accelerator and motor to hold the vehicle on a hill. Doing so for more than
3 - 4 seconds will cause permanent damage to motor.
To decrease the risk of permanent damage to the drive system, do not allow roll-back
when you start the vehicle on a hill.
1.
2.
3.
Press the brake pedal with your left foot when releasing the parking brake. Keep pressure on the pedal to prevent the vehicle from rolling back.
Press the accelerator pedal with your right foot as you release the brake pedal.
Press the accelerator pedal with gradual and steady pressure until the vehicle reaches the desired speed.
ACCELERATING
Accidental movement of the accelerator pedal can cause the vehicle to suddenly move
and cause severe injury or death.
Make sure the key is in the OFF position and the parking brake is engaged any time the
vehicle is parked.
1.
2.
3.
Release the parking brake.
Move the key switch to the desired direction.
Apply slow, steady pressure to the accelerator pedal to increase vehicle speed. When you release the accelerator pedal, the motor decreases the speed of the vehicle.
NOTICE: If the key switch is in the F, N, or R position and the parking brake is engaged, the brake releases
when you press the accelerator pedal and can cause the vehicle to move suddenly. This is a feature
to make sure the vehicle is not driven with the parking brake engaged. Pressing the accelerator
pedal is not the recommended method to release the parking brake.
24
OPERATION
BRAKING
When carrying cargo or towing a trailer, the weight of the load will increase the braking
distance required to slow or stop the vehicle. Not allowing for increased braking distance under load can cause an accident or injury.
1.
Release the accelerator pedal completely.
NOTICE: Pressing the top section of the brake pedal engages the parking brake.
2.
3.
Press the brake pedal to slow vehicle speed or stop the vehicle completely.
Practice slowing and stopping using the brake to become familiar with the controls.
Coasting
Do not allow the vehicle to coast at above recommended speeds. Control vehicle speed
with the brake.
The vehicle has a braking feature (pedal-up) that decreases the speed when the accelerator pedal is released. The
feature continues to decrease the speed until the vehicle stops. Press the brake if you need to decrease speed or stop
the vehicle quickly.
DRIVING PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
Perform the pre-ride inspection. See page 21.
Sit in the driver’s seat.
Check surroundings and determine the path of travel.
Press the brake pedal and release the parking brake.
Insert the key and turn to the desired direction.
With both hands on the steering wheel, release the brake and immediately start to apply gradual and steady
pressure to the accelerator pedal.
Practice maneuvering the vehicle using the accelerator and brake pedals. Drive slowly and cautiously until you
are comfortable with the controls.
Do not drive with a passenger until you have at least two hours of experience driving this vehicle.
Coasting
Vehicle speed can increase quickly when driving downhill. Allowing the vehicle to coast
downhill at high speeds can cause loss of control and result in severe injury or death.
Limit your vehicle speed by pressing the brake.
Do not allow the vehicle to coast at speeds that are above the maximum recommended speed. Apply constant brake
pressure when descending a hill to control the speed of the vehicle.
DRIVING WITH A PASSENGER
• All passengers must be at least 59 in. (150 cm) tall. Passengers must be able to sit with their back against the seat,
both feet on the floor.
• Do not allow more than one passenger in the vehicle.
• Do not allow a passenger to ride anywhere on the vehicle except the passenger seat.
• Travel at speeds appropriate for your skills, your passenger’s skills and the operating conditions. Avoid unexpected
or aggressive maneuvers that could cause discomfort or injury to the passenger.
• Handling characteristics can change with the added weight of a passenger. Allow more time and distance for braking.
25
OPERATION
SLIPPERY SURFACES
Skidding or sliding can cause loss of control. Skidding or sliding can cause rollover if
tires have lost traction, then regain traction suddenly. When operating on slippery surfaces, travel at reduced speed to help maintain control of the vehicle.
When operating in conditions such as ice, water, muddy trails, loose gravel or freezing temperatures, follow these
guidelines:
• Do not operate on excessively rough, slippery or loose terrain.
• Slow down before entering potentially slippery areas.
• Maintain a high level of alertness, carefully evaluate the path of travel and avoid quick, sharp turns.
• Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
DRIVING UPHILL
When driving up a hill, follow these guidelines:
• Drive straight up the hill.
• Avoid excessively steep hills.
• Keep both feet on the floor or pedals.
• Check the terrain before driving up a hill. Do not try to climb hills that have excessively slippery or loose surfaces.
• Drive at a steady rate of acceleration and speed.
• Do not drive over the crest of a hill at high speed. An obstacle, sharp drop, or another person or vehicle could be on
the other side of the hill.
• Do not attempt to drive up a hill that is beyond your skill level.
TRAVERSING HILLSIDES
Traversing a hillside is not recommended. Improper procedure can cause loss of control or a rollover. Avoid crossing
the side of a hill unless absolutely necessary. If traversing a hillside is unavoidable, check the terrain and determine if
it can be accomplished safely. Do not proceed if the terrain is beyond the vehicle or driver’s ability.
If traversing a hillside is unavoidable, follow these guidelines:
• Drive slowly.
• Use extreme caution.
• Avoid crossing the side of a hill that has a slippery surface.
• Avoid crossing the side of a steep hill.
• When traversing a hillside that has soft terrain, it may be necessary to steer slightly uphill to keep the vehicle traveling in a straight line.
• If you feel that you are losing control of the vehicle, steer downhill if possible to regain control.
DRIVING DOWNHILL
When carrying cargo or towing a trailer, the weight of the load will increase the braking
distance required to slow or stop the vehicle. Not allowing for increased braking distance under load can cause an accident or injury.
When driving down a hill, follow these guidelines:
• Avoid excessively steep hills.
• Check the terrain carefully before descending any hill.
• Never drive down hills with excessively slippery or loose surfaces.
• Drive slowly.
26
OPERATION
• Drive straight down the hill. Avoid descending the hill at an angle that could cause the vehicle to lean sharply to one
side.
• Apply light and constant pressure to the brakes to maintain slow speed and control of the vehicle.
STALLING ON A HILL
A rollover can result from stalling or rolling backward while climbing a hill. Drive uphill at a constant speed.
If your vehicle completely stalls while climbing a hill:
1. Apply the brakes.
2. Verify that the area behind you is clear.
3. Put the direction selector in R (reverse).
4. Use steady brake pressure to control speed, and allow the vehicle to slowly roll straight downhill.
If your vehicle begins to roll downhill:
1. Do not press the accelerator.
2. Apply the brakes gradually until the vehicle fully stops.
3. Verify that the area behind you is clear.
4. Put the direction selector in R (reverse).
5. Use steady brake pressure to control speed, and allow the vehicle to slowly roll straight downhill.
DRIVING IN REVERSE
When driving in reverse, follow these guidelines:
• Check that the area behind the vehicle is clear of obstacles and people.
• Check left and right fields of vision before driving in reverse.
• Do not back down a steep hill.
• Drive in reverse slowly.
• Press the brakes lightly for stopping.
• Accelerate slow and steady.
• Avoid turning at sharp angles.
PARKING THE VEHICLE
NOTICE: When parking the vehicle inside a garage or structure, the space must be well ventilated. Park the
vehicle away from any source of flame or sparks, including any appliance with a pilot light.
Park the vehicle on a flat surface if possible. If parking on an incline is unavoidable, be sure to
chock the wheels as shown in the following illustration to keep the vehicle from rolling.
1.
2.
3.
4.
5.
Press the brake to stop the vehicle.
Engage the parking brake.
Turn the key switch to OFF.
Remove the key from the ignition to prevent unauthorized use.
If parking on an incline, chock the wheels on the downhill end as shown in the following illustration.
27
OPERATION
HAULING CARGO
Hauling cargo incorrectly can alter vehicle handling characteristics and cause loss of
control, brake instability, and possibly lead to serious injury or death.
Never exceed the maximum weight capacity of the vehicle. The total load (operator, passenger, accessories, cargo and load on hitch) must never exceed the maximum weight
capacity of the vehicle. See the chart in Maximum Cargo Load / Maximum Weight Capacity on page 28.
Position the load as far forward, and as low as possible in the truck bed.
Secure all loads before operating. Unsecured loads can shift and create unstable operating conditions.
