Cushman Model Year 2018-2020 Stock Chaser Electric Manual

Owner’s Guide

ELECTRIC POWERED VEHICLE

628570-H

ISSUED OCTOBER 2012 REVISED JULY 2018

WELCOME

Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s

Guide. This guide contains the information that will assist you in maintaining this highly reliable vehicle. Some illustrations may show items that are optional for your vehicle. This guide covers the operation of several vehicles; therefore, some illustrations may not represent your vehicle. Physical differences in controls will be illustrated.

Most of the service procedures in this guide can be accomplished using common, automotive hand tools. Contact your service representative on servicing the vehicle in accordance with the Periodic Service Schedule.

Repair or replacement parts are available through your CUSHMAN retailer or Genuine CUSHMAN Service Parts.

The following information is needed when contacting CUSHMAN concerning service or parts for your vehicle:

Vehicle Model ____________________________________________________________________________

VIN or Serial Number ______________________________________________________________________

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.

FOREWORD

Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

OWNER’S GUIDE

ELECTRIC POWERED VEHICLE

STOCK CHASER

STARTING MODEL YEAR 2013

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron Inc. prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously.

The information contained in this manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.

E-Z-GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON-

SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

These are the original instructions as defined by 2006/42/EC.

TO CONTACT US

CUSHMAN

1451 Marvin Griffin Road.

Augusta, Georgia, 30906-3852

USA

E-mail: [email protected]

This vehicle has been designed and manufactured in the United States of America (USA).

North America:

The Standards and Specifications listed in the following text originate in the USA unless

Technical Assistance & Warranty PHONE: 1-800-774-3946 FAX: 1-800-448-8124 otherwise indicated.

Service Parts PHONE: 1-888-438-3946 FAX: 1-800-752-6175

International:

PHONE: 001-706-798-4311 FAX: 001-706-771-4609

Page i

FOREWORD


The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty.

Failure to properly maintain batteries may void the warranty. Refer to the battery manual for instructions on the proper maintenance and care of the batteries.

BATTERY PROLONGED STORAGE

All batteries will self-discharge over time. The rate of self-discharge varies depending on the ambient temperature, the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75°F (- 60°C).

For winter storage, the batteries must be clean, fully charged and disconnected from any source of electrical drain.

The battery charger may be left connected to the vehicle to maintain a full charge on the batteries, provided the charger is plugged into an active electrical source. If power to the electrical source is disconnected or interrupted the battery charger will continue to check the charge on the battery pack, this will draw power from the battery pack and eventually drain the batteries if power is not restored in a timely manner.

As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals.

Remember to check and maintain the proper fluid level in all battery cells during the storage period; proper fluid level is required for maximum battery performance.

BATTERY DISPOSAL

Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.

Page ii

TABLE OF CONTENTS


TITLE PAGE NO.

SAFETY ................................................................................................................ 1-1

GENERAL SPECIFICATIONS .............................................................................. 2-1

INTRODUCTION ................................................................................................... 3-1

OPERATING PROCEDURES ............................................................................... 4-1

MAINTENANCE .................................................................................................... 5-1

DELTA-Q CHARGER INSTRUCTIONS ........................................... APPENDIX A-1

DELCARATION OF CONFORMITY................................................. APPENDIX B-1

Page iii

TABLE OF CONTENTS


Notes:

Page iv

SAFETY


TITLE PAGE NO.

GENERAL............................................................................................................. 1-2

1

NOTICES, CAUTIONS, WARNINGS, AND DANGERS ........................................ 1-2

GENERAL OPERATION ....................................................................................... 1-4

MAINTENANCE ................................................................................................... 1-5

VENTILATION ...................................................................................................... 1-6

LABELS AND PICTOGRAMS .............................................................................. 1-7

1 - 1

SAFETY


1

GENERAL

For any questions on material contained in this manual, contact an authorized representative for clarification.

Read all labels located on the vehicle. Always replace any damaged or missing labels.

On steep hills it is possible for vehicles to coast at greater speeds. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. See GENERAL SPECIFI-

CATIONS. Limit speed by applying the service brake.

Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered abuse and will not be covered under warranty.

Use extra caution when towing the vehicle. Do not tow a single vehicle at speeds in excess of 12 mph (19 kph). If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.

NOTICES, CAUTIONS, WARNINGS, AND DANGERS

Throughout this guide NOTICE, CAUTION, WARNING, and DANGER will be used. Please observe these NOTICES,

CAUTIONS, WARNINGS, and DANGERS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.

NOTICE

Address practices not related to personal injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury or property damage, the following must be carefully observed:

Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-

Z-GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph. When an E-Z-GO-manufac-

1 - 2

SAFETY


tured vehicle is modified an any way by the Distributor, Dealer or customer to operate at or in excess of 20mph,

UNDER FEDERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the

State laws applicable in the places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.

E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.

The Company recommends that all E-Z-GO products sold as personal transportation vehicles BE OPERATED ONLY

BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE REQUIRE-

MENTS. This restriction is important to the SAFE USE AND OPERATION of the product.

All customers should adhere to this SAFETY RESTRICTION, in connection with the use of all E-Z-GO products, new and used, the Distributor or Dealer has reason to believe may be operated in personal transportation applications.

Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or through the Internet at the web site for the U.S. Department of Transportation - at Dockets and Regulation, then to Title

49 of the Code of Federal Regulations (Transportation).

All vehicles can be used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warning can take replace good common sense and prudent driving practices.

Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. E-Z-GO strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.

If you have any questions regarding this vehicle, contact your E-Z-GO/CUSHMAN dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.

E-Z-GO reserves the right to make design changes without obligation to make these changes on units previously sold.

The information contained in this manual is subject to change without notice.

E-Z-GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL OR CONSE-

QUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL.

This vehicle conforms to the current applicable standard(s) for safety and performance requirements.

These vehicles are designed and manufactured for off-road use. They DO NOT conform to Federal Motor Vehicle

Safety Standards of the United States of America (USA) and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances.

With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.

Never use the chassis or body as a ground connection.

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

1

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability, or increase the speed or extend the stopping distance beyond the factory specification. Such modifications can result in serious personal injury or death.

Do not make any such modifications or changes. E-Z-GO prohibits and disclaims responsibility for all such modifications or and alterations which would adversely affect the safety of the vehicle.

Some models may be certified as a Type E or Type EE vehicle from the factory, any modification to one of these vehicles may void the certification.

Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense.

Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).

1 - 3

SAFETY


1

GENERAL OPERATION

Read the following warnings before attempting to operate the vehicle.

To prevent personal injury or death, observe the following:

When vehicle is to be left unattended, turn key to OFF position AND REMOVE KEY.

Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain and traffic conditions. Consider environmental factors which affect the terrain and the ability to control the vehicle.

Avoid driving fast downhill. Sudden stops or change of direction may result in a loss of control. Use brake to control speed when traveling down an incline.

Use extra care and reduced speed when driving in poor conditions or on poor surfaces.

Stay in designated areas where provided and avoid steep slopes.

Keep feet, legs, hands, and arms inside vehicle at all times.

Avoid extremely rough terrain.

Check area behind the vehicle before operating in reverse.

Make sure the direction selector is in correct position before depressing the accelerator pedal.

Slow down before and during turns.

Always bring vehicle to a complete stop before shifting the direction selector.

See GENERAL SPECIFICATIONS for vehicle load and seating capacity.

NOTICE

Read the following text and warnings before attempting to service vehicle.

In any product, components may eventually fail to perform properly as the result of normal use, age, wear, or abuse.

It is impossible to anticipate all possible component failures or the manner in which each component may fail.

A vehicle requiring repair is no longer functioning as designed and therefore could be potentially hazardous. Therefore, use extreme care when working on any vehicle. When diagnosing, removing, or replacing any components that are not operating correctly, take time to consider the safety of yourself and others around you.

Some components are heavy, spring-loaded, highly corrosive, explosive, may produce high amperage, or reach high temperatures. Exposure to battery acid and hydrogen gas could result in serious bodily injury. Be careful to protect hands, face, feet, and body from injury.

Always use the appropriate tools listed in the tool list and wear approved safety equipment.

Before working on the vehicle, remove all jewelry.

Be sure no loose clothing or hair can contact moving parts.

Use care not to touch hot objects.

Wear eye protection when working on or around the vehicle. In particular, use care when working around batteries, using solvents or compressed air.

Hydrogen gas is formed when charging batteries. Do not charge batteries without adequate ventilation.

1 - 4

SAFETY


Do not permit open flame or anyone to smoke in an area that is being used for charging batteries.

Do not charge the vehicle batteries in a hazardous location or atmosphere. Refer to NFPA 505 for definitions of hazardous and non-hazardous locations.

ALWAYS:

• use the vehicle in a responsible manner and maintain the vehicle in safe operating condition

• read and observe all warnings and operation instruction labels affixed to the vehicle

• follow all safety rules established in the area where the vehicle is being operated

• leave the vehicle when there is a risk of lightning.

