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OWNER’S MANUAL
AMBUSH iS
ISSUED JULY
,
2014
640691
REVISED NOVEMBER
,
2015
WELCOME
Thank you for purchasing this vehicle. Before driving the vehicle, please take time to read and understand this entire
Owner’s Manual. This manual contains important safety information, as well as information that will assist in maintaining the vehicle for optimum performance.
This manual may cover the operation of several different models or show items that are optional; therefore, some illustrations/images may not be representative of all models.
Most service procedures can be accomplished using common tools. Perform service procedures at intervals shown in the
Periodic Service Schedule located elsewhere in this manual.
Repair or replacement parts are available through your BAD BOY BUGGIES retailer.
The following information is needed when contacting us concerning service or parts for your vehicle:
Vehicle Model: ___________________________________________________________
VIN, PIN or Serial Number: _________________________________________________
Manufacture Date Code: ___________________________________________________
OWNER’S MANUAL
HYBRID VEHICLE
4 X 4 HYBRID UTILITY VEHICLE
AMBUSH iS
STARTING MODEL YEAR 2015
CALIFORNIA Proposition 65 Warning
WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates, all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. Bad Boy Buggies prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Bad Boy Buggies reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously.
The information contained in this manual may be revised periodically by Bad Boy Buggies, and therefore is subject to change without notice.
Bad Boy Buggies DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL
AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this manual.
These are the original instructions as defined by 2006/42/EC.
CONTACT US:
Bad Boy Buggies
1451 Marvin Griffin Rd.
Augusta, GA, USA 30906
FAX: 855-256-9900
E-mail: [email protected]
For parts and repair, contact local dealer. Dealers can be located at www.BADBOYBUGGIES.com
i
FORWARD ii
This vehicle has been designed and manufactured in the United States of America (USA).
The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated.
When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of america Federal and State emission certification applicable at the time of manufacture.
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
Batteries self-discharge over time. The rate of self-discharge varies depending on the ambient temperature, the age and condition of the batteries.
Fully charged batteries will not freeze in winter temperatures unless the temperature falls below -75°F (- 60°C).
For winter storage, the batteries must be clean, fully charged and disconnected from any source of electrical drain.
The battery charger may be left connected to the vehicle to maintain a full charge on the batteries, provided the charger is plugged into an active electrical source. If power to the electrical source is disconnected or interrupted, the battery charger will continue to check the charge on the battery pack. This will draw power from the battery pack and eventually drain the batteries if power is not restored in a timely manner.
The batteries must be checked and recharged as required or at a minimum of 30 day intervals.
Check and maintain the proper fluid level in all battery cells during the storage period.
Proper fluid level is required for maximum battery performance.
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.
WARRANTY
Separate inserts supplied in packaging with the vehicle provide information on Product
Warranty and on Emissions Warranty. Failure to follow instructions for emission parts replacement may violate Federal Law (40 CFR part 1068.105 (b)) and be subject to fines and other penalties as described in the Clean Air Act.
Owner’s Manual
TABLE OF CONTENTS
STARTING THE VEHICLE WITH DISCHARGED BATTERY......................................... 23
B iii Owner’s Manual
TABLE OF CONTENTS
B
WINCH OPERATION (IF EQUIPPED WITH WINCH) ..................................................... 27
BATTERY CHARGING AND MAINTENANCE ................................................................ 38
iv Owner’s Manual
TABLE OF CONTENTS
B
Owner’s Manual v
TABLE OF CONTENTS
Notes: vi Owner’s Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SAFETY
This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury or property damage, the following must be carefully observed:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z-GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph. When an E-Z-GOmanufactured vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER FEDERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to
Federal law the Distributor or Dealer MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571.565. Pursuant to FMVSS
571.500, and in accordance with the State laws applicable in the places of sale and use of the product, the
Distributor, Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company recommends that all E-Z-GO products sold as personal transportation vehicles BE OPERATED ONLY BY
PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS.
This restriction is important to the SAFE USE AND OPERATION of the product.
All customers should adhere to this SAFETY RESTRICTION, in connection with the use of all E-Z-GO products, new and used, the Distributor or Dealer has reason to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or through the Internet at the web site for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
GENERAL
All vehicles can be used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warning can replace good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. E-Z-GO strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.