Operating the vehicle with passengers in the truck bed can
result in severe injury or death. Never allow a passenger to
ride in the truck bed. Passengers must always ride seated in
the passenger seat.
Drive slowly and carefully.
Operate only with stable and safely arranged loads. When
handling loads that are impossible to center in the truck bed,
make sure the load is secured as tightly as possible and operate the vehicle with extra caution.
Reduce speed and allow greater distances for braking when
hauling cargo.
Heavy loads affect braking and handling characteristics. Use
extra caution when applying brakes with a heavily loaded
vehicle. Avoid terrain or situations that may require reverse
downhill travel.
Use extra caution when operating with loads that extend over
the truck bed sides. Stability and maneuverability can be
affected and increase risk of rollover.
This vehicle is designed to carry or tow specific capacities. Read and comply with the load distribution warnings on the
warning label affixed to the bed. The total load (operator, passenger, accessories, cargo and load on hitch) must never
exceed the maximum weight capacity of the vehicle.
Maximum Cargo Load / Maximum Weight Capacity
Maximum Cargo Load Capacity
325 lbs. (147.4 kg)
Maximum Vehicle Weight Capacity
725 lbs. (328 kg)
• Do not exceed the maximum cargo load capacity.
• Do not exceed the maximum vehicle weight capacity (includes weight of operator, passenger, cargo and accessories).
28
OPERATION
TRUCK BED OPERATION
Failure to follow these instructions can cause personal injury, damage the vehicle or
cause the vehicle to tip over. Be aware of the load when you operate the vehicle. Read,
understand and follow the warning label attached to the front of the truck bed.
Do not allow passengers to ride in the truck bed. A sudden move or stop can cause
severe injury or death to passengers in the truck bed.
Before operating, make sure the area behind the vehicle is clear.
Load Bed (P/N 74821G08)
Located on the truck bed.
MAX
325 lb.
147 kg
PP
MAX
5 in.
12 cm
MAX
100 lb.
45 kg
MAX
14o / 25%
74821G08
A truck bed warning label is attached to the inside front of the truck bed. Understand and comply with the warnings on
this label for safe operation of the vehicle.
• See the truck bed warning label for maximum load.
• Position the load in the truck bed as far forward as possible.
• Make sure the center of gravity of the load is within the height limit shown on label.
• Secure the load to the truck bed.
• Be aware of the load when you operate the vehicle.
• Do not let passengers to ride in the truck bed. Do not drive the vehicle with the truck bed lifted or with the tailgate
unsupported.
DUMPING THE TRUCK BED
Manual Bed Release Lever
The truck bed can be tilted by lifting up the release lever on either side of the vehicle. See DUMPING THE TRUCK
BED on page 29.
Electric Lift (If Equipped)
If the vehicle has an electric lift, the switch is located on the center dash console. Press and hold the top part of the
switch to raise the truck bed. Press the bottom part of the switch to lower the truck bed.
29
OPERATION
If the bulk of the cargo weight is at the rear of the bed, the bed may unexpectedly dump
when the release lever is pulled and cause serious injury to anyone close by. Never pull
the release lever unless the load is positioned evenly or located at the front of the truck
bed.
Never leave the truck bed in the upright position after emptying the cargo. The bed can
unexpectedly close and cause serious injury. Never drive the vehicle with the truck bed
in the raised position.
1.
2.
3.
4.
5.
6.
7.
8.
Select a level location to dump the truck bed load. Do not attempt to dump or unload the vehicle if it is on an
incline.
Apply the brakes and engage the parking brake.
Put the direction selector in forward (F).
Exit the vehicle.
Make sure the cargo is positioned evenly or located at the
front of the truck bed.
Release the tailgate latches.
Truck Bed
Manual bed lift vehicles:
Release Lever
a. Stand clear and pull the release handle. Lift up on the
truck bed to dump the cargo.
b. When the truck bed is empty, lower the bed back into
place.
c. Push down to latch the bed.
Electric lift vehicles:
a. Press the top of the switch to activate the electric lift
and raise the bed.
b. Press the bottom of the switch to lower the bed back
into place.
Close and latch the tailgate.
TOWING
NOTICE: Vehicles must be equipped with a rear hitch to tow a load.
Attach a trailer to the tow hitch only. Attaching the trailer at any other location can cause
loss of vehicle control.
Do not attach baskets or extensions to the hitch receiver. These types of items change
the performance qualities of the vehicle and cause dangerous handling characteristics,
possible rollover or vehicle damage.
When towing a load, follow these guidelines:
• Do not tow more than the recommended towing weight for the vehicle. See the following table and the Hauler
800Ex - VEHICLE SPECIFICATIONS on page 1.
VEHICLE LOADING
Occupant Capacity
MAX. WEIGHT
400 lbs. (181.4 kg)
Cargo Capacity
325 lbs.(147.4 kg)
Vehicle Rated Capacity = Occupant + Cargo
725 lbs. (328.8 kg)
VEHICLE WEIGHT
Curb Weight (includes batteries
1,122 lbs. (508 kg)
Gross Weight = Curb Weight + Rated Capacity
1,847 lbs. (838 kg)
VEHICLE TOWING (0% - 20% GRADE)
30
Drawbar Pull
475 lb (215 kg)
Maximum Trailer Tongue Weight
150 lbs. (68 kg)
Maximum Gross Trailer Weight
900 lbs. (408.2 kg)
Maximum Vehicle Combined Towing Weight = Curb Weight +
Occupant Capacity + Trailer Weight
2,422 lbs. (1098 kg)
OPERATION
• The total capacity of the vehicle, operator, passenger, load bed contents and accessories must be reduced to compensate for the trailer tongue load.
• The range of motion of the trailer is limited by the ball and hitch. Do not tow a trailer on rough terrain.
• Drive slowly and carefully.
• Towing a load increases braking distances required for slowing or stopping the vehicle.
• Do not attach baskets or extensions to the hitch receiver.
• Avoid parking on an incline.
• Do not operate on a grade exceeding 25%.
• Always secure the cargo
31
OPERATION
32
SPECIFICATIONS
SPECIFICATIONS
VEHICLE SPECIFICATIONS
• Solid State continuously variable AC speed
controller
• Full torque, reduced speed reverse
• Key Switch direction selector
(Forward-Neutral-Reverse)
• Inductive throttle sensor
• Anti-roll back, walkway braking and alarm
• Diagnostic indicator
• Anti-stall motor protection
• Factory programmable to application
• Regenerative ‘Pedal Down’ and/or ‘Pedal
Up’ braking
Battery Charger: 600 Watt, 48 VDC, 120/230 VAC 50/60 Hz. Underwriters Laboratories (U.L.) Listed, (C.S.A. Certified)
Motor: 48 Volt AC Induction, solid copper windings. Non vented 4.4 hp (3.3 kW) Continuous.
Drive Train: Direct motor shaft connected to transaxle pinion shaft
Electrical System: 48 Volt AC, six, 8 volt deep cycle storage batteries (110 minutes minimum 160 amp-hour @ 20 hour
discharge rate)
Transaxle: Differential with helical gears
Brakes: Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with selfcompensating system.
Cargo Bed: Roto-molded cross-linked polyethylene. Lifts for access to powertrain. Removable hinged multi-position tailgate with cam over latch mechanism.