• reduce speed to compensate for poor terrain or conditions

• apply service brake to control speed on steep grades

• maintain adequate distance between vehicles

• reduce speed in wet areas

• use extreme caution when approaching sharp or blind turns

• use extreme caution when driving over loose terrain

• use extreme caution in areas where pedestrians are present

1

MAINTENANCE

ALWAYS:

• replace damaged or missing warning, caution or information labels

• maintain the vehicle in accordance with the manufacturer’s periodic service schedule

• ensure that repairs are performed by trained and qualified personnel

• follow the manufacturer’s maintenance procedures

• insulate any tools used within the battery area in order to prevent sparks or battery explosion

• check the polarity of each battery terminal and be sure to rewire the batteries correctly

• use specified replacement parts, NEVER use replacement parts of lesser quality

• use recommended tools

• determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle

• support the vehicle using wheel chocks and jack stands, NEVER get under a vehicle that is supported by a jack, lift the vehicle in accordance with the manufacturer’s instructions

• maintain the vehicle in an area away from exposed flame or persons who are smoking

• be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated

• test drive the vehicle after any repairs or maintenance in a safe area that is free of both vehicular and pedestrian traffic

• keep complete records of the maintenance history of the vehicle

1 - 5

SAFETY


1

VENTILATION

ALWAYS:

• charge the vehicle in a well-ventilated, non-hazardous area

• charge in an area free of flammable liquids and items

• charge a vehicle in an area that is free from flame or spark, pay particular attention to natural gas or propane water heaters and furnaces

• use a dedicated 15-amp circuit for each battery charger, DO NOT permit other appliances to be plugged into the receptacle when the charger is in operation

• operate the charger in accordance with manufacturers recommendations or applicable electrical code

1 - 6

SAFETY


LABELS AND PICTOGRAMS

DANGER

Read manual.

DO NOT stand on top step

628826

628826

Maximum ladder weight 250 pounds with counterbalance weight installed

WARNING

Read manual

Maximum ladder weight 180 pounds without counterbalance weight installed

250 lbs.

(113 kg)

628827

628827

628828

628828

WARNING

Read manual

Use ladder on flat surface only

DO NOT use ladder on slanted or sloped surfaces

1

OFF

ON

FORWARD

NEUTRAL

630044

REVERSE

629696

WARNING

Read manual

Tip over possibility

DO NOT operate under influence of drugs or alcohol

DO NOT drive accross slopes or ramps

Keep entire body inside vehicle

Type EE Vehicle

One label each side of vehicle

Load capacity total weight 992 pounds including operator

Secure load

Load center of gravity must not be more than

4.9” above deck

DO NOT ride on deck

DO NOT drive on highway

992 lbs. 450 kg MAX

4.9 in.

12.5 cm

MAX

F

Turn key to ON

Select Forward

Press accelerator to start movement

R

P

Use caution in inclement weather

N

35491-G01

35491G01

Turn key to

OFF Select

Neutral

Turn key to ON

Select Reverse

Warning indicator will sound

Press accelerator to start movement

1 - 7

SAFETY


1 Notes:

1 - 8

GENERAL SPECIFICATIONS


TITLE PAGE NO.

VEHICLE DIMENSIONS ............................................................................................. 2-2

VEHICLE RAMP, SIDE SLOPE and TURNING DIAMETER ...................................... 2- 3

VEHICLE SPECIFICATIONS ....................................................................................... 2-4

2

2 - 1

2



29 in.

(74 cm)

17.5 in.

(44 cm)

48 in. (122 cm)

22.5 in.

(57 cm)

21.5 in.

(55 cm)

98 in.

(248 cm)

78 in.

(198 cm)

48 in.

(122 cm)

5 in. (13 cm)

29.5 in.

(75 cm)

48.3 in.

(122.7 cm)

77.5 in.

(197 cm)

88.4 in.

(224.5 cm)

2 - 2

RECOMMENDED MAXIMUM RAMP GRADE

25% or 14° MAXIMUM

RECOMMENDED MAXIMUM SIDE TILT

25% or 14° MAXIMUM



2

TURNING CLEARANCE

DIAMETER

12.4 ft. (3.8 m)

INTERSECTING

AISLE CLEARANCE

56 in.

(142 cm)

56 in.

(142 cm)

2 - 3



2

MODEL: STOCK CHASER

TYPE: 3 WHEEL ELECTRIC POWERED PARTS PICKER

MODEL YEAR: 2013

Part No:. 628521

Speed Control: z

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

Solid State 275 amp controller. Potentiometer throttle sensor

Dash mounted direction selector switch (Forward-Neutral-Reverse) z Four, Six Volt Deep Cycle

Battery Charger: 24 Volt On-Board. Fully line compensating. Underwriters Laboratories (U.L.) Recognized, and CE Marked z Input: 100 – 240 Volt, 50/60 Hz, 12/6A z Output: 24 Volt, 25A, 20A@100V

Motor:

Drive Train:

24 Volt DC series wound, brazed armature, solid copper armature. 8.94 hp (6.67 kW) @ 1490 rpm

Direct motor shaft connected to transaxle pinion shaft

Electrical System: 24 Volt DC, four, 6 volt deep cycle batteries (115 minute minimum, 225 amp-hour @ 20 hr. discharge rate)

Transaxle: Differential with helical gears

Dual rear wheel mechanical drum brakes. Automatic park brake Brakes:

Convenience:

Towing Capacity:

4 & 6 rung ladders available

Normal Draw Bar Pull 60 lb (27.2 kg). Maximum Draw Bar Pull 715 lb (324 kg)

Dimensions

Overall Length

Overall Width

88.4 in (225 cm)

29.5 in (75 cm)

Overall Height (No Ladder) 48.0 in (122 cm)

Overall Height (4 Step Ladder) 78.0 in (198 cm)

Overall Height (6 Step Ladder) 97.0 in (246 cm)

Wheel Base 48.3 in (123 cm)

PRODUCT OVERVIEW

Performance

Capacity

Dry Weight

Curb Weight

1 Person (Standing)

522.0 lb (237 kg) (Without Batteries)

810.0 lb (367 kg)

Cargo Deck Load Capacity 750.0 lb (340 kg)

Vehicle load capacity

Outside Clearance Circle

1000.0 lb (450 kg)

12.4 ft (3.8 m)

Front Wheel Track

Rear Wheel Track

N/A

24.75 in (63 cm)

Gnd Clearance @ Differential 4.0 in (10 cm)

Cargo Deck Width 29.0 in (74 cm)

Cargo Deck Length

Cargo Deck Material

Vehicle Power

Power Source

48.0 in (122 cm)

Plywood

Motor Type

Max. Horsepower (kW)

Electrical System

Batteries (Qty, Type)

24 Volts DC

Series Wound

8.94 hp (6.67 kW) @ 1490 rpm

24 Volt

Key or Pedal Start

Battery Charger

Speed Controller

Four, 6 Volt Deep Cycle

Pedal Start

24 V, 100-240 VAC On-Board, UL & CE

Solid State 275 Amp Rated

Drive Train

Transaxle

Gear Selection

Rear Axle Ratio

Motor Shaft Direct Drive

Differential with helical gears

Dash Mounted Forward-Neutral-Reverse

14.78:1

Intersecting Aisle Clearance 56.0 in (142 cm)

Speed (Level Ground) 8.5 mph max (13.7 kph max)

Towing Capacity (Draw Bar) 60 lb (27.2 kg) Normal. 715 lb (324 kg) Max.

Steering & Suspension

Steering

Front Suspension

Rear Suspension

Service Brake

Parking Brake

Front Tires

Rear Tires

Direct Chain & Linkage

Solid

Solid

Rear Wheel Mechanical Drum

Automatic

4.80 x 8 (Load Range B)

4.80 x 8 (Load Range B)

Body & Chassis

Frame & Body

Body & Finish

Standard Color

Welded steel with DuraShield™ powder coat

Diamond plate pattern. Polyester primer/Acrylic

Safety Yellow

Noise & Vibration

Noise Sound pressure; continued A-weighted equal to or less

Vibration, WBV

Vibration, HAV than 70 db(A)

Highest RMS value of weighted acceleration is less than 2.5 m/s

Highest RMS value of weighted acceleration is less than 2.5 m/s

The uncertainty of measurement is 0.12 m/s

Measurement methods were applied per the ISO 2631 and ISO 5349

2

2

Some items shown may be optional equipment standards under conditions of typical vehicle surfaces.

2 - 4



Notes:

2

2 - 5



2

Notes:

2 - 6

INTRODUCTION


TITLE PAGE NO.

OPERATOR CONTROLS AND FEATURES ................................................................ 3-2

Key Switch.................................................................................................................................. 3-2

Direction Selector ....................................................................................................................... 3-2

State of Charge Meter ................................................................................................................ 3-2

Hour Meter ................................................................................................................................. 3-2

Headlight Switch......................................................................................................................... 3-2

Charger Receptacle ................................................................................................................... 3-2

Charger Cord.............................................................................................................................. 3-2

Cord Storage .............................................................................................................................. 3-2

Emergency Stop Switch ............................................................................................................. 3-2

Horn Button ................................................................................................................................ 3-3

Accelerator and Brake Combination Pedal ................................................................................ 3-3

Operator Present Switch ............................................................................................................ 3-3

Cargo Bed Tie Down Holes........................................................................................................ 3-3

3

3 - 1

INTRODUCTION


OPERATOR CONTROLS AND FEATURES

1. Key Switch

3

Located on the control panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key. To prevent inadvertent operation of the vehicle when left unattended, the key should be turned to the OFF position and removed.

2. Direction Selector

Located on the control panel, this switch permits the selection of either ‘F’ (forward), ‘R’ (reverse) or neutral (the position between forward and reverse). Vehicle should be left in neutral and the key removed when unattended.

3. State of Charge Meter

The vehicle is equipped with a state of charge meter located in the control panel. The state of charge meter indicates the amount of usable power in the batteries, with ‘F’ indicating a full charge on the battery pack and ‘E’ indicating the battery pack needs to be charged.

4. Hour Meter

Located on the control panel, the hour meter indicates the total hours of operation.

5. Headlight Switch

Located on the left side of the control panel, this switch will turn the headlights and tail light on or off.