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.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to a negative (-) battery post.
Never use the chassis or body as a ground connection EXCEPT for grounding the gas engine starting battery.
Refer to GENERAL SPECIDICATIONS for vehicle seating capacity.
Owner’s Manual 1
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease it’s stability, or increase the speed or extend the stopping distance beyond the factory specification. Such modifications can result in serious personal injury or death.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease it’s stability, or increase the speed or extent the stopping distance beyond the factory specification. E-Z-GO prohibits and disclaims responsibility for all such modifications which would adversely affect the safety of the vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense.
Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).
GENERAL OPERATION
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.
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
2
Owner’s Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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.
B
Before working on the vehicle, remove all jewelry.
Be sure no loose clothing or hair can contact moving parts.
Use care not to touch hot objects.
Wear eye protection when working on or around the vehicle. In particular, use care when working around batteries, using solvents or compressed air.
ALWAYS:
• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
• Read and observe all warnings and operation instruction labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being operated.
• Leave the vehicle and seek shelter when there is a risk of lightning.
• Reduce speed to compensate for poor terrain or conditions.
• Apply service brake to control speed on steep grades.
• Maintain adequate distance between vehicles.
• Reduce speed in wet areas.
• Reduce speed and use extreme caution when approaching sharp or blind turns.
• Reduce speed and use extreme caution when driving over loose terrain.
• Reduce speed and use extreme caution in areas where pedestrians are present.
MAINTENANCE
ALWAYS:
• Replace damaged or missing warning, caution or information labels.
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.
• Ensure that repairs are performed by trained and qualified personnel.
• Follow the manufacturer’s maintenance procedures.
• Insulate any tools used within the battery area in order to prevent sparks or battery explosion.
• Use specified replacement parts, NEVER use replacement parts of lesser quality.
• Use recommended tools.
• Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle.
• Support the vehicle using wheel chocks and jack stands. NEVER get under a vehicle that is supported by a jack. 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.
Owner’s Manual 3
4
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LABELS AND PICTOGRAMS
FOR INFORMATION
REFER TO OWNERS
MANUAL OR
WEBSITE
NO PUBLIC
ROAD USE
WARNING USE CAUTION IN
INCLEMENT WEATHER
OPERATOR MUST
BE MIN 4 FT-11 IN
(150 CM)
OPERATE FROM cm
DRIVERS SIDE
ONLY
OCCUPANT MUST
WEAR SEAT BELTS
DRIVE IN ACCORDANCE
WITH LOCAL RULES
AND REGULATIONS www.badboybuggies.com
MIN 150
NO
UNATTENDED
CHILDREN
638040
WARNING
READ THE
MANUAL
DO NOT OPERATE
UNDER DRUG/ALCOHOL
INFLUENCE
SECURE LOAD
MAX BED WEIGHT
500 lbs or 255 kg
NO PASSENGERS
IN TRUCK BED
MAX TAILGATE
WEIGHT 100 lbs
OR 45kg
LEAVE VEHICLE
IN THREAT OF
LIGHTNING
74821G01
TIP OVER
REMAIN SEATED
KEEP ARMS / LEGS
WITHIN VEHICLE
HIGH CENTER OF
GRAVITY MAY CAUSE
MAX SIDE
SLOPE 14°
REAR
DIFFERENTIAL
LOCK
LOCKED
638040
NO MORE THAN
TWO OCCUPANTS
PER SEAT
DO NOT ENGAGE
FRONT DIFFERENTIAL
LOCK WITH WHEELS TURNED
633615
633615
MAX
500 lbs.
255 kg
P
P
MAX
5 in.
12 cm
MAX
100 lbs.