Item
Overall Length
Specification
103.5 in. (263 cm)
Overall Width
48.5 in. (123 cm)
Overall Height (No Canopy)
50.6 in (128.5 cm) (Top of steering wheel)
Overall Height (With Canopy)
71.6 in (182 cm)
Wheel Base
65.5 in. (166 cm)
Front Wheel Track
37 in. (94 cm)
Rear Wheel Track
38 in. (97 cm)
Ground Clearance (at Differential)
5.5 in. (13.97 cm)
Cargo Box Width (inside)
40.75 in. (103.5 cm)
Cargo Box Length (inside)
28 in. (71 cm)
Cargo Box Depth (inside)
12 in. (30 cm)
Cargo Box Capacity
7.9 cu ft. (0.22 cu m)
Cargo Box material
Roto-molded polyethylene
Power Source
48 Volts DC
Motor Type
AC Induction
Horsepower (kW)
4.4 hp (3.3 kW) Continuous
Electrical System
48 Volt
Batteries (Qty, Type)
Six, 8 Volt Deep Cycle
Key or Pedal Start
Pedal Start
Battery Charger
600 Watt, 48VDC
Speed Controller
235 Amp AC
Drive Train
Motor Shaft Direct Drive
Transaxle
Differential with helical gears
33
SPECIFICATIONS
Gear Selection
Key Switch Forward-Neutral-Reverse
Rear Axle Ratio
17:1
Seating Capacity
2 Person
Dry Weight
756 lb (343 kg) (Without Batteries)
Curb Weight
1122 lb (509 kg)
Bed Load Capacity
325 lb (147.4 kg)
Vehicle Load Capacity
725 lb (328 kg)
Outside Clearance Circle
18.9 ft. (5.76 m)
Speed (Level Ground)
16.5 mph ± 0.5 mph (26.6 kph ± 0.8 kph)
Towing Capacity
900 lbs. (408 kg) max load
Steering
Self-compensating rack and pinion
Front Suspension
Leaf springs with hydraulic shock absorbers
Rear Suspension
Leaf springs with hydraulic shock absorbers
Service Brake
Rear wheel mechanical self-adjusting drum
Parking Brake
Self-compensating, single point engagement
Front and Rear Tires
K500 20 X 8 - 10 (6 Ply Rated)
Frame
Welded steel, DuraShieldTM powder coat
Front Body and Finish
Injection Molded TPO
Standard Color
Patriot Pearl Blue
Noise
Sound pressure; continued A-weighted ≤ 70 db(A)
Vibration, WBV
Highest RMS value of weighted acceleration is less than 1.92 m/s²
The uncertainty of measurement is 0.17 m/s²
Vibration, HAV
Highest RMS value of weighted acceleration is less than 2.5 m/s²
Measurement methods were applied per the ISO 2631 and ISO 5349
standards under conditions of typical vehicle surfaces.
Some items shown may be optional equipment
34
MAINTENANCE
MAINTENANCE
MAINTENANCE SAFETY
To prevent serious injury or death, follow the procedures and comply with the safety
information in this manual while performing vehicle service or maintenance.
Use the tools shown in the tool list and wear the specified safety equipment when performing vehicle service or maintenance.
Remove all jewelry before you service the vehicle.
Do not allow loose clothing or hair to contact the moving parts.
Do not touch hot objects.
Before you disconnect or connect a battery or any other wires, move the run/tow switch
to the TOW position and the key switch to the OFF position.
Disconnect the negative battery terminal before you service the vehicle to prevent accidental operation.
The drive wheels must be lifted and supported on jack stands before you do any service
to the powertrain when the motor is in operation.
Chock the wheels and support the vehicle with jack stands. NEVER get under a vehicle
that is supported by a jack. Lift the vehicle according to the manufacturers instructions.
When you service the vehicle, always wear eye protection. Be careful
when working around batteries, using solvents or compressed air.
Use insulated tools within the battery area to prevent sparks or battery
explosion.
The electrolyte in a battery is an acid solution which can cause burns to the skin and
eyes. Completely clean all electrolyte spills that contact the body and eyes with clear
water. Contact a physician immediately.
Neutralize electrolyte spills with a solution of 2 teaspoons (10 ml) sodium bicarbonate
(baking soda) mixed in 1 quart (1 liter) of water. Clean with water.
Maintain constant awareness that some components are heavy, spring loaded, corrosive, explosive, can cause high amperage or get extremely hot. Battery acid and hydrogen gas can cause bodily injury. Keep your hands, face, feet and body away from any
area that can expose them to injury if an unexpected situation occurs.
After performing maintenance, test the vehicle in a safe area that is free from vehicle and
person traffic.
NOTICE: To decrease the risk of damage to the controller or motor, move the run/tow switch to the TOW position before you tow the vehicle.
After you connect a battery or any other wires, wait a minimum of 30 seconds before you move the
switch to the RUN position.
To decrease the risk of engine damage, do not operate the vehicle at full throttle for more than 5
seconds if the drive wheels are lifted off the ground.
SCHEDULED MAINTENANCE
Consistent inspection, adjustment and lubrication of some components are necessary to maintain your vehicle so that
it remains in safe and reliable condition. Refer to the SCHEDULED MAINTENANCE CHART on page 36 for detailed
requirements.
Inspect, clean, lubricate, adjust and replace parts as necessary. Use OEM or equivalent replacement parts.
Record the maintenance items performed along with details in the MAINTENANCE LOG beginning on page 53.
NOTICE: Service and adjustments are important for safe and reliable vehicle operation. If not familiar with
safe service and adjustment procedures, have your dealer perform the operations.
35
MAINTENANCE
Severe Use Conditions
Vehicles subjected to heavy or severe use must be inspected and serviced more frequently than those of normal use
patterns.The following conditions are considered severe use:
• frequent or prolonged use in a dusty environment
• prolonged low speed operation
• prolonged heavy load operation
• frequent use in mud, water or sand
• short trips in cold weather
SCHEDULED MAINTENANCE CHART
Perform all services at the maintenance interval reached first.
S – Indicates operations that need to be performed on vehicles subjected to severe use.
Interval
Item
(perform at interval
that comes first)
Hours
S
S
36
Remarks
Page
Calendar
Overall vehicle condition
Pre-ride
Inspect.
Batteries
Pre-ride
Check state of charge, battery condition, loose terminals, corrosion, hold down and hardware.
Steering
Pre-ride
Check for smooth and free operation.
Front suspension
Pre-ride
Inspect. Check for leaks and loose or missing hardware.
Rear suspension
Pre-ride
Inspect. Check for leaks and loose or missing hardware.
Tires
Pre-ride
Check condition and pressure.
12
Wheel lug nuts
Pre-ride
Check for loose or missing.
40
Accelerator
Pre-ride
Check for smooth operation.
43
43
Brake system
Pre-ride
Check for smooth operation and acceptable stopping distance.
Frame hardware
Pre-ride
Check for loose or missing.
Headlights and taillights
Pre-ride
Check operation. Replace bulbs as needed.
Reverse warning alarm
Pre-ride
Check operation.
Switches
Pre-ride
Check operation.
Fluid leakages
Pre-ride
Inspect entire vehicle for leaks
Brake shoes
10
Monthly
Inspect. Replace as needed.
Batteries
20
Monthly
Clean.
Batteries
20
Monthly
Check electrolyte level; fill with water (distilled only) if required.
Charger receptacle
20
Monthly
Clean connections.
Parking brake
20
Monthly
Conduct brake performance test; adjust as necessary.
Check for correct hold on an incline.
Accelerator
20
Monthly
Check for smooth operation.
Wiring
20
Monthly
Inspect for loose connections, broken or missing insulation.
Steering
20
Monthly
Check for excess play, loose or missing hardware.
Tie rods
20
Monthly
Check for excess play, bent rods, loose or missing hardware.
Front suspension
20
Monthly
Inspect strut for leaks. Check hubs and kingpins, for excessive
play, worn bushings, loose or missing hardware.
Rear axle
20
Monthly
Check for leakage; add oil as required.
Brakes
20
Monthly
Front wheel alignment
60
3 Months
Check for smooth operation and acceptable stopping distance.
Check for unusual tire wear.
41
43
MAINTENANCE
Interval
(perform at interval
that comes first)
Item
Page
Hours
Calendar
60
3 Months
Check for shock oil leakage, worn bushings, loose or missing
hardware.
General lubrication
50
3 Months
Lubricate all fittings, pivots, cables, etc. where required.
Rear axle
500
5 years
Replace fluid.
20,000
Amp
Hours
5 years
Add anti-seize compound (approx. 1 tbsp.)
Rear Suspension
S
Remarks
Motor coupling
37
RECOMMENDED LUBRICANTS AND FLUIDS
Check and lubricate all components at the intervals shown in the SCHEDULED MAINTENANCE CHART beginning
on page 36.
Item
Capacity
Rear axle oil
25 oz. (0.7 L)
Mobil 424
Part Number 603967
Rear axle oil
2.0 oz (59 mL)
Friction Modifier E-Z-GO
Part Number 611242
Universal joint grease or equivalent
Do not exceed 3 pumps
of grease in each fitting.