6. Charger Receptacle

The battery pack charge receptacle for use with the portable charger is located on the side of the control panel.

Always check to be sure the receptacle is free from dirt and debris before connecting the charger cord.

7. Charger Cord

The on-board charger cord is located on the side of the control panel. Read all information supplied for the onboard charger before use.

8. Cord Storage

Storage for the on-board charger cord is located on the side of the control panel near the outlet for the on-board charger cord.

9. Emergency Stop Switch

The emergency stop switch is located between the operator and the load deck to the right of the control panel. Pushing down on this switch will disconnect all electrical power to the vehicle motor.

7

8

4

9

1

5

6

3

2

3 - 2

INTRODUCTION


10. Horn Button

The horn is operated by pushing the horn button located on the right side of the control panel behind the steering wheel.

10

3

11. Accelerator and Brake Combination Pedal

This vehicle is equipped with a combination accelerator and brake pedal. When at rest, the pedal keeps the brakes applied to prevent the vehicle from moving when parked.

Applying pressure to the toe of the pedal releases the brakes and causes the vehicle to accelerate. Decreasing pressure on the toe of the pedal reduces speed but does not apply the brakes. Completely releasing the pedal activates the brakes. Applying pressure to the heel of the pedal will stop the vehicle more quickly. When leaving the vehicle unattended, release pedal completely, move direction selector to neutral, turn the key to OFF and remove the key.

12. Operator Present Switch

The operator present switch must be held down for the vehicle to operate.

13. Cargo Bed Tie Down Holes

There are four holes located in the frame of the cargo bed, two along each side, these holes are for use with cargo straps with hooks on each end or cargo nets with hooks used for securing items to the deck during transport.

14. Cargo Bed Lock (Type EE Vehicles)

Type EE vehicles have a locking mechanism installed in the cargo bed. The lock restricts access to the batteries and drive train by unauthorized personnel. The lock is released by use of a key supplied with the vehicle.

12

11

13

14

3 - 3

3

INTRODUCTION


Notes:

3 - 4

OPERATING PROCEDURES


TITLE PAGE NO.

SERIAL NUMBER LOCATION .................................................................................... 4-2

Serial and Manufacturing Number Label.................................................................................... 4-2

Serial Number Bar Code Label .................................................................................................. 4-2

BEFORE INITIAL USE................................................................................................. 4-2

CHARGERS ................................................................................................................. 4-3

ON-BOARD CHARGER ............................................................................................... 4-3

PORTABLE CHARGER ............................................................................................... 4-4

LIFT OUT BATTERY TRAYS ...................................................................................... 4-5

BEFORE ENTERING VEHICLE ................................................................................... 4-5

OPERATING THE VEHICLE........................................................................................ 4-6

STARTING THE VEHICLE........................................................................................... 4-6

COASTING .................................................................................................................. 4-7

4

4 - 1



SERIAL NUMBER LOCATION

There are serial number labels in several locations on the vehicle.

Design changes take place on an ongoing basis. In order to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must be provided when ordering parts.

A

Serial and Manufacturing Number Label

4 Part A of the Supplemental Information Label is located on the plate below the first step of the ladder. This label contains the vehicle type if applicable, the Model, Date Code, Serial Number, Gross

Vehicle Weight (GVW), Vehicle Weight with Batteries and Horsepower.

Part B of the Supplemental Information Label is located on the same plate as Part A. This label contains the Rated Capacity With

Operator, Vehicle Weight Without Batteries, Maximum Battery

Weight, System Voltage, Maximum Draw Bar Weight and UL, FM or CE certification mark, if applicable.

B

Serial Number Bar Code Label

Part C is a smaller label containing the Serial Number and a Bar

Code is located on the deck frame to the left of the control panel.

BEFORE INITIAL USE

All operators and those performing maintenance should read this entire manual; paying particular attention to the CAUTIONS,

WARNINGS and DANGERS included in the manual. Read and follow the safety label on the control panel. Be sure you understand how to operate the vehicle, its equipment as well as how to use it safely. Maintaining good, safe performance depends to a large extent on the operator.

C

Hydrogen gas is generated as a natural part of the lead acid battery charging process. A 4% concentration of hydrogen gas is explosive and could cause severe injury or death. Charging must take place in an area that is adequately ventilated (minimum of 5 air exchanges per hour).

To reduce the chance of battery explosion that could result in severe injury or death, never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc.

Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%.

Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air exchanges per hour is considered the minimum requirement.

Never charge a vehicle in a hazardous area or area that is subject to flame or spark. Pay particular attention to natural gas or propane gas water heaters and furnaces.

4 - 2



Before a new vehicle is put into operation, the items shown in the INITIAL SERVICE CHART must be performed.

The vehicle batteries must be fully charged before initial use.

Check for leaks that could have developed in shipment from the factory.

Check for correct tire inflation. See GENERAL SPECIFICA-

TIONS.

Backrest Remove protective plastic covering

Brakes

Tires

Check operation and adjust if necessary

Check air pressure (see SPECIFICATIONS)

Check the operation of the vehicle brakes, including the parking brake, make adjustments if necessary.

Remove the protective clear plastic from the seat bottom and back rest before placing the vehicle in service

4

CHARGERS

Both off board and on board chargers should be operated in accordance with the charger manufacturer’s instructions. On board charger is standard equipment on this vehicles, if a no charger or 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 of the vehicle before and during the charging cycle. Never charge batteries in a hazardous environment.

ON-BOARD CHARGER

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 battery terminal.

Do not open or disassemble charger. Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow, or otherwise damaged in any way – refer all repair work to qualified personnel. Not for use by children.

To prevent a physical hazard that could result in an electrical shock or electrocution, be sure that the charger plug is not damaged and is inserted fully into a grounded receptacle.

The power (AC) cord is equipped with a grounded plug. Do not attempt to pull out, cut or bend the ground post.

4 - 3



The on-board charger is located under the cargo deck on the right hand side of the vehicle, it is wired directly to the batteries. Before charging the batteries park the vehicle in a well ventilated area, set the parking brake, turn the key switch to OFF and remove the key. Open the Charger Door

(1) and unwrap the charger cord (2) from the storage area and plug into a dedicated 15 amp AC outlet to start the charger.

4

When the charging cycle is complete, disconnect the AC cord and rewrap the cord in storage area provided and close the charger door.

2

1

PORTABLE CHARGER (if equipped)

To prevent overheating that may cause serious damage to the charger and create the potential for fire, do not block or obstruct the airways. Portable chargers must be mounted on a platform above the ground or in such a manner as to permit the maximum air flow underneath and around the charger.

Portable chargers are shipped with the vehicle. Prior to vehicle or charger operation, chargers must be removed and mounted on a platform or wall above the ground to permit maximum air flow around and underneath the charger. If the charger is operated in an outdoor location, rain and sun protection must be provided.

A dedicated circuit is required for the charger. Refer to label on side of charger for appropriate circuit protection. The charger may remain plugged in to the AC outlet. To charge the vehicle, refer to the instruction labels on the charger. Insert the DC plug completely into the vehicle receptacle. The receptacle is located on the side of the instrument panel to the left of the steering wheel. After inserting the polarized DC plug, wait a few seconds and observe ammeter on charger to make sure it moves indicating that charger is charging.

Provide Protection From Elements

Do Not Block Louvered Airways

The charger will automatically start a few seconds after plug insertion. The charger will automatically stop when batteries are fully charged and the DC plug can be removed to permit use of the vehicle.

NEMA 15 - 5R Grounded AC Receptacle

110 - 120 VAC. Dedicated 15 AMP Circuit

NOTICE

Locations outside the US and Canada: Reference appropriate local electrical code and charger manufacturer recommendations for AC power requirements

Looping the DC cord through the steering wheel when charging, serves as a good reminder to store the cord out of the way when finished with charging. The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away

To prevent a physical hazard that could result in an electrical shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle.

The power (AC) cord is equipped with a grounded plug, do not attempt to pull out, cut or bend the ground post.

4 - 4



To disconnect charger before the charging cycle is completed, disconnect the AC cord from the AC outlet first and then disconnect the DC cord from the vehicle.

The charging (DC) cord is equipped with a polarized connector which fits into a matching receptacle on the vehicle .

The power (AC) cord is equipped with a ground plug, do not attempt to pull out, cut or bend the ground plug

LIFT OUT BATTERY TRAYS (if equipped)

The vehicle may be equipped with lift out battery trays. Lift out battery trays permit the vehicle to operate on one set of batteries while another set is charging.

4

Before separating the battery connector, always turn off any electrical accessories or options.

Breaking a live circuit will result in an electrical arc that could cause a battery explosion.

Be sure that any hoist used to remove batteries has a working rating that exceeds the weight of the batteries and battery tray. The hoist must be capable of lifting the battery tray without allowing the batteries to tip.

To eliminate the possibility of battery explosion, batteries must be covered to prevent the possibility of shorting live battery terminals which could result in an explosion.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Turn the key and any accessories to the OFF position in order to remove any electrical load from the batteries. To gain access to the battery trays, the cargo deck must be removed. The vehicle has a total of four batteries separated into a left and right side tray containing two batteries each. Unplug the two large battery wire connectors from the receptacles mounted on the vehicle frame.

Use a hoist with a minimum working rating of 150 lbs. (70 kg). The hoist must be fitted with insulated lifting hook and chain or cable to prevent any possibility of shorting exposed battery terminals or connections. As an added precaution, cover the batteries to further prevent the possibility of shorting battery terminals or connections. Each tray has a lift point to attach the hoist to. Lift out only one tray at a time and lower to floor.