45 kg
74821G01
MAY CAUSE
EXPLOSION
DO NOT FILL
MAX HEIGHT FOR
CENTER OF GRAVITY
5” OR 12 cm ABOVE FLOOR
FUEL CONTAINERS
IN TRUCK BED
NO TAMPERING
KEEP HANDS OUT
SHORTING BATTERY
UNLEADED
GASOLINE
DO NOT
NEGATIVE GROUND
EXPOSE
TO FLAME
BATTERY
(GAS STARTING)
TERMINALS MAY
CAUSE EXPLOSION
MAX
14 o / 25%
FRONT
DIFFERENTIAL
LOCK
UNLOCKED
WARNING
READ THE
MANUAL
1 2 3
WARNING
DO NOT SPILL
FUEL ON HOT
ENGINE
74099G01
74093-G01
CLEAN UP FUEL
SPILLS WITH
WATER BEFORE
STARTING ENGINE
74093G01
WEAR SAFETY
GLASSES
RECYCLE
BATTERIES
74099-G01
DO NOT RELEASE BED
LATCH WITH ANYONE
STANDING BEHIND BED
INFORMATION
FOUND IN
OWNERS MANUAL
DO NOT EXPOSE
TO OPEN FLAME
DO NOT DISPOSE
OF BATTERIES IN
LANDFILL
DANGER
LETHAL
VOLTAGE
LOCATED ON BATTERY HOLD DOWN
WARNING
ELECTRIC
SHOCK
640561
WARNING
EXPLOSIVE
WARNING
CORROSIVE
Owner’s Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LABELS AND PICTOGRAMS
B
NO PUBLIC
ROAD USE
WARNING USE CAUTION IN
INCLEMENT WEATHER
OPERATOR MUST
BE MIN 4 FT-11 IN
(150 CM)
OPERATE FROM
DRIVERS SIDE
ONLY
OCCUPANT MUST
WEAR SEAT BELTS
FOR INFORMATION
REFER TO OWNERS
MANUAL OR
WEBSITE cm
MIN 150
NO UNATTENDED
CHILDREN www.badboybuggies.com
638040 DRIVE IN ACCORDANCE
WITH LOCAL RULES
AND REGULATIONS
DO NOT OPERATE
UNDER DRUG/ALCOHOL
INFLUENCE
REAR DIFFERENTIAL
LOCK
LOCKED
DO NOT ENGAGE
FRONT DIFFERENTIAL
LOCK WITH WHEELS TURNED
633615
633615
LEAVE VEHICLE
IN THREAT OF
LIGHTNING
REMAIN SEATED
KEEP ARMS / LEGS
WITHIN VEHICLE
638040
NO MORE THAN
TWO OCCUPANTS
PER SEAT
628943
FRONT DIFFERENTIAL
LOCK
WARNING
READ THE
MANUAL
UNLOCKED
SHORTING BATTERY
NO TAMPERING
UNLEADED
GASOLINE
KEEP HANDS OUT
DO NOT
EXPOSE
TO FLAME
NEGATIVE GROUND
BATTERY
(GAS STARTING)
TERMINALS MAY
CAUSE EXPLOSION
WARNING
1
DO NOT SPILL
FUEL ON HOT
ENGINE
75696G01
2 3
74093-G01
74093G01
CLEAN UP FUEL
SPILLS WITH
WATER BEFORE
STARTING ENGINE
75696G01
WARNING
HOT SURFACE
LOCATED ON UNDERSIDE OF SEAT BOTTOM / LOAD DECK
630398
5 Owner’s Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Failure to follow these instructions could result in DEATH or SERIOUS INJURY
ALWAYS remain PROPERLY SEATED with SEAT BELT FASTENED and HOLDING ON.
ONLY 2 occupants on bench seat.
Children may need assistance to remain PROPERLY SEATED with SEAT BELT FASTENED and HOLDING ON. NEVER leave children unattended.
KEEP feet, legs, hands and arms inside the vehicle at all times.
NEVER attempt to enter or exit a moving vehicle.
AVOID standing in front of or behind vehicle.
628943
6
Failure to follow these instructions could result in DEATH or SERIOUS INJURY
Maximum deck load is 250 lbs. (110 kg)
The center of gravity of the load must not exceed 12 inches (30 cm) above the deck floor.
The load must be as far forward as possible and secured.
Top heavy loads may cause vehicle instability or tip over.
Drive slowly straight up or down slopes and in turns.
NEVER allow passengers to ride on load deck.