Grease fittings
Lubricants/Fluids
Notes
REPLACEMENT OF MAINTENANCE ITEMS
These items or their equivalents can be purchased through your dealer, directly from or any other qualified source.
Item
Part Number
58V, 10A Mini Fuse
636455G22
32V, 15A Mini Fuse
636455G13
32V, 20A Mini Fuse
636455G14
32V, 10A Mini Fuse
636455G12
Throttle Resistor
LED Headlight Assembly
Headlight Bulb
Turn Signal Bulb
Taillight Bulb
662004
651411G03
619100
619102
21759G1
37
MAINTENANCE
LIFTING THE VEHICLE
Read and comply with all of the following warnings and lifting procedures to prevent the
possibility of the vehicle falling and causing serious injury or death.
For some maintenance procedures, it is necessary to lift the vehicle. Comply with the following warnings and follow
the lifting procedure to ensure the safety of you, your vehicle and surroundings.
The vehicle must be on a firm and level surface for lifting.
Remain constantly aware that the vehicle is not stable during the lifting process.
Place the jack and jack stands only in the areas indicated in the following illustration.
Do not get under a vehicle until it’s stability on the jack stands is verified; never get
under a vehicle while it is on a jack only.
Put wheel chocks in front and behind all wheels that are not being lifted.
Do not allow anyone to remain or get on the vehicle at any time during the lifting process
or when the vehicle is lifted.
When performing any service to the drivetrain, lift drive wheels off the ground.
Tools
• jack
• jack stands (4)
• wheel chocks
Lifting Front
1.
2.
3.
4.
5.
6.
7.
Chock the rear wheels to keep the vehicle from rolling backward.
Put a jack under the center of the front axle.
Raise the vehicle with the jack.
Install a jack stand under the front frame cross member as
shown.
Lower the vehicle until it rests on the jack stands.
Remove the jack.
Confirm that the vehicle is stable on the jack stands before
proceeding with any service.
Center of
Front Axle
Lifting Rear
1.
2.
3.
4.
5.
6.
7.
Chock the front wheels to keep the vehicle from rolling forward.
Put a jack under the center of the rear frame cross member.
Raise the vehicle with the jack.
Install a jack stand under each end of the rear axle.
Lower the vehicle until it rests on the jack stands.
Remove the jack.
Confirm that the vehicle is stable on the jack stands before
proceeding with any service.
Lowering Vehicle
1.
2.
3.
4.
38
Outer Ends
of Rear Axle
Flat Portion
of Frame
Make sure chocks are still in place on any wheels that
remain on the ground.
Put the jack in the same location that was used to raise the
vehicle.
Raise the vehicle enough to remove the jack stands. Remove the jack stands from underneath the vehicle.
Slowly lower the vehicle to the ground and remove the jack.
MAINTENANCE
VEHICLE CLEANING AND CARE
Keeping your vehicle clean is not only beneficial to its appearance, but can also help extend the life of various components.
Washing the Vehicle
NOTICE: Do not use a pressure washer to wash your vehicle. High water pressure can damage components.
Some products, including insect repellents and chemicals, will damage plastic surfaces. Do not
allow these types of products to contact the vehicle.
• Do not use a pressure washer to clean the vehicle.
• Use an automotive type cleaner or mild soap to wash the vehicle. Harsh cleaners can scratch the finish.
• Use clean or new cloths and pads for washing. Reused cloths and pads can contain dirt particles that will scratch
the finish.
• Inspect all grease fittings for dirt intrusion or lack of grease after washing. Apply grease as required to maintain
proper function.
• Use a sponge or soft brush and a soap/water solution to clean the vinyl seats. Rinse with clean water.
• Use an automotive type wash cloth to wash the body of the vehicle. To prevent the soap from drying on the vehicle,
rinse with clean water frequently.
• Clean the windshield with water and a clean cloth. Remove small scratches with a plastic polish.
• Clean the bottom of the vehicle where mud or dirt can collect. Loosen any packed sediment to help with removal.
Be careful not to damage the paint.
• Dry the vehicle with a chamois before the water dries to prevent water spots.
Polishing the Vehicle
• Do not use medium to heavy duty compounds on the finish. Use wax that is for clear coat automotive finishes only.
Do not apply wax or polish to matte finish surfaces.
• Use clean or new cloths and pads for polishing. Old or reused cloths and pads can contain dirt particles that will
scratch the finish.
TIRES
Follow the tire maintenance procedures as instructed in this manual and on the labels on the vehicle.
Always use approved size and type of replacement tires. See VEHICLE SPECIFICATIONS on page 33.
Worn, improperly inflated, improper sized, or incorrectly installed tires will affect vehicle
handling and could cause an accident resulting in severe injury or death.
Inflate all tires to the same pressure. Operating with unequal or incorrect pressure can
adversely affect steering and handling and could cause an accident resulting in severe
injury or death.
To decrease the risk of tire explosion, do not exceed the tire inflation rating on the tire
sidewall. Make sure the tires are properly inflated at all times of operation. See Tire Pressure on page 40.
To decrease the risk of tire explosion, inflate small amounts of air into the tire at intervals to allow the beads to seat properly. Because of the low volume of the small tires,
over inflation can occur in seconds. Never exceed the tire inflation pressure rating on
the tire sidewall when seating a bead. Protect your face and eyes when you remove a
valve core.
When you remove the wheels, use only sockets made for impact wrenches to decrease
the risk of injury by a broken socket.
Do not use tires with low rated pressure. Do not use tires that have a recommended tire
inflation pressure less than the tire inflation pressure recommended in the owner’s
guide.
Do not over inflate the tires. Excess pressure can cause the tire to separate from the
wheel or cause a tire explosion.
39
MAINTENANCE
Tire Pressure
Maintaining correct tire inflation pressure is essential for safe vehicle operation. You can vary the inflation pressure,
within the recommended range to suit the condition of the terrain.
TIRE PRESSURE RANGE
TERRAIN CONDITIONS
RECOMMENDATION
hard surfaces or pavement
Inflate to higher pressure within the range; never exceed
maximum pressure indicated.
soft terrain or turf
Inflate to lower pressure within the range to reduce
potential damage to the terrain or turf.
18 - 22 psi (124 - 152 kPa)
Tire Repair
Tools
• lug wrench, 3/4”
• impact wrench
• impact socket, 3/4”
• torque wrench, ft.lbs.
NOTICE: Tire plug tools and plugs are available at automotive outlets. The tire does not have to be removed
from the wheel to install the tire plug.
Use a tire plug to repair small holes in the tread part of the tire. For large holes or holes/cuts in the tire sidewall, the tire
must be replaced.
1. Remove the wheel from the vehicle. See Wheel Removal on page 40.
2. Locate the leak in the tire.
a. If the tire is very low or flat, fully inflate the tire.
b. Brush soapy water over the surface of the tire. Air bubbles will be visible where the air is leaking from the
tire.
c. Mark the hole with chalk.
3. Install the plug according to the manufacturer’s instructions.
4. Install the wheel on the vehicle. See Wheel Installation on page 41.
5. Fully inflate the tire. See Tire Pressure on page 40.
Tire Replacement
Tire replacement requires a tire mounting machine and must be done by a qualified tire center or your TSV dealer.
WHEELS
Worn, improperly inflated, improper sized, or incorrectly installed tires will affect vehicle
handling and could cause an accident resulting in severe injury or death.
To decrease the risk of component damage, do not tighten the lug nuts to more than the
torque specified below.
Check lug nuts for tightness at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 36.
Wheel Removal
Valve Stem Cap
Tools
• lug wrench, 3/4”
• impact wrench
1.
2.
3.
• impact socket, 3/4”
• torque wrench, ft.lbs.
Lift the vehicle. See LIFTING THE VEHICLE on page 38.
Remove the lug nuts.
Remove the tire from the vehicle.
Tire style may vary.
40
MAINTENANCE
Wheel Installation
Lug Nut Torque
65 - 85 ft.lbs. (88 - 115 Nm)
NOTICE: To decrease the risk of component damage, do not tighten the lug nuts
to more than the specified torque.