NOTICE

The left side of the cargo deck frame is notched to allow the left side battery tray to clear the steering linkage.

Connect the charger distribution harness to the discharged battery set and then plug the portable charger into the small connector of the charger distribution harness.

To

Charger

BEFORE ENTERING VEHICLE

1. Check for correct tire inflation.

2. Inspect for fluid leaks.

To

Batteries

3. Be sure everything is properly stored and secured.

If vehicle has on board charger, unplug power cord from electrical outlet and properly store cord under instrument panel prior to moving vehicle. If vehicle has a portable charger, remove charger plug from vehicle receptacle and properly store cable prior to moving vehicle.

4 - 5



OPERATING THE VEHICLE

Improper use of the vehicle or the lack of proper maintenance may result in decreased performance or damage to the vehicle.

Read the following warnings before attempting to operate the vehicle.

4

To reduce the possibility of severe injury or death resulting from loss of vehicle control, the following warnings must be observed:

Drive the vehicle only as fast as terrain and safety considerations allow. Consider the terrain, traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle.

Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.

Avoid extremely rough terrain.

Avoid driving fast down hill. A sudden stop or change of direction may result in loss of control.

Use service brake to control speed when traveling down an incline.

Slow down before and during turns. All turns should be executed at reduced speed.

All travel should be directly up or down hills.

Use extra care when driving the vehicle across any incline.

Do not permit anyone to ride on cargo deck.

Stay in designated areas and avoid steep slopes. To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings must be observed:

Refer to GENERAL SPECIFICATIONS for capacity.

Depressing accelerator pedal will release brakes and may cause inadvertent vehicle movement. Turn the key to the ‘OFF’ position whenever the vehicle is parked.

Make sure that the direction selector is in correct position before attempting to start the vehicle.

Do not take vehicle out of ‘gear’ while in motion (coast).

Always bring the vehicle to a complete stop before shifting the direction selector.

Check the area behind the vehicle before operating in reverse.

Always remain standing with back against backrest and hold on while the vehicle is in motion.

Keep feet, legs, hands and arms inside the vehicle at all times.

Check stability of vehicle when using optional ladder for reaching or placing cargo on shelves.

Do not overextend reach.

To prevent inadvertent movement when the vehicle is to be left unattended, release pedal completely, move direction selector to neutral position, turn key to ‘OFF’ position and remove key.

4 - 6



STARTING THE VEHICLE

To start the vehicle: Place the key in the key switch and turn to the

‘ON’ position. Move the direction selector to the direction desired and press the toe of the pedal to start the motor.

NOTICE

When the direction selector is in the reverse position, a warning signal will sound. This is a device to indicate the vehicle is ready to run in reverse.

The motor stops and the brake is applied when the toe of the pedal is completely released. To stop the vehicle more quickly, press the heel of the pedal.

Depress toe to accelerate

Release pressure - Engages service brake

Front of

Vehicle

4

Depress heel to brake rapidly

To avoid component damage, the vehicle must be brought to a complete stop before shifting the direction selector.

Do not hold vehicle on hill by using accelerator and motor. Leaving motor in a stalled condition for more than 3-4 seconds will cause permanent damage to motor.

COASTING

Heel Toe

To prevent injury or death resulting from coasting at above recommended speeds, limit speed with service brake.

On steep hills, it is possible for vehicles to coast at faster than normal speeds that may be encountered on a flat surface. To prevent loss of vehicle control, speeds should be limited to no more than the maximum speed on level ground (see GENERAL SPECIFICATIONS). Limit speed by releasing the toe of the pedal and applying pressure to the heel of the pedal. Severe damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of control, is costly, is considered abuse and will not be covered under warranty.

4 - 7

4



Notes:

4 - 8

MAINTENANCE


TITLE PAGE NO.

VEHICLE CLEANING AND CARE............................................................................... 5-3

Vehicle Cleaning......................................................................................................................... 5-3

SERVICE AND REPAIR ............................................................................................... 5-4

Lifting the Vehicle ....................................................................................................................... 5-5

WHEELS AND TIRES .................................................................................................. 5-5

Tire Repair.................................................................................................................................. 5-5

Wheel Removal and Installation................................................................................................. 5-6

LIGHT BULB REPLACEMENT .................................................................................... 5-7

Headlight .................................................................................................................................... 5-7

Tail/Brake Light........................................................................................................................... 5-7

FUSE REPLACEMENT ................................................................................................ 5-7

TRANSPORTING VEHICLE ........................................................................................ 5-8

Towing ........................................................................................................................................ 5-8

Hauling ....................................................................................................................................... 5-8

SERVICE AND MAINTENANCE .................................................................................. 5-8

5

ROUTINE MAINTENANCE .......................................................................................... 5-9

Lubrication Points..................................................................................................................... 5-10

Tire Inspection .......................................................................................................................... 5-10

BRAKES .................................................................................................................... 5-10

Periodic Brake Test For Hydraulic Brakes................................................................................ 5-10

REAR AXLE............................................................................................................... 5-11

Checking the Lubricant Level ....................................................................................................5-11

HARDWARE .............................................................................................................. 5-11

PERIODIC SERVICE SCHEDULE ............................................................................. 5-12

BATTERY CHARGING AND MAINTENANCE ........................................................... 5-13

Safety ....................................................................................................................................... 5-13

Battery Disposal ....................................................................................................................... 5-13

Battery ...................................................................................................................................... 5-13

Battery Maintenance ................................................................................................................ 5-14

At Each Charging Cycle ........................................................................................................... 5-14

Monthly..................................................................................................................................... 5-14

Electrolyte Level and Water ..................................................................................................... 5-14

Battery Cleaning....................................................................................................................... 5-17

Battery Replacement................................................................................................................ 5-18

Prolonged Storage.................................................................................................................... 5-18

5 - 1

5

MAINTENANCE

Battery Charging....................................................................................................................... 5-19

AC Voltage................................................................................................................................ 5-19

Troubleshooting ........................................................................................................................ 5-20

HYDROMETER ..........................................................................................................5-20

Using A Hydrometer ................................................................................................................. 5-21

5 - 2

MAINTENANCE


VEHICLE CLEANING AND CARE

Vehicle Cleaning

To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.

When pressure washing exterior of vehicle, do not use pressure in excess of 700 psi (4800 kPa). To reduce the possibility of cosmetic damage, do not use any abrasive or reactive solvents to clean plastic parts.

It is important that proper techniques and cleaning materials be used. Using excessive water pressure may cause severe injury to operator or bystander, damage to seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi (4800 kPa) to wash exterior of vehicle.

Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth.

Removal of oil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber cleaner.

The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces.

Occasional cleaning and waxing with non-abrasive products designed for ‘clear coat’ automotive finishes will enhance the appearance and durability of the painted surfaces.

Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle. These materials will cause corrosion of underbody parts unless flushed occasionally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to ease it’s removal, taking care not to chip or otherwise damage paint.

5

5 - 3

MAINTENANCE


SERVICE AND REPAIR

Servicing the Electric Vehicle

To prevent severe injury or death, resulting from improper servicing techniques, observe the following Warnings:

5

Do not attempt any type of servicing operations before reading and understanding all notes, cautions and warnings in this manual.

Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with the entire vehicle raised.

Wear eye protection when working on the vehicle. In particular, use care when working around batteries, or using solvents or compressed air.

To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the batteries before removing any heavy gauge battery wires.

To prevent the possibility of motor disintegration, never operate vehicle at full throttle for more than 4 - 5 seconds while vehicle is in a “no load” condition.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

It is in the best interest of both vehicle owner and servicing dealer to carefully follow the procedures recommended in this manual. Adequate preventative maintenance, applied at regular intervals, is the best guarantee for keeping the vehicle both dependable and economical.

Some servicing operations may require the front wheels, the rear wheels, or the entire vehicle to be raised.

To reduce the possibility of severe injury or death from a vehicle falling from a jack:

Be sure the vehicle is on a firm and level surface.

Never get under a vehicle while it is supported by a jack.

Use jack stands and test the stability of the vehicle on the stands.

Always place chocks in front and behind the wheels not being raised.

Use extreme care since the vehicle is extremely unstable during the lifting process.

Never attempt to raise the rear wheels of a three wheel vehicle without first raising the front of the vehicle and supporting on jack stands.

When lifting the vehicle, position the jacks and jack stands at the areas indicated only.

5 - 4

MAINTENANCE


Lifting The Vehicle

Tool List Qty.Tool ListQty.

Floor Jack ................................................................... 1

Jack Stands................................................................. 4

Wheel Chocks ............................................................. 4

Chain hoist .................................................................. 1

Detail

Turn wheel as shown to permit jack placement

1 2

Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while lifting.

Due to the low ground clearance and short wheel base, the vehicle should only be raised enough to remove the front axle or the rear wheels. Servicing that requires access to the underside of the vehicle should be accomplished by raising the front of the vehicle with a chain hoist attached to the front frame members. Always use an additional safety chain to prevent injury should the hoist malfunction.

Place jack along the under floor support

2

(See detail)

5

WHEELS AND TIRES

4

3

4

View from underside of vehicle

A tire explosion can cause severe injury or death. Never exceed the inflation pressure rating on the tire sidewall.

To reduce the possibility of tire explosion, pressurize tire with small amounts of air applied intermittently to seat beads. Due to the low volume of the small tires, overinflation can occur in seconds. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face and eyes from escaping air when removing a valve core.

To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for impact wrench use.

Use caution when inflating tires. Overinflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause severe injury.

Tire Repair

Tool List Qty.