628942
Owner’s Manual
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
GENERAL SPECIFICATIONS
MODEL: BAD BOY BUGGIES - AMBUSH iS
TYPE: GAS / ELECTRIC PARALLEL DRIVE VEHICLE
MODEL YEAR: 2015
Part No:. 640373G01
PRODUCT SPECIFICATION
CONFIGURATION HIGHLIGHTS
Engine: z
Valve Train:
Subaru EH72 Fuel Injection 28 hp (20.8 kW) Rated, 43.9 ci (720 cc)
Overhead valve z Lubrication: Pressurized oil system, spin-on oil filter z
Balancer: Internal counter rotating balance shaft z
Fuel System: Fuel injection with electromagnetic fuel pump z Ignition: Electronic spark/magneto z
Air Cleaner: Replaceable dry cartridge w/pre-filter
Electrical: Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (525 CCA, 60 minute reserve)
Drive Train Gas: Automatic, continuously variable transmission (CVT). Manual locking differentials (front and rear)
Drive Train Elec: 48V (6x8V) AC with speed sensor
Brakes:
Transaxle:
Seating:
Cargo Bed:
4-wheel hydraulic disc brakes. Hand operated park brake (floor mounted).
Differential with helical gears, ground speed governor, forward/reverse
Bench Seat
Roto-molded cross-linked polyethelene. Lifts for access to powertrain.
PRODUCT OVERVIEW
Dimensions
Overall Length
Overall Width
Overall Height
Wheel Base
Front Wheel Track
Rear Wheel Track
115.5 in (293.4 cm)
54.5 in (138.4 cm)
51 in (130 cm) top of steering wheel
76 in (193 cm) from canopy
81.5 in (207 cm)
43.38 in (110 cm)
44.3yeah
Gnd Clearance @ Differential 7 in (17.8 cm) front skid plate
Cargo Box Width (inside) 44.0 in (112 cm)
Cargo Box Length (inside) 36.0 in (91 cm)
Cargo Box Depth (inside)
Cargo Box Capacity
10.5 in (27 cm)
9.6 cu ft (0.27 m
3
)
Roto-molded polyethylene Cargo Box Material
Vehicle Power
Power Source
Valve Train
Horsepower (kW)
Electrical System
Battery (Qty, Type)
Key or Pedal Start
Air Cleaner
Lubrication
Oil Filter
Cooling System
Fuel Capacity
)XHO&DSDFLW\
Differential
GAS: 4 cycle, 43.9 ci (720 cc)
Elec: 48V AC Motor
V Twin Cylinder OHV
GAS 28 hp (20.8 kW) rated
Vehicle Power Cont.
Gear Selection
Front Axle Ratio
Rear Axle Ratio
Performance
Seating Capacity
Curb Weight
Bed Load Capacity
Vehicle load capacity
Outside Clearance Circle
Speed (Level Ground)
Towing Capacity
Steering & Suspension
Steering
Front Suspension
Rear Suspension
Service Brake
Parking Brake
Elec 17.2 hp (12.8 kW) Peak
Starter/Generator, solid-state regulator
Front Tires
Rear Tires
One 12 Volt maintenance free for starter/gen Body & Chassis
6x8 V for Elec Drive
Key Start
Dry cartridge w/ pre-filter
Frame
Front Body & Finish
Rear Body & Finish
Pressurized oil system
Spin-on oil filter
Air cooled
5.3 gallon (20 L) HDUO\SURGXFWLRQ tank
JDOORQ/ODWHSURGXFWLRQWDQN
Helical gears wi WK manual front rear lock-up
Standard Color
Cargo Bed
Forward-Reverse
14.87:1
14.38:1 Fwd; 14.36 Rev
2 Persons
1791 lb (812 kg)
500 lb (225 kg)
900 lb (408 kg)
33.2 ft (10.1 m)
2WD Elec: 25 mph ± 1 mph (40.1 kph ± 1.6 kph)
4WD : 25 mph ± 1 mph (40.1 kph ± 1.6 kph)
1200 lb (544 kg)
Self-compensating rack and pinion
Independent Mc Pherson Strut
Independent Mc Pherson Strut
4 wheel hydraulic disc brakes
Hand Operated
Kenda 25x8-12 Uni-Directional
Kenda 25x11-12 Uni-Directional
Welded steel with DuraShield™ powder coat
Injection Molded TPO
Steel. Base coat/clear coat
Matte Black
5.9 Cu. Ft. Polyethelyne Bed
Owner’s Manual 7
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
VEHICLE DIMENSIONS
52.5”
(133.5 cm)
76.5”
(194.3 cm)
43.75”
(111.1 cm)
Front and Rear Wheels
70”
(177.8 cm)
112”
(284.5 cm)
113”
(287 cm)
53.75”
(136.5 cm)
8
Maximum Recommended Ramp Grade
25% or 14° Max.