Lug Nut Tightening Pattern
Always install lug nuts using a cross sequence pattern to ensure even
seating of the wheel against the hub.
1.
2.
3.
Install the wheel on the hub with lug nuts. Make sure the valve stem is to the outside.
Finger tighten the lug nuts.
Using the tightening pattern shown at right, tighten the lug nuts to 65 - 85 ft.lbs. (88
- 115 Nm). Tighten in increments of 20 ft. lbs. (27 Nm).
LIGHTS
• Clean the lights frequently to maximize visibility.
• Replace burned out bulbs promptly.
Do not operate this vehicle at night or in low light if any bulbs are burned out. Poor lighting reduces visibility that could cause an accident resulting in severe injury or death.
NOTICE: Replacement bulbs are available from a local distributor, an authorized branch or the service parts
department.
Halogen Headlight Bulb Replacement
Light components can get hot if they have been in operation. Allow the lights to cool
before servicing to prevent burns to the skin.
NOTICE: Do not touch a halogen bulb with bare fingers.
Oil from skin leaves a residue that causes a hot
spot and will diminish the life of the bulb.
1.
2.
3.
4.
Inside of Cowl
Disconnect the headlight harness from the headlight.
Rotate the bulb 1/4-turn to remove the headlight from the
housing.
Insert and rotate the new bulb to lock into place.
Connect the harness to the bulb.
LED Headlight Assembly Replacement
1.
2.
3.
4.
Disconnect the headlight harness from the headlight.
Remove the screws securing the headlight assembly to
the headlight bezel.
Remove the headlight assembly and install the new one
with screws.
Connect the harness to the headlight assembly.
Taillight
1.
2.
3.
Roll the rubber bezel from around the edge of the taillight and remove the
lens.
Install the new bulb.
Replace the lens.
Screw
Headlight Housing
or
LED Headlight Assembly
Roll rubber bezel
away from body.
Taillight
Brake Light
41
MAINTENANCE
FUSE REPLACEMENT
58V, 10A Mini Fuse
NOTICE: Have the vehicle inspected by your
dealer if fuses continue to blow after
they have been replaced.
1.
2.
3.
4.
32V, 20A Mini Fuse
Lift the seat bottom to access the PDM.
Open the PDM to access the fuses.
Remove the old fuse and replace with a new fuse
of the same type and size.
Fuses are available from a local Distributor, an
authorized Branch or the Service Parts Department.
CONTROLLER SYSTEM TEST
At monthly intervals, test the controller by allowing the
vehicle to roll down an incline with the accelerator
pedal released. Braking force should be felt at approximately 2 mph (3 kph) indicating that the system is
functioning. If vehicle speed continues to rise, apply
the brake and have vehicle inspected by a trained
mechanic.
32V, 10A Mini Fuse
32V, 15A Mini Fuse
REAR AXLE
The only maintenance necessary for the first five years is the inspection of the rear axle for lubricant leakage. Unless
leakage is visible, the lubricant needs to be replaced after five years. Refer to the Service and Repair Manual for the
fluid replacement procedure.
Change the axle oil at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 36.
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 lubricant starts to seep from
the hole. Install the check/fill plug. In the event that the lubricant is to be replaced, the oil pan must be removed or the
oil siphoned through the check/fill hole.
LUBRICATION
Do not use more than three pumps of
grease in a grease fitting at any one time.
Excess grease can cause grease seals to
fail, or allow grease into areas that could damage components.
King Pin
Putting more than three pumps of grease in a grease fitting
could damage grease seals and cause premature bearing failure.
Lubricate components at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 36.
Rack Ball Joint
View from Underside of Vehicle
42
MAINTENANCE
BRAKES
Always inspect the pedal travel before you operate a vehicle to confirm some brake function is present.
All driving brake tests must be done in a safe location with regard for the safety of all
personnel.
NOTICE: Over time, a subtle loss of performance may take place; therefore, it is important to establish the
standard with a new vehicle.
Test and service the brake system at the intervals indicated in the SCHEDULED MAINTENANCE CHART on
page 36.
Periodic Brake Test
The Periodic Brake Test must be performed initially and regularly as an evaluation of your vehicle’s brake system performance. It is a method of identifying subtle loss of braking
performance over time.
Establish the ‘acceptable stopping distance’ when your vehicle
is new and the brakes are at their peak of performance. As
your vehicle is used, a subtle loss of braking performance may
be detected, so it is important to establish the standard with a
new vehicle.
Actual stopping distances are influenced by weather conditions, terrain, road surface condition, vehicle weight and
speed. No specific braking distance can be reliably specified,
so it is important to establish a base to test with.
The test is conducted by engaging the park brake instead of
the brake pedal to eliminate different pedal pressures, to
include affects of linkage mis-adjustment and provide a more
accurate test.
NOTICE: You must have enough space to accelerate to
maximum speed before engaging the parking
brake. Use a marker to indicate the predetermined line to engage the parking brake that you
will use for the performance test.
1.
2.
3.
4.
5.
On a dry, level, clean, paved surface, accelerate the vehicle to maximum speed.
Engage the parking brake at the predetermined and
marked line.
Mark the line where the vehicle comes to a complete
stop.
If the vehicle stops in a significantly greater distance than
the established distance in future tests, or pulls to one
side, it should be tested again.
If the vehicle fails the second test, discontinue use until it
can be inspected and determined safe for operation by a
qualified mechanic.
NOTICE: If the vehicle is equipped with 4-wheel mechanical brakes and pulls to one side, the brake mechanisms must be adjusted. Refer to the repair and
service manual for brake adjustment procedure.
Dry, Level, Clean, Paved Surface
Accelerate To
Maximum Speed
Engage
Parking
Brake
Established
Acceptable
Stopping
Distance
Line or Marker
Line or Marker
Unacceptable
distance required
to stop the
vehicle.
BATTERY
A battery is described 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 in this vehicle are lead acid.
43
MAINTENANCE
A battery does not store electricity, but it can produce electricity as the result of a chemical reaction which releases
stored chemical energy in the form of electrical energy. The chemical reaction occurs 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 adjust for temperature differences.
An older battery can perform adequately except that its capacity is decreased. Capacity describes the time that a battery can continue to supply its design amperes from a full charge.
A battery has a maximum life. Good maintenance maximizes the available life and decreases the conditions that can
reduce the life of the battery.
Use insulated wrenches to prevent direct contact of a wrench with the battery terminals.
Direct contact of a bare wrench with battery terminals can cause an explosion resulting
in severe injury or death.
To prevent the risk of battery explosion, keep all flammable materials, open flames or
sparks away from the batteries.
Hydrogen gas is made as batteries are charged. Do not charge batteries without good
ventilation. A 4% concentration of hydrogen gas is explosive.
Make sure that the key switch is in the OFF position and all electrical accessories are off
before you start to work on the vehicle.
Be careful when you use aerosol containers near the battery terminals. Use a container
with insulation to prevent an explosion.
Turn off all accessories before disconnecting from the battery terminal.
Always wear a safety shield or approved safety goggles when you add water or charge
the batteries.
The electrolyte in a battery is an acid solution which can cause burns to the skin and
eyes. Completely clean all electrolyte spills that contact the body and eyes with clear
water. Contact a physician immediately.
Do not tilt the batteries during removal or installation. An electrolyte spill can cause
burns and damage.
Neutralize electrolyte spills with a solution of 2 teaspoons (10 ml) sodium bicarbonate
(baking soda) mixed in 1 quart (1 liter) of water. Clean with water.
Use safe procedures to move the batteries. Always lift the battery with a commercially
available battery lifting device.
NOTICE: If you fill the batteries with electrolyte above the maximum level, you can cause an electrolyte spill
during the charge cycle. An electrolyte spill can cause damage to the vehicle and storage facility.
BATTERY DISPOSAL
Return used batteries to the manufacturer or lead smelter for recycling purposes. For neutralized spills, put residue in
acid-resistant containers with absorbent material such as sand. Dispose in accordance with state and federal regulations for acid and lead compounds. Contact authorized environmental agencies for information about disposal.
BATTERY CLEANING
Clean the batteries according to the Periodic Service Schedule.