Lug Wrench, 3/4”......................................................... 1

Impact Wrench ............................................................ 1

Tool List Qty.

Impact Socket, 3/4” ................................................. 1

Torque Wrench, ft. lbs. ............................................ 1

Use caution when inflating tires. Due to the low volume of the small tires, overinflation can occur in seconds. Overinflation could cause the tire to separate from the wheel or cause the tire to explode.

Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section for recommended tire inflation pressure. For outdoor applications with major use on grassy areas, the following should be considered. On hard turf, it is desirable to have a slightly higher inflation pressure. On very soft turf, a lower pressure reduces the possibility of tires cutting into the turf. For vehicles being used on paved or hard surfaces, tire inflation pressure should be in the higher allowable range, but under no condition should inflation pressure be higher than recommended on tire sidewall. All four tires should have the same pressure for optimum handling characteristics. Be sure to install the valve stem dust cap after checking or inflating.

The vehicle is fitted with low pressure tubeless tires mounted on one piece rims; therefore, the most cost effective way to repair a puncture in the tread is to use a commercial tire plug.

5 - 5

MAINTENANCE


NOTICE

Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel.

If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire. Immerse the tire in water to locate the leak and mark with chalk. Insert tire plug in accordance with manufacturer’s instructions.

5

To reduce the possibility of severe injury, be sure the mounting/demounting machine is anchored to floor. Wear OSHA approved safety equipment when mounting/demounting tires.

If the tire is to be removed or mounted, the tire changing machine manufacturer’s recommendations must be followed in order to reduce possibility of severe injury.

Wheel Removal and Installation

To reduce the possibility of component damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.

NOTICE

It is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will assure even seating of the wheel against the hub.

To remove a wheel or the front axle, loosen the hardware and turn the front wheel to the position indicated. Position a jack in the location indicated and carefully raise the front of the vehicle. Position the jack stands as shown. Use care not to place the jack or stands where they could interfere with wiring or linkages. Slowly lower the jack and test the stability of the vehicle.

To raise the rear of the vehicle, first raise the front of the vehicle as previously described and support on jack stands.

Then position the jack in the position shown at the rear of the vehicle. Carefully raise the rear of the vehicle with the jack and place two jack stands in the position shown. Slowly lower the jack and check that the vehicle is securely supported by the jack stands before proceeding.

With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger tighten the lug nuts (1) in a

‘cross sequence’ pattern. Tighten the lug nuts to 50 to 85 ft. lbs. (68 to 115 Nm) torque in 20 ft. lbs. (27 Nm) increments following the ‘cross sequence’ pattern.

Lower the vehicle by reversing the lifting sequence.

Tire/wheel style

may vary

'Cross Sequence'

1 3

3

'Cross Sequence'

1

4

4 2

5 2

5 - 6

MAINTENANCE


LIGHT BULB REPLACEMENT

To reduce the possibility of premature bulb failure, do not touch new bulbs with bare fingers. Use clean, dry tissue or paper towel to handle the glass portion of the bulb.

Headlight

Tool List Qty.

Torx Driver, T-20.......................................................... 1

Tool List Qty.

Clean Cloth ............................................................. 1

Loosen four torx head screws, back them out until the light bezel is free, remove bezel with screws captured in it.

Pull headlight out away from recess, locate the retaining clip on the back of the housing. Squeeze clip wires together until free of latch edges and pivot out of the way and remove bulb housing from the lens, set lens aside.

Remove old bulb and replace with new 12V/55W, H3 bulb, be sure to use clean, oil free cloth to hold the new bulb, never touch the bulb with bare hands.

Replace bulb and housing in the lens, latch retaining clip wires, making sure that wires are not caught between the clip and the lens.

Place the bezel with the captured screws over the lens, with the word TOP located at the upper edge. Align lens and bezel with the housing and start all four screws. Tighten screws alternately, making sure that the bezel is seated against the housing.

5

Tail/Brake Light

Tool List Qty.

Phillips Screwdriver..................................................... 1

Tool List Qty.

Clean Cloth ............................................................. 1

Wipe light and lens housing to remove dirt, remove two phillips head screws and that secure the lens to the backing plate. Remove the old bulb and replace with bulb of the same size, replace the lens and secure with the phillips head screws.

FUSE REPLACEMENT

Fuses on this vehicle are located in line throughout the vehicle, each fuse is labeled with the correct fuse size.

Replace blown fuse with specified size only.

FUSE #

3

4

1

2

5

6

7

8

SIZE

FOR

2AMP Key Switch

2AMP SOC Meter

15AMP Horn

5AMP

Reverse Warning

Indicator

5AMP Tail Light

15AMP Headlights

2AMP

5

Forward Motion

Indicator

Strobe Light

LOCATION PART

NUMBER

Inside control panel, remove lower front housing to gain access 18392G8




Under the deck on the driver’s right

Under the deck on the driver’s right

Under deck board near forward motion indicator on driver’s left

Under deck board near middle of vehicle

18392G7

18392G1

18392G8

18392G7

5 - 7

MAINTENANCE


TRANSPORTING VEHICLE

Towing

This vehicle is NOT designed to be towed.

It is recommended that the vehicle be moved by placing the entire vehicle on a trailer, flat bed truck or other suitable transport.

5

Before pushing inoperative vehicle set the Run-Tow/Maintenance/Storage switch to the TOW/MAINTENANCE/

STORAGE position to prevent damage to the electric motor and controller.

The Run-Tow/Maintenance/Storage switch is located behind the access panel in the center of the dashboard.

Remove two phillips head screws and swing the panel downward to access the switch. Set the switch to the TOW/

MAINTENANCE/STORAGE position before moving an inoperative vehicle, before performing battery maintenance, repairs or for prolonged storage.

The TOW/MAINTENANCE/STORAGE position allows the vehicle to roll freely without activating the warning beeper and eliminating potential damage to the controller or motor. In the TOW/MAINTENANCE/STORAGE position all power to the motor and controller are shut off.

Hauling

To reduce the possibility of severe injury or death while transporting the vehicle:

Secure the vehicle and contents.

Never ride on the vehicle being transported.

Always check that the vehicle and contents are adequately secured before transporting. The rated capacity of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load plus 400 lbs. (181 kg). Set the park brake and secure the vehicle using ratchet tie downs.

SERVICE AND MAINTENANCE

To reduce the possibility of severe injury or death from improper servicing techniques:

DO NOT attempt any type of servicing operations before reading all notes, cautions and warnings in this manual.

Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with both drive wheels raised and vehicle properly supported on jack stands.

To reduce the possibility of motor damage, never operate vehicle at full throttle for more than

4 - 5 seconds while vehicle is in a ‘no load’ condition.

Reduce the possibility of accidental starting by disconnecting battery at negative terminal before servicing.

5 - 8

MAINTENANCE


Wear eye protection when working on the vehicle. Use extra care when working around batteries, or using solvents or compressed air.

To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the battery before removing battery wires.

Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench

‘shorting out’ a battery, which could result in an explosion.

The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.

Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liters) of water and flushed with water.

Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion.

It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual. Preventative maintenance, applied at recommended intervals, is the best guarantee for keeping the vehicle both dependable and economical.

5

To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, frequent use with maximum load.

To access powertrain for routine maintenance, lift and remove load deck. For major repair, refer to appropriate Technician’s Repair and Service Manual.

Some service procedures may require the vehicle to be lifted. Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information.

ROUTINE MAINTENANCE

To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, or frequent use with maximum load.

To access the powertrain for routine maintenance, remove the load bed. For major repair, refer to the appropriate

Technician’s Repair and Service Manual.

Some service procedures may require the vehicle to be lifted. Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information.

5 - 9

MAINTENANCE


Lubrication Points

Grease Fitting

Use maximum of three pumps of grease for each grease fitting -

Over greasing may damage grease seals.

Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure.

Tire Inspection

5

Tire condition should be inspected per the Periodic Service Schedule. Inflation pressures should be checked when the tires are cool.

Be sure to install the valve dust cap after checking or inflating.

BRAKES

Grease Fitting

4 Ball Joints

Steering with steering wheel and cover removed for clarity

To reduce the possibility of severe injury or death, always evaluate pedal travel before operating a vehicle to verify some braking function is present.

All driving brake tests must be done in a safe location with regard for the safety of all personnel.

NOTICE

Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.

The Periodic Brake Performance Test should be performed regularly as an evaluation of braking system performance. It is useful as a method of identifying subtle loss of performance over time.

Periodic Brake Test For Hydraulic Brakes

Depress the brake pedal; the pedal should have some free travel and then become hard. A brake pedal that has no free travel, excessive free travel or a spongy feel indicates that a brake inspection is required. A brake pedal that fails after it is applied indicates a leak in the master or wheel cylinders.

It is important to periodically check and maintain proper brake fluid levels in the brake master cylinder. The fill cap for the master cylinder is located under the access panel in the front floorboard. When checking the fluid, wipe off any dirt from the fill cap before removing it to reduce the possibility of contamination. Fluid level should be maintained between the MAX and MIN fill lines. If fluid must be added, inspect the system for fluid leaks.

Wheel bearings and fork pivot

View from underside of vehicle

Rear axle check and fill

5 - 10

MAINTENANCE


REAR AXLE

The only maintenance required for the first five years is the periodic inspection of the rear axle for lubricant leakage. Unless leakage is evident, the lubricant need only be replaced after five years.

Refer to the Service and Repair Manual for the fluid replacement procedure.