Always wear eye protection when cleaning the battery.
To prevent battery damage, make sure you correctly install all battery caps.
NOTICE: To decrease the risk of damage to vehicle or floor, neutralize acid before you spray the battery with
water.
44
MAINTENANCE
To decrease the risk of damage to electrical components surrounding the battery while cleaning, do
not use a pressure washer.
When you clean the battery cases and terminals, do not use a water hose without neutralizing any
acid deposits first. The water hose moves the acid from the top of the batteries to another area of
the vehicle or storage facility, where it can cause damage. After spraying the batteries, a conductive
residue remains on the batteries and contribute to the discharge of the batteries
1.
2.
3.
4.
5.
Remove corrosion with a wire brush.
Wash top and sides of the batteries with a solution of:
• 2 tsp. (10 ml) baking soda
• 1 quart (1 liter) water
Wash all metal components near the battery.
Allow the solution to set a minimum of three minutes. Use a soft bristle brush or cloth to clean the top of each battery to remove residue that can cause the discharge of the battery.
Rinse with tap water and dry with shop towels.
After the batteries are clean and dry, coat the terminals with a commercially available battery terminal spray.
BATTERY CHARGING AND MAINTENANCE
Hydrogen gas is produced as batteries are charged. Charge batteries only in well-ventilated areas.
Tools
• insulated wrench, 9/16”
• hydrometer
• battery protective spray
• battery carrier
• battery maintenance kit (P/N 25587-G01)
At Each Charging Cycle
• Before you charge the batteries, inspect the plug of the battery charger and vehicle receptacle housing for dirt
or other particles.
• Charge the batteries after each use.
Monthly
•
•
•
•
Inspect all wires for wear, loose connections, corrosion or damage of insulation.
Make sure that the electrolyte level is correct and add clean water as required.
Clean the batteries and wire connections.
Apply battery protectorate to the battery terminals.
Electrolyte Level and Water
Maintaining correct electrolyte level is important because any part of
the plates open to air will be damaged.
Do not overfill batteries with water. Too much water pushes the electrolyte from the battery by release of gas and a decrease in volume of
the electrolyte.
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.
NOTICE: DO NOT overfill batteries. The charge cycle will expel
electrolyte and cause component damage in overfilled
batteries.
As a battery is being charged, it produces hydrogen gas. Most of this
gassing occurs at the end of the charge cycle. Hydrogen gas is lighter
than air. Water and sulphuric acid droplets will be carried out of the
battery vents by the hydrogen gas, however, this loss is minimum. If
the electrolyte level is high, the electrolyte will block the vent tube and
the gas will push it out the vent tube and battery cap. The water will dry
but the sulphuric acid will stay and damage the vehicle components
Correct Electrolyte Level
Vent Cap
Gas Vent
Expansion
Space
1/4” - 3/8”
(6 - 10 mm)
Vent
1/2”
(13 mm)
Plates
Electrolyte level should be at least
45
MAINTENANCE
and surface below the vehicle. Sulphuric acid loss will weaken the amount of acid within the electrolyte and decrease
the life of the battery.
Over the life of the battery, a large amount of water is used. The water added to the batteries must be clean and without contamination. Unclean water decreases the life of the battery by reducing the chemical reaction. Use distilled
water or filtered water only. Test water that is not distilled water and filter if needed. Refer to the following water purity
table for requirements.
IMPURITY
PARTS PER MILLION
color
clear
suspended
trace
total solids
100
calcium and magnesium oxides
40
iron
5
ammonia
8
organic and volatile matter
50
nitrites
5
nitrates
10
chloride
5
The electrolyte in a battery is an acid solution which can cause severe burns to the skin
and eyes. Clean all electrolyte spills to the body and eyes with clear water. Contact a
physician immediately.
Always wear a safety shield or approved
safety goggles when you add water or charge
the batteries.
Watering device similar to the type included in
the Battery Maintenance Kit
Hand held watering devices available at automotive parts
stores, or automatic watering devices like the one included in
the Battery Maintenance Kit (P/N 25587-G01) can be used with
an approved water supply. These watering devices are accurate,
easy to use and allow for fast fill. They also keep the correct
electrolyte level within the battery cells.
NOTICE: The watering device should only be used if the
electrolyte level is less than 1/2” (13 mm) above
top of plates.
Valve consistently
fills to a predetermined
level
To clean an electrolyte spill, use a solution of:
• 2 tsp. (10 ml) baking soda
• 1 quart (1 liter) water
Electrolyte
Level
Wash all metal components near the battery.
Pure Water
Single Battery Cell
BATTERY REPLACEMENT
Before you disconnect or connect a battery or any other wires, move the run/tow switch
to TOW position.
After you connect a battery or any other wires, wait a minimum of 30 seconds before you
move the run/tow switch to the RUN position.
1.
2.
46
Remove the battery hold downs and cables.
Remove the batteries with a commercially available lifting device.
MAINTENANCE
3.
4.
5.
If the batteries have been cleaned and the acid in the battery rack area is neutralized as recommended, no corrosion to the battery racks or surrounding area should be present. If any corrosion remains, remove it with a putty
knife and a wire brush. Wash the area with a sodium bicarbonate (baking soda) and water solution, and then dry
before primer and corrosion resistant paint is applied.
Put the batteries in the battery racks and tighten the hold downs to 45 - 55 in. lbs. (5 - 6 Nm) torque. The hold
downs must be tight enough to prevent movement of the battery, but not tight enough to cause distortion of the
battery cases.
Inspect all wires and terminals. Clean corrosion from the battery terminals or the wire terminals with a sodium
bicarbonate (baking soda) and water solution and soft brush if needed.
Be careful when using aerosol containers near battery terminals. Always use a container
with insulation to prevent an explosion.
6.
7.
8.
Connect the battery wires as shown.
Tighten the battery post hardware to 90 - 100 in.
lbs. (6 -8 Nm) torque. Do not over-tighten the terminal stud nut, this will cause a “mushroom” effect on
the battery post which will prevent the terminal nut
from being correctly tightened.
Protect the battery terminals and battery wire terminals with a commercially available coating.
Front of Vehicle
+
+
-
+
-
BL +
BL -
+
-
-
-
+
+
BATTERY STORAGE
NOTICE: Disconnect the battery charger, controller
and other electronic devices for extended storage. All connected electronic components cause the
discharge of batteries.
Put the run/tow switch in the TOW position for extended storage of the vehicle to prevent draining
of the batteries.
During storage, the batteries must not be allowed to discharge.
47
MAINTENANCE
In high temperatures the chemical reaction is fast, while
OF OC
low temperatures cause the chemical reaction to slow. A
vehicle that is stored at 90° F (32° C) will lose .002 of spe+15 -9
cific gravity each day. If a completely charged battery has a E
L +5 -15
specific gravity of 1.275, and the battery is not used, it will
E
become partially discharged. When it reaches 1.240, which C
-5 -21
it will do in less than 20 days, it must be charged again. If a T
battery stays in a discharged state, sulfating occurs on and R
-15
-26
O
within the plates. This condition is not reversible and will
L
cause permanent damage to the battery. To prevent damY -25 -32
age, the battery must be charged again. Use a hydrometer T
to find the specific gravity and the state of charge of a batE -35 -37
tery.
T -45 -43
In winter conditions, the battery must be completely
E
M
charged to prevent the risk of freezing. A completely
P -55 -48
charged battery will not freeze in temperatures above -75°
E
F (-60° C). Although the chemical reaction is decreased in
R -65 -54
cold temperatures, the battery must be stored completely
A
charged, and disconnected from circuits that can discharge T -75 -60
U
the battery. The controller must be disconnected from the
-85 -65
batteries by setting the run/tow switch to the TOW position. R
E
-95 -71
For portable chargers, disconnect the charger plug from the
1.140
1.180
1.220
1.260
1.300
1.100
vehicle receptacle.
For on-board chargers, disconnect the charging harness
1.120
1.160
1.200
1.240
1.280
from the batteries.
The batteries must be cleaned and all deposits neutralized
SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT
and removed from the battery case to prevent self discharge.
The batteries must be tested or charged again at 30 day minimum intervals.
BATTERY CHARGING
The battery charger is designed to completely charge the battery set. If the batteries are severely deep cycled, some
automatic battery chargers contain an electronic module that will not activate and the battery charger will not operate.
Automatic chargers determine the correct length of charge to the battery set and turns off when the batteries are
charged. Always refer to the instructions of the charger used.
Do not overfill batteries. The charge cycle will expel electrolyte and cause component
damage.
Before charging, observe the following:
• The electrolyte level in all cells must be at the recommended level and above the plates.
• Charging must occur in an area with good ventilation to remove hydrogen gas that is produced during the charge
cycle. A minimum of five air replacements for each hour is recommended.
• The charger connector components must be in good condition and free from dirt and particles.
• The charger connector must be completely plugged into the vehicle receptacle.
• The charger connector and cord set must be protected from damage. The charger connector and cord set must be
used in an area where it is not possible for personnel to run over or trip over the cord set.
• The charger automatically turns off during the connect and disconnect cycle, so there is no electrical arc generated
at the DC plug and receptacle contacts.
AC Voltage
The battery charger output is directly related to the input voltage. If the vehicle receives an incomplete charge in a normally adequate time period, low AC voltage can be the cause. Consult an electrician if necessary.
BATTERY FAULT DIAGNOSIS
Fault diagnosis is done for two reasons:
• A battery that performs poorly and is outside of the manufacturers specification must be identified to replace it
within the terms of the manufacturer’s warranty. Different manufacturers have different requirements. Refer the battery manufacturer or the manufacturer’s representative for specified requirements.
48
MAINTENANCE
• Find the reason a vehicle does not perform adequately. Performance problems can cause a vehicle to run slowly or
can not operate for the time needed.
A new battery must mature before it develops its maximum capacity. Maturing can take 100 or more charge and discharge cycles. After the maturing phase, the older a battery gets, the lower the capacity. The only method to find the
capacity of a battery is a load test with a discharge machine. Refer to the discharge machine manufacturer instructions.
A hydrometer is used to identify a poorly performing battery in a set with a low specific gravity. When the particular cell
or cells that are the problem are identified, the battery can be removed and replaced. The battery can not be restored.
The individual battery should be replaced with a good battery of the same brand, type and approximate age.Hydrometer
To prevent battery explosion, never insert
a metal thermometer into a battery. Use a
hydrometer with a built in thermometer
that is designed for testing batteries.
A hydrometer (P/N 50900-G1) 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.
Specific gravity is the measurement of a liquid that is compared to a
baseline. The baseline is water which is assigned a base number of
1.000. The concentration of sulfuric acid to water in a new golf car
battery is 1.280 which means that the electrolyte weighs 1.280
times the weight of the same volume of water. A fully charged battery will test at 1.275 - 1.280 while a discharged battery will read in
the 1.140 range.
Cylinder
Thermometer
Bulb
Float
Add to Float
Reading
Subtract
from Float
Reading
Weight
NOTICE: Do not perform a hydrometer test on a battery that
has just been watered. The battery must go through at least one charge and discharge cycle in
order to permit the water to adequately mix with the electrolyte.
The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80° F (27° C). High
quality hydrometers are equipped with an internal thermometer that will measure the temperature of the electrolyte
and will include a conversion scale to correct the float reading. It is important to recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been operated.
49
MAINTENANCE
Using A Hydrometer
1.
2.
3.
4.
5.
Draw electrolyte into the hydrometer and release it 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.
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.
Hold the hydrometer in a vertical position at eye level
and note the reading where the electrolyte meets the
scale on the float.
Add or subtract four points (.004) to the reading for
every 10° F (6° C) the electrolyte temperature is above
or below 80° F (27° C). Adjust the reading to conform
with the electrolyte temperature, e.g., if the reading indicates a specific gravity of 1.250 and the electrolyte temperature is 90° F (32° C), add four points (.004) to the
1.250 which gives a corrected reading of 1.254. Similarly if the temperature is 70° F (21° C), subtract four
points (.004) from the 1.250 to give a corrected reading
of 1.246.
Test each cell and note the readings (corrected to 80° F
or 27° C). A variation of fifty points between any two cell
readings (example 1.250 - 1.200) indicates a problem
with the low reading cell(s).
As a battery ages the specific gravity of the electrolyte will
decrease at full charge. This is not a reason to replace the
battery providing all cells are within fifty points of each other.
Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should be recharged
and the test repeated. If the results indicate a weak cell, the
battery or batteries should be removed and replaced with a
good battery of the same brand, type and approximate age.
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
+.032
+.030
+.028
+.026
+.024
+.022
+.020
+.018
+.016
+.014
+.012
+.010
+.008
+.006
+.004
+.002
0
-.002
-.004
-.006
-.008
-.010
-.012
-.014
-.016
-.018
-.020
-.022
-.024
-.026
-.028
EXAMPLE #1
ELECTROLYTE TEMPERATURE
Above 80 °F (27 °C)
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
Hydrometer Temperature Correction
50
MAINTENANCE
TRANSPORTING THE VEHICLE
Do not ride or allow other people on a vehicle being transported on a trailer or being
towed with another vehicle.
Towing the Vehicle
Do not try to tow the vehicle with ropes, chains or any device.
This vehicle is not designed to be towed.
Hauling the Vehicle
Loose cargo or vehicle components can fly off when the vehicle is being transported.
Secure or remove all cargo. Inspect the vehicle for loose components prior to transport.
Do not allow any people on a vehicle being transported on a trailer.
Remove the windshield before you transport a vehicle on a trailer.
Maximum speed with canopy top installed is 50 mph (80 kph).
• If the vehicle is being hauled on a trailer or truck at highway speeds, the canopy top must be removed.
• If the vehicle is being hauled on a trailer or truck below highway speeds, check that canopy top hardware is tight
and there are no cracks in the canopy top at the mounting points.
• The rated capacity of the hauling trailer or truck must be more than the weight of the vehicle and load plus 1000 lbs.
(454 kg). See GENERAL SPECIFICATIONS for the weight of the vehicle.
1.
2.
3.
4.
5.
Drive the vehicle onto the trailer or truck.
Engage the parking brake.
Turn the key switch to the OFF position. To prevent loss of the key, remove it from the ignition switch.
Make sure the seats are secured.
Secure the vehicle to the trailer or truck with tie downs, straps or ropes.
51
MAINTENANCE
52
MAINTENANCE LOG
MAINTENANCE LOG
Record periodic maintenance in the following maintenance log.
DATE
HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
53
MAINTENANCE LOG
DATE
54
HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
MAINTENANCE LOG
DATE
HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
55
MAINTENANCE LOG
DATE
56
HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
APPENDIX A
APPENDIX A
DELTA-Q USER’S GUIDE
A
APPENDIX A
8VHU·V*XLGH
SAVE THESE IMPORTANT
SAFETY INSTRUCTIONS
INFORMATIONS IMPORTANTES
DE SÉCURITÉ
Ce manuel contient des instructions importantes
concernant la sécurité et le fonctionnement.
This manual contains important safety and operating
instructions – read before using charger.
Warning:
Use charger only with an algorithm selected that is
appropriate to the specific battery type. 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, ie. maximum
charge rates and if cell caps should be removed while charging.
Attention:
Utiliser le chargeur seulement avec un algorithme
approprié au type spécifique de batterie. D´autres types de batteries
pourraient éclater et causer des blessures ou dommages. Les
batteries peuvent produire des gaz explosifs en service normal. Ne
jamais fumer près de la batterie et éviter toute étincelle ou flamme
nue à proximité des batteries. Fournissez une ventilation adéquate
du chargement. Ne jamais charger une batterie gelée. Prendre
connaissance des mesures de précaution spécifiées par le fabricant
de la batterie, p. ex., vérifier s´il faut enlever les bouchons des
cellules lors du chargement, et les taux de chargement.
Danger:
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. Do not touch uninsulated portion of output
connector or uninsulated battery terminals. Disconnect the AC
supply before making or breaking the connections to the battery. Do
not open or disassemble charger. Do not operate this 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 the manufacturer, or qualified personnel. This
appliance is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a
person responsible for their safety. Children should be supervised
to ensure that they do not play with the appliance.