Checking The Lubricant Level

With the vehicle on level ground, clean the area around the check/fill plug and remove plug. The correct lubricant level is just below the bottom of the threaded hole. If lubricant is low, add as required. Add lubricant slowly until lubricant starts to seep from the hole. Install the check/fill plug. In the event that the lubricant is to be replaced, the vehicle must be elevated and the oil pan removed or the oil siphoned out through the check/fill hole.

Check/Fill

Plug

HARDWARE

Generally, three classes of standard hardware and two classes of metric hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head. Metric hardware is marked on the head with 8.8 or 10.9. Unmarked hardware is Grade 2.

Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened with care and in accordance with the Torque Specifications table or as specified in the Repair and Service Manual for this vehicle.

ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)

Unless otherwise noted in text, tighten all hardware in accordance with this chart.

This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.

BOLT SIZE

Grade 2

1/4"

4

(5)

5/16"

8

(11)

3/8"

15

(20)

7/16"

24

(33)

1/2"

35

(47)

9/16"

55

(75)

5/8"

75

(102)

3/4"

130

(176)

7/8"

125

(169)

1"

190

(258)

Grade 5

Grade 8

6

(8)

6

(8)

13

(18)

18

(24)

23

(31)

35

(47)

35

(47)

55

(75)

55

(75)

80

(108)

80

(108)

110

(149)

110

(149)

170

(230)

200

(271)

280

(380)

320

(434)

460

(624)

480

(651)

680

(922)

BOLT SIZE

Class 5.8

(Grade 2)

5.8

Class 8.8

(Grade 5) 8.8

Class 10.9

(Grade 8) 10.9

M4

1

(2)

2

(3)

3

(4)

M5

2

(3)

4

(6)

M6

4

(6)

7

(10)

M8

10

(14)

18

(24)

M10

20

(27)

35

(47)

M12

35

(47)

61

(83)

M14

55

(76.4)

97

(131)

6

(8)

10

(14)

25

(34)

49

(66)

86

(117)

Torque Specifications and Bolt Grades

136

(184)

5

5 - 11

MAINTENANCE


PERIODIC SERVICE SCHEDULE



- CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE

REMARKS

5

Tires - pressure, condition of tires & rims

Hardware - loose or missing

Reverse Warning Indicator

Horn operation (if equipped), Forward Motion Indicator (if equipped)

Brake/Tail Lights, Headlights (if equipped) all lights operational

Overall Vehicle Condition

Battery Pack - state of charge, condition, loose terminals, corrosion, hold down & hardware

Brake Pedal - smooth operation

Brakes - check fluid level in master cylinder

Brakes - aggressive stop test

Park Brake - operation, does it hold on a hill

P

P

P

P

P

P

P

P

P

P

P

P

P

P

P

P

P

P

P

P

CL

P

P

P

P

P

P

CL

P

P

P

P

P

P

CL

P

P

P

P

P

P

CL

Accelerator - smooth operation

Charger - inspect charger AC cord, plug, receptacle at each charge

Wiring - loose connections, broken or missing insulation

Steering Assembly - excessive play, loose or missing hardware

Tie Rods - excessive play, bent rods, loose or missing hardware

Rear Axle - fluid level, oil leakage, noise, loose or missing hardware

Rear Axle - drain & replace fluid

Rear Suspension - shock oil leakage, worn bushings, loose or missing hardware

P

P

P

P

P

P

P

P

P

C&A

C&A

P

P

P

P

P

P

P

C&A

C&A

P

P

P

P

P

P

P

P

C&A

C&A

P

P

P

P

P

P

P

P

P

C&A

C&A

P

P

P

P

P

P

P

R

Front Wheel Bearings - adjust and repack with bearing grease

P P

Front Wheel Alignment - unusual tire wear C&A C&A C&A

NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.

5 - 12

MAINTENANCE


BATTERY CHARGING AND MAINTENANCE

Safety

Always observe the following warnings when working on or near batteries.

To prevent battery explosion that could result in severe personal injury or death, keep all smoking materials, open flames or sparks away from the batteries.

Hydrogen gas is formed when charging batteries. Do not charge batteries without adequate ventilation. A 4% concentration of hydrogen gas is explosive.

Be sure that the key switch is off and all electrical accessories are turned off before starting work on the vehicle.

5

Never disconnect a circuit under load at a battery terminal.

Batteries are heavy. Use proper lifting techniques when moving them.

Always lift the battery with a commercially available battery lifting device.

Use care not to tip batteries when removing or installing them; spilled electrolyte can cause burns and damage.

The electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.

Always wear a safety shield or approved safety goggles when adding water or charging batteries.

Any electrolyte spills should be neutralized with a solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1 1/2 gallons (6 liters) of water and flushed with water.

Overfilling batteries may result in electrolyte being spilled from the battery during the charge cycle. Expelled electrolyte may cause damage to the vehicle and storage facility.

Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to prevent can from contacting battery terminals which could result in an explosion.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from shorting out a battery, which could result in an explosion and severe personal injury or death.

Never charge a vehicle in a hazardous location or atmosphere. Reference NFPA

505 for definitions of hazardous and non-hazardous locations.

Battery Disposal

Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spells, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.

Battery

A battery is defined as two dissimilar metals immersed in an acid. If the acid is absent or if the metals are not dissimilar, a battery has not been created. The batteries most commonly used in these vehicles are lead acid.

5 - 13

MAINTENANCE


A battery does not store electricity, but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy. The chemical reaction takes place faster in warm conditions and slower in cold conditions. Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences.

As a battery ages, it still performs adequately except that its capacity is diminished. Capacity describes the time that a battery can continue to provide its design amperes from a full charge.

A battery has a maximum life, therefore good maintenance is designed to maximize the available life and reduce the factors that can reduce the life of the battery.

Battery Maintenance

Tool List Qty.

5 Insulated Wrench, 9/16”...............................................1

Hydrometer ..................................................................1

Battery Protective Spray ..............................................1

Socket, 9/16”................................................................1

Battery Carrier ........................................................ 1

Battery Maintenance Kit P/N 25587-G01................ 1

Torque Wrench, in. lbs ............................................ 1

At Each Charging Cycle

To reduce the possibility of fire, never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle. Overcharging could cause damage to the vehicle batteries and result in extreme overheating. The charger should be checked after 24 hours and unplugged after the charge cycle is complete.

Before charging the batteries, inspect the cord of the battery charger for missing or cracked insulation, inspect the plug to be sure the grounding prong is intact.

Charge the batteries after each day’s use.

Monthly

• Inspect all wiring for fraying, loose terminations, corrosion or deterioration of insulation.

• Check that the electrolyte level is correct and add suitable water as required.

• Clean the batteries and wire terminations.

• Coat battery terminals with commercially available protectant.

Electrolyte Level and Water

The correct level of the electrolyte is 1/2" (13 mm) above the plates in each cell.

This level will leave approximately 1/4" - 3/8" (6 - 10 mm) of space between the electrolyte and the vent tube. The electrolyte level is important since any portion of the plates exposed to air will be ruined beyond repair. Also avoid filling with too much water, which will result in electrolyte being forced out of the battery due to gassing and a decrease in volume of the electrolyte that results from the charging cycle.

DO NOT overfill batteries. The charging cycle will expel electrolyte and result in component damage.

5 - 14

MAINTENANCE


A battery being charged will’gas’ with the majority of the gassing taking place at the end of the charging cycle. This gas is hydrogen with is lighter than air. Water and sulphuric acid droplets will be carried out of the battery vents by the hydrogen gas, however, this loss is minimal. If the battery electrolyte level is too high, the electrolyte will block the vent tube and the gas will force it out of the vent tube and battery cap. The water will evaporate but the sulphuric acid will remain where it can damage vehicle components and the storage facility floor. Sulphuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery.

Over the life of the battery, a considerable amount of water is consumed. It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction. The water must be distilled or purified by an efficient filtration system.

Water that is not distilled should be analyzed and, if required, filtration installed to permit the water to meet the requirements of the water purity table.

Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it does not exceed the impurity levels specified in the table.

Expansion

Space

1/4” to 3/8”

(6 mm to 10mm)

Plates

Vent Cap

Gas Vent

Vent

1/2” (13 mm)

Electrolyte level should be at least 1/2” (13mm) above the plates and 1/4” to 3/8” (6 to 10 mm) below vent

Correct Electrolyte Level

5

Impurity

Color

Suspended

Total Solids

Calcium & Magnesium Oxides

Iton

Ammonia

Organic & Volatile Matter

Nitrites

Nitrates

Chloride

Water Purity Table

Parts Per

Million

Clear

Trace

100

40

5

8

50

5

10

5

5 - 15

5

MAINTENANCE


Automatic watering devices such as the one included in the

Battery Maintenance Kit (P/N 25587-G01) can be used with an approved water source. These watering devices are accurate, easy to use and allow for rapid filling. They also maintain the correct electrolyte level within the battery cells.

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

Electrolyte Level

Pure Water

Single Battery Cell

Automatic Watering Gun

Distilled Water

Dispensing valve consistently fills to a predetermined level

Electrolyte Level

Single Battery Cell

Hand Held Watering Device

The electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water.

Contact a physician immediately.

Any electrolyte spills should be neutralized with a solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1 1/2 gallons (6 liters) of water and flushed with water.

Always wear a safety shield or approved safety goggles when adding water or charging batteries.

5 - 16

MAINTENANCE


Battery Cleaning

To prevent battery damage, be sure that all battery caps are tightly installed.

To reduce the possibility of damage to vehicle or floor, neutralize acid before rinsing battery.

To reduce the possibility of damage to electrical components while cleaning, do not use a pressure washer.

Cleaning should take place per the Periodic Service Schedule.

When cleaning the outside of the batteries and terminals, do not use a water hose without first spraying the batteries with a solution of baking soda (sodium bicarbonate) and water to neutralize any acid deposits. Use of a water hose without first neutralizing the acid will move the acid from the top of the batteries to another area of the vehicle or storage facility, where it will attack the metal structure or the concrete/asphalt floor. After hosing down the batteries, a residue will be left on the batteries which is conductive and will contribute to the discharge of the batteries.

5

NOTICE

To reduce the possibility of battery explosion that could result in severe injury or death, do not use metallic spray wand to clean battery and keep all smoking materials, open flame or sparks away from the battery.

The correct cleaning technique is to spray the top and sides of the batteries with a solution of baking soda and water.

This solution is best applied with a garden-type sprayer equipped with a non-metallic spray wand or plastic spray bottle. The solution should consist of 1/4 cup (60 ml) of baking soda mixed with 1 1/2 gallons (6 litres) of clear water.

In addition to the batteries special attention should be paid to metallic components adjacent to the batteries, these should also be sprayed with the baking soda solution.

Allow the solution to set for at least three minutes; use a soft bristle brush or cloth to wipe the tops of the batteries in order to remove any residue that could cause the self-discharge of the battery. Rinse the entire area with low pressure clear water. All of the items required for complete battery cleaning and watering are contained in the Battery Maintenance

Kit (P/N 25587-

G01).

1/4 Cup (60 ML)

Baking Soda

1 1/2 GAL (6 Liters) Water

Non-Metalic Wand

OR

2 GAL (8 Liters)

Gargen Sprayer

(1 1/2 GAL (6 Liters)

Baking Soda Solution

1 quart

(1 liter)

Clear Water

2 Teaspoons

(10 ml)

Sodium

Bicarbonate

(Baking Soda)

Plastic

Spray

Bottle

Cleaning should take place once a month or more often under

Preparing Acid Neutralizing Solution extreme conditions. After batteries are clean and dry, the terminals should be coated with a commercially available protectant.

Aerosol containers of battery terminal protectant must be used with extreme care. Insulate the metal container to prevent the can from contacting the battery terminals.

5 - 17

MAINTENANCE


Battery Replacement

Remove battery hold downs and cables. Lift out batteries with a commercially available lifting device.

If the batteries have been cleaned and any acid in the battery rack area neutralized as recommended, no corrosion to the battery racks or surrounding area should be present. Any corrosion found should be immediately removed with a putty knife and a wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint.

The batteries should be placed into the battery racks and the battery hold downs tightened to 45 - 55 in. lbs. (5 - 6

Nm) torque, to prevent movement but not tight enough to cause distortion of the battery cases.

Inspect all wires and terminals. Clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate (baking soda) and brush clean if required.

5

To prevent battery explosion that could result in severe personal injury or death, extreme care must be used with aerosol containers of battery terminal protectant. Insulate the metal container to prevent the metal can from contacting battery terminals which could result in an explosion.

Use care to connect the battery wires as shown.

Tighten the battery post hardware to 90 - 100 in. lbs. (6 -8 Nm) torque . Do not over-torque the terminal stud nut, this will cause a “mushroom” effect on the battery post which will prevent the terminal nut from being properly tightened.Protect the battery terminals and battery wire terminals with a commercially available coating.

Protect the battery terminals and battery wire terminals with a commercially available coating.

+

Front of Vehicle

RED to Fuse inside Console

-

+

+

-

BLK to

Charger

-

BL- to

ESC

WHT to

Charger

+

BL+ to

Solenoid

Front of Vehicle with Lift Out Battery Tray

+ -

+

+

-

-

+

+ -

BL-

Connector

- +

BL+

Connector

Prolonged Storage

Battery charger, controller and other electronic devices need to be disconnected since they will contribute to the premature discharge of batteries.

NOTICE

The RUN-TOW/MAINTENANCE/STORAGE switch, located behind the access panel in the dash is set to TOW/MAINTENANCE/

STORAGE position for long term storage of the vehicle to avoid draining of the batteries.

During periods of storage, the batteries will need attention to keep them maintained and prevent discharge. In high temperatures the chemical reaction is faster, while low temperatures cause the chemical reaction to slow down. A vehicle that is stored at 90° F (32° C) will lose.002 of specific gravity each day. If a fully charged battery has a specific gravity of 1.275, and the battery is allowed to sit unused, it will become partially discharged. When it reaches

5 - 18

MAINTENANCE


1.240, which it will do in less than twenty days, it should be recharged. If a battery is left in a discharged state, sulfating takes place on and within the plates. This condition is not reversible and will cause permanent damage to the battery. In order to prevent damage, the battery should be recharged. A hydrometer can be used to determine the specific gravity and therefore the state of charge of a battery.

In winter conditions, the battery must be fully charged to prevent the possibility of freezing. A fully charged battery will not freeze in temperatures above -75° F (-60° C).

Although the chemical reaction is slowed in cold temperatures, the battery must be stored fully charged, and disconnected from any circuit that could discharge the battery.

For portable chargers, disconnect the charging plug from the vehicle receptacle. For on-board chargers, disconnect the charging harness from the batteries. The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge. The batteries should be tested or recharged at thirty day minimum intervals.

O F

+15

+5

-5

O C

-9

-15

-21

-15 -26

-25 -32

-35 -37

-45 -43

-55 -48

5

Battery Charging

The battery charger is designed to fully charge the battery set. If the batteries are severely deep cycled, some automatic battery chargers contain an electronic module that may not activate and the battery charger will not function.

Automatic chargers will determine the correct duration of charge to the battery set and will shut off when the battery set is fully charged. Always refer to the instructions of the specific charger used.

Before charging, the following should be observed:

-65 -54

-75 -60

-85 -65

-95 -71

1.100

1.140

1.120

1.180

1.160

1.220

1.200

1.260

1.240

SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT

1.300

1.280

Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage.

• The electrolyte level in all cells must be at the recommended level and cover the plates.

• The charging must take place in an area that is well ventilated and capable of removing the hydrogen gas that is generated by the charging process. A minimum of five air exchanges per hour is recommended.

• The charging connector components must be in good condition and free from dirt or debris.

• The charger connector must be fully inserted into the vehicle receptacle.

• The charger connector/cord set is protected from damage and is located in an area to prevent injury that may result from personnel running over or tripping over the cord set.

• The charger is automatically turned off during the connect/disconnect cycle and therefore no electrical arc is generated at the DC plug/receptacle contacts.

NOTICE

In some portable chargers, there will be a rattle present in the body of the charger DC plug. This rattle is caused by an internal magnet contained within the charger plug. The magnet is part of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the vehicle charging receptacle.

AC Voltage

Battery charger output is directly related to the input voltage. If multiple vehicles are receiving an incomplete charge in a normally adequate time period, low AC voltage could be the cause and the power company should be consulted.

5 - 19

MAINTENANCE


Troubleshooting

In general, troubleshooting will be done for two distinct reasons. First, a battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturer’s warranty. Different manufacturers have different requirements. Consult the battery manufacturer or the manufacturer’s representative for specific requirements.

The second reason is to determine why a particular vehicle does not perform adequately. Performance problems may result in a vehicle that runs slowly or in a vehicle that is unable to operate for the time required.

A new battery must mature before it will develop its maximum capacity. Maturing may take up to 100 charge/discharge cycles. After the maturing phase, the older a battery gets, the lower the capacity. The only way to determine the capacity of a battery is to perform a load test using a discharge machine following manufacturer’s recommendations.

5

A cost effective way to identify a poorly performing battery is to use a hydrometer to identify a battery in a set with a lower than normal specific gravity. Once the particular cell or cells that are the problem are identified, the suspect battery can be removed and replaced. At this point there is nothing that can be done to salvage the battery; however, the individual battery should be replaced with a good battery of the same brand, type and approximate age.

HYDROMETER

A hydrometer (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.

Thermometer

Cylinder

Add to Float

Reading

Bulb Float

To prevent battery explosion that could result in severe personal injury or death, never insert a metal thermometer into a battery. Use a hydrometer with a built in thermometer that is designed for testing batteries.

Subtract from Float

Reading

Specific gravity is the measurement of a liquid that is compared to a baseline. The baseline is water which is assigned a

Weight 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

Hydrometer 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.

NOTICE

Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte.

The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80° F (27° C). High quality hydrometers are equipped with an internal thermometer that will measure the temperature of the electrolyte and will include a conversion scale to correct the float reading. It is important to recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been operated.

5 - 20

MAINTENANCE


Using A Hydrometer

1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading. Examine the color of the electrolyte. A brown or gray coloration indicates a problem with the battery and is a sign that the battery is nearing the end of its life.

2. Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder.

3. Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float.

4. Add or subtract four points (.004) to the reading for every 10° F (6° C) the electrolyte temperature is above or below 80° F (27° C). Adjust the reading to conform with the electrolyte temperature, e.g., if the reading indicates a specific gravity of 1.250 and the electrolyte temperature is 90° F (32° C), add four points (.004) to the

1.250 which gives a corrected reading of 1.254. Similarly if the temperature was 70° F (21° C), subtract four points (.004) from the 1.250 to give a corrected reading of 1.246.

5. Test each cell and note the readings (corrected to 80° F or 27° C). A variation of fifty points between any two cell readings (example 1.250 - 1.200) indicates a problem with the low reading cell(s).