Danger:
Risque de chocs électriques. Ne pas toucher les
parties non isolées du connecteur de sortie ou les bornes non
isolées de la batterie. Toujours connecter le chargeur à une prise de
courant mise à la terre. Déconnectez la source AC avant de faire ou
défaire les connections à la batterie en chargement. Ne pas utiliser
le chargeur si le cordon d’alimentation AC est endommagé ou si le
chargeur est abîmé suite à une chute ou autre indicent. Ne pas
ouvrir ni désassembler le chargeur – référer toute réparation aux
personnes qualifiées. Cet appareil n’est pas destiné à un usage par
des personnes (dont les enfants) avec des facultés motrices,
sensorielles ou mentales réduites, ou ayant une expérience et des
connaissances insuffisantes, à moins qu’elles sont sous la
supervision ou reçoivent les instructions sur l’utilisation de
l’appareil d’un répondant garant de leur sécurité. Les enfants
devraient être surveillés afin qu’il ne jouent en aucun temps avec
l’appareil.
Operating InstructionsCAUTION: Charger enclosure may be hot during charging. Use hand protection if handling the charger while charging.
1. Extension cords must be 3-wire cord no longer than 30m(100’) at 10AWG or 7.5m(25’) at 16AWG per UL guidelines.
2. Only connect ONE QuiQ charger to a single 15A circuit or the circuit may become overloaded.
3. Charger 10-LED Display:
LED Colour
Indication (following “Power-On Self Test”)
Ammeter
(Amber)
Solid:
Displays approximate scale of current output during
bulk phase.
Flashing:
High internal charger temperature. Output reduced.
Also displays algorithm #1-6 for 11 seconds if no
battery is connected.
Solid:
Bulk charge phase complete, 80% charged. In
Absorption phase.
Flashing:
With no battery connected, indicates algorithm #
selected by number of flashes.
100% Charge
(Green)
Solid:
Charging complete. Charger in Maintenance Mode.
Flashing:
Absorption phase complete. In Finish phase
AC On
(Amber)
Solid:
AC Power good
Flashing:
Low AC Voltage, check voltage and extension cord
length (see above for guidelines).
Fault
(Red)
Flashing:
Charger error. Reset charger power and refer to
Troubleshooting Instructions below.
80% Charge
(Amber)
B
APPENDIX A
4. Optional Charger Single-LED Display (internal or external)
LED Colour
Indication (following “Power-On Self Test”)
Green
Solid:
Charging complete. Charger in Maintenance Mode.
Flashing:
Short: <80% Charge.
Long: >80% Charge.
When battery is not connected: Algorithm Number
display.
Amber
Flashing:
Reduced Power Mode: Low AC Voltage or High
internal charger temperature.
Red
Flashing:
Charger error. Reset charger power and refer to
Troubleshooting Instructions below.
Maintenance Instructions1. Do not expose charger to oil, dirt, mud or direct heavy water spray when cleaning vehicle.
2. If the detachable input power supply cord set is damaged, replace with a cord that is:
a.) for North America - UL or CSA listed/approved detachable cord, 3 conductor, 16AWG minimum, and rated SJT;
terminating in a grounding type IEC 60320 C14 plug rated 250V, 13A minimum; or
b.) for all other countries – a safety approved detachable cord, 3 conductor, 1.5mm² minimum, rated appropriately for
industrial use. The cord set must be terminated on one end with a grounding type input connector appropriate for
use in the country of destination and, on the other end, an output grounding type IEC 60320 C14 plug.
3. The enclosure of the charger has been tested successfully to EN60529, meeting IP66. The AC supply inlet is rated to
IP20, which is suitable for indoor use only. Keep all AC connections clean and dry.
Troubleshooting InstructionsIf a fault occurs, count the number of red flashes between pauses and refer to the table below:
Red Flashes
Cause
Solution
Battery High Voltage
Check battery size and condition and reset charger
(interrupt AC power for 15 seconds).
Battery Low Voltage
Check battery size and condition and reset charger
(interrupt AC power for 15 seconds).
Charge Timeout caused by
battery pack not reaching required
voltage. Charger output was
reduced due to high temperatures
Check connections.
Check Battery: battery could not
be trickle charged up to minimum
voltage
Check for shorted or damaged cells.
Over-Temperature: Charger shut
down due to high internal
temperature.
Ensure sufficient cooling air flow and reset charger
(interrupt AC power for 15 seconds).
Charger Internal Fault
Reset charger (interrupt AC power for 15 seconds).
Return to qualified service depot if fault persists.
Operate charger at a lower ambient temperature.
Note: This is a Class A product complying with United States Federal Communications Commission, Code of Federal Regulations; 47CFR part 15. In a domestic
environment this product may cause radio interference, in which case the user may be required to take adequate measures.
2009 © Delta-Q Technologies Corp. All rights reserved. PN: 710-0098 Rev 1
C
APPENDIX A
D
APPENDIX B
APPENDIX B
DECLARATION OF CONFORMITY
A
APPENDIX B
B
APPENDIX B
C
APPENDIX B
D
Normal use, age and wear on vehicle components can affect the safe operation and reliability of the vehicle. The recommended Inspection and maintenance procedures are crucial for safety, performance, reliability and maximum longevity of your vehicle.
A damaged vehicle, or a vehicle that is not functioning properly is dangerous and must not be operated until repairs
are made.
NOTICE: Read the following operational warnings before driving the vehicle:
Before you leave the vehicle, turn the key to the OFF position and remove the key from
the vehicle to prevent unauthorized use.
Drive the vehicle at appropriate speeds for the terrain and conditions. Be aware of environmental conditions that change the terrain and your ability to control the vehicle.
Do not drive on excessively steep hills. Evaluate the terrain before descending a hill.
Drive slowly and deliberately. Use the brake to limit speed and maintain control. Sudden
braking or turning can cause loss of vehicle control. Drive straight down the hill; do not
drive across the hill.
Operate in approved areas.
Keep feet, legs, hands and arms inside vehicle at all times.
Avoid driving on terrain that is too rough for your vehicle’s capabilities and your driving
skills.
Before you drive in the reverse direction, make sure the area behind the vehicle is clear.
Accelerate slowly and avoid making sharp turns.
Make sure the direction selector is in the correct position before you press the accelerator pedal.
Decrease speed before and during turns.
Bring the vehicle to a complete stop before you move the direction selector.
See GENERAL SPECIFICATIONS for the vehicle load and seat capacity.
NOTICE: Read the following maintenance information and warnings before servicing or repairing the vehicle:
Follow the procedures and comply with the safety information in this manual when performing vehicle service or maintenance.
Use the tools shown in the tool list and wear the specified safety equipment when performing vehicle service or maintenance.
Remove all jewelry before you service the vehicle.
Do not allow loose clothing or hair to contact the moving parts.
Do not touch hot objects.
The drive wheels must be lifted and supported on jack stands before you perform any
service to the powertrain while the motor is in operation.
When you service the vehicle, always wear eye protection. Be careful
when working around batteries, using solvents or compressed air.
Use insulated wrenches to decrease the risk of a short-circuit if a wrench
contacts the battery terminals. A short-circuit in a battery can cause an
explosion.
To prevent the risk of battery explosion, keep all flammable materials, open flames or
sparks away from the batteries.
Hydrogen gas is produced as batteries are charged. Charge batteries only in well-ventilated areas.
Maintain constant awareness that some components are heavy, spring loaded, corrosive, explosive, can cause high amperage or get extremely hot. Battery acid and hydrogen gas can cause bodily injury. Keep your hands, face, feet and body away from any
area that can expose them to injury if an unexpected situation occurs.
TEXTRON SPECIALIZED VEHICLES
1451 Marvin Griffin Road
Augusta, GA, USA 30909-3852
Phone: (706) 798-4311 Fax: (706) 796-4540
Customer Care Hotline: 1-800-774-3946
For Cushman Genuine Parts and Accessories: 1-800-438-3946
www.cushman.com
Service Parts Manuals and Repair Manuals are available from the manufacturer.
Copyrighted Material
This manual may not be reproduced in whole or in
part without the express permission of
TSV (Augusta), Technical Publications Department