ELECTROLYTE

TEMPERATURE

°F °C

160 71

150 65

140 60

130 54

120 49

110 43

100 37

90 32

80 26

70 21

60 15

50 10

40 4

30 -1

20 -6

10 -12

+.008

+.006

+.004

+.002

0

-.002

-.004

-.006

-.008

-.010

-.012

-.014

-.016

-.018

-.020

-.022

-.024

-.026

+.032

+.030

+.028

+.026

+.024

+.022

+.020

+.018

+.016

+.014

+.012

+.010

-.028

EXAMPLE #1

ELECTROLYTE TEMPERATURE

Above 80 °F (27 °C)

AMBIENT TEMPERATURE

Above 80 °F (27 °C)


Above 90 °F (32 °C)

HYDROMETER READING 1.250

1.250 + .004 = 1.254

CORRECTED SPECIFIC GRAVITY

READING

EXAMPLE #2


Above 80 °F (27 °C)

AMBIENT TEMPERATURE

Above 80 °F (27 °C)


Above 70 °F (21 °C)

HYDROMETER READING 1.250

1.250 - .004 = 1.246

CORRECTED SPECIFIC GRAVITY

READING

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

Hydrometer Temperature Correction replaced with a good battery of the same brand, type and approximate age.

5

5 - 21

5

MAINTENANCE


Notes:

5 - 22

APPENDIX A


TTITLE PAGE NO.

DELTA Q BATTERY CHARGER .................................................................................. A - 2

A - 1

APPENDIX A


User’s Guide for:

912-2400, 912-3600-07, 912-4800-14

SAVE THESE IMPORTANT

SAFETY INSTRUCTIONS

This manual contains important safety, operating, and installation instructions read before using charger.

Battery Safety Information

Warning:

Use charger only on battery systems 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 such as recommended rates of charge and removing or not removing cell caps while charging.

Electrical Safety Information

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 terminal. Disconnect the

AC supply before making or breaking the connections to the battery while charging. Do not open or disassemble charger. Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way – refer all repair work to qualified personnel. Not for use by children.

INFORMATIONS IMPORTANTES

DE SÉCURITÉ

Conserver ces instructions. Ce manuel contient des instructions importantes concernant la sécurité et le fonctionnement.

Information de Sécurité de la Batterie

Attention:

Utiliser seulement sur les systèmes batteries avec un algorithme approprié au type spécifique de batterie. Dáutres types de batteries pourraient éclater et causer des blessures ou dommages. Les batteries peuvent produire des gaz explosives en service normal. Ne jamais fumer près de la batterie et éviter toute

étincelle ou flame nue à proximité de ces derniers. Fournisser la bonne ventilation lors du chargement. Ne jamais charger une batterie gelée. Prendre connaissance des mesures de précaution spécifiées par le fabricant de la batterie, p. ex., vérifier síl faut enlever les bouchons des cellules lors du chargement de la batterie, et les taux de chargement recommandés.

Information de Sécurité Électrique

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. Ne pas ouvrir ni desassembler le chargeur – referer toute reparations aux personnes qualifiés. Pas à lúsage des enfants.

Operating Instructions

CAUTION: 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. connect QuiQ charger to a single 15A circuit or the circuit may become overloaded.

LED indications following Power-On Self Test flashes:

Ammeter

(Amber)

Solid: Displays approximate scale of current output during charging.

Flashing: High internal temperature, current output reduced.

Also displays algorithm #1-6 for 11 seconds if no battery is connected.

80% Charge

(Amber)

100% Charge

(Green)

Fault

(Red)

AC On

(Amber)

Solid: Bulk charge phase complete, 80% charged. In

Absorption phase.

Flashing: With no battery connected, indicates algorithm # selected by number of flashes.

Solid: Charging complete. Charger in Maintenance Mode.

Flashing: Absorption phase complete. In Finish phase

Solid: AC good

Flashing: Low AC Voltage, check voltage and extension cord length (see above for guidelines).

Flashing: Charger error. Reset charger power and refer to

Troubleshooting below.

Maintenance Instructions

1. Do not expose charger to oil, dirt, mud or direct heavy water spray when cleaning vehicle.

2. 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.

A - 2

APPENDIX A


Troubleshooting Instructions

If a fault occurs, count the number of red flashes between pauses and refer to the table below:

Red Flashes Cause Solution

Charge Enable Fault or

Battery Temperature Fault

Battery Voltage Too Low or High

Check connector contacts and retry.

Check that battery temperature is between

-10°C and +50°C.

Check battery size and condition of batteries.

Charge Timeout caused by battery pack not reaching required voltage.

Charger output was reduced due to high temperatures.

Check for loose connections or corrosion.

Operate charger at a lower ambient temperature or increase cooling air flow.

Check Battery: battery could not be trickle charged up to minimum voltage

Over-Temperature: Charger shut down due to high internal temperature.

Charger Internal Fault

Check for shorted or damaged cells.

Ensure sufficient cooling air flow and reset charger (interrupt AC power for 15 seconds).

Reset charger (interrupt AC power for 15 seconds). Return to qualified service depot if fault persists.

Specifications

DC Output – see Operating Instructions

QuiQ Model: 912-2400

628089

912-3600-07

628102

Voltage-nom (V) 24 36

Voltage-max (V)

Current-max (A)

Battery Type

Reverse Polarity

Short Circuit

34

25

51

21

912-4800-14

624206

48

67

18

Lead acid (Wet / AGM / GEL)

Electronic protection auto-reset

Electronic current limit

AC Input

All models

Voltage-max (Vrms)

Frequency (Hz)

Current - max (Arms)

AC Power Factor

85 265

45 - 65

9.5A @ 120VAC

5A @ 230VAC

>0.99 at 120VAC

>0.98 at 230VAC

Mechanical

All models

Dimensions

Weight

Environmental

Operating

Temperature

Storage Temperature

AC input connector

28.0 x 24.5 x 11.0 cm (11 x 9.7 x

4.3)

<5 kg (11 lbs)

Enclosure: IP66

-30°C to +50°C (-22°F to 122°F), derated above 30°C, below 0°C

-40°C to +70°C (-40°F to 158°F)

IEC320/C14

(require 1.8m localized cord)

OEM specific w/ 12AWG wire DC output

Operation

All models

Battery Temperature

Compensation

Maintenance Mode w/Default Algo 1

Automatic

Auto-restart if V < 2.08V/cell

or 30 days elapse

Regulatory

Safety

EN 60335-2-29

UL2202 (1 st

Ed.)

UL1564 3rd Ed.

Safety of Appliances/ Battery Chargers

EV Charging System Equipment

Industrial Battery Charger

CSA- 107.2 Battery Chargers- Industrial

Emissions

Unintentional Radiators Class A FCC Part 15/ICES

003

EN 55011

EN 61000-3-2

EN 61000-3-3

Radio disturbance characteristics

(Class A)

Limits for harmonic current emissions

Limits of voltage fluctuations and flicker

Immunity

EN 61000-4-2 Electrostatic discharge immunity

EN 61000-4-3

EN 61000-4-4

Radiated, radio-frequency,

EMF immunity

Electrical fast transient/burst immunity

EN 61000-4-5

EN 61000-4-6

EN 61000-4-11

Surge immunity

Conducted Immunity

Voltage variations immunity

Product warranty is dependent on model - please contact dealer of original equipment for warranty service.

Note: This is a Class A product. In a domestic environment this product may cause radio interference, and the user may be required to take adequate measures.

2012 © Delta-Q Technologies Corp. All rights reserved. PN: 710-0141 Rev 1

A - 3

APPENDIX A


Notes:

A - 4

APPENDIX B


TITLE PAGE NO.

DECLARATION OF CONFORMITY ..............................................................................B - 2

B - 1

APPENDIX B


B - 2

APPENDIX B


B - 3

APPENDIX B


N o t e s :

B - 4

E-Z-GO Division of Textron Inc.,

1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA

Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch,

Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.

Copyrighted Material

This manual may not be reproduced in whole or in part without the express permission of

E-Z-GO Division of Textron Inc.

Technical Communications Department

Cushman Model Year 2018-2020 Stock Chaser Electric Manual

Owner’s Guide

ELECTRIC POWERED VEHICLE

628570-H

ISSUED OCTOBER 2012 REVISED JULY 2018

WARNING

OWNER’S GUIDE

ELECTRIC POWERED VEHICLE

STOCK CHASER

STARTING MODEL YEAR 2013

BATTERY PROLONGED STORAGE

BATTERY DISPOSAL

Notes:

GENERAL

NOTICES, CAUTIONS, WARNINGS, AND DANGERS

DANGER

GENERAL OPERATION

MAINTENANCE

VENTILATION

LABELS AND PICTOGRAMS

SERIAL NUMBER LOCATION

BEFORE INITIAL USE

CHARGERS

ON-BOARD CHARGER

PORTABLE CHARGER (if equipped)

LIFT OUT BATTERY TRAYS (if equipped)

BEFORE ENTERING VEHICLE

OPERATING THE VEHICLE

STARTING THE VEHICLE

COASTING

VEHICLE CLEANING AND CARE

SERVICE AND REPAIR

WHEELS AND TIRES

LIGHT BULB REPLACEMENT

FUSE REPLACEMENT

TRANSPORTING VEHICLE

SERVICE AND MAINTENANCE

ROUTINE MAINTENANCE

BRAKES

REAR AXLE

HARDWARE

PERIODIC SERVICE SCHEDULE

BATTERY CHARGING AND MAINTENANCE

HYDROMETER

SAVE THESE IMPORTANT

SAFETY INSTRUCTIONS

INFORMATIONS IMPORTANTES

DE SÉCURITÉ

Notes:

Key Features

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Frequently Answers and Questions

What is the weight carrying capacity of the vehicle?

What type of motor powers the vehicle?

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What is the design of the vehicle?

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