Owner’s Manual
Maximum Recommended Side Tilt
25% or 14° Max.
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
Owner’s Manual 9
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
10 Owner’s Manual
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
INTRODUCTION
FEATURES
General Information
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’ position.
ALL accessories that do NOT use the accessory wiring harness MUST be connected to draw from the entire
48 Volt battery pack. A DC to DC converter is required for accessories that require voltage other than 48 volts to operate properly.
Accessories connected to this vehicle that do not use the accessory harness must be connected to the DC to DC converter.
5
4
3 2 1 6
7 8
4WD
GAS
GAS ENGINE
REGEN
OFF
632916
LOW
632918
632907
NOTE: Shown with steering wheel removed.
10
12V
10Amp
MAX
9
1. Key / Direction Selector Switch
Located on the dash to the right of the steering wheel, this four position switch allows the vehicles electrical system to be activated. It allows the operator to turn the electrical system off completely by moving the key to the OFF position; or select Reverse, Neutral, or Forward by rotating key to the right.
2. Fuel Gauge with Low Oil Pressure Indicator
Located in the dash panel below the state of charge meter. The fuel gauge indicates the amount of gasoline in the fuel
Owner’s Manual 11
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
tank, with ‘F’ indicating a full tank and ‘E’ indicating an empty fuel tank. The fuel gauge is equipped with a low oil pressure indicator. A low engine oil pressure condition is alerted with a yellow indicator light.
3. State of Charge Meter
The illuminated state of charge meter is located in the dash. It indicates the amount of usable power in the batteries, with
‘F’ indicating a full charge on the battery pack and ‘E’ indicating the batteries are low. The yellow light indicates the batteries must be charged immediately.
4. Light Switch
Located on the left side of dash, this ON/OFF switch controls the lights. In the ON position, the headlights, taillights and dash panel lights will illuminate.
5. Accessory Switch Location
Rectangular hole plugs may be removed to accommodate switches for accessory items.
6. Mode Switch
Located to the right of the key switch/direction selector, this switch permits the selection of either gas powered rear wheel drive, electric powered front wheel drive or four wheel drive utilizing both electric and gas powertrains at the same time.
7. Gas Engine Start Switch
Located on the dash panel to the right of the fuel gauge, this switch starts the gasoline engine when pressed with the key switch turned to ON.
8. Regen Mode Switch
Located on the dash panel to the right of the mode switch and the gas engine start switch. The operator can switch from high and low regen mode to suit terrain/range conditions.
9. 12 Volt Power Outlet
Located in the lower part of the dash above the cup holder, the 12 volt outlet supplies constant power for additional equipment equipped with a 12 volt plug.
10. Cupholder
A cupholder is provided for convenience of vehicle occupants.
11. Accelerator Pedal
With the key switch set to ‘R’, ‘ON’ or ‘F’, pressing the accelerator pedal starts the electric motor, depending upon the position of the
MODE switch.
12. Brake Pedal
The brake pedal is located on the floor to the left of the accelerator pedal. The brake pedal function is to slow or stop the moving vehicle.
This vehicle is equipped with four wheel hydraulic disc brakes.
12
11
12 Owner’s Manual
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
13. Park Brake
The hand operated park brake is located in the middle of the floorboard. The function of the park brake is to keep the vehicle from inadvertent movement when in a stationary position.
The brake is engaged when the handle is vertical and disengaged when the handle is almost parallel to the floor (as shown).
When leaving the vehicle unattended, engage the park brake by raising the handle until it locks in place. To release the park brake push the handle down towards the floor.
13 14
14. Differential Locks
15
Located in the seat wrap panel below the driver seat. The front and rear drive axles are equipped with manually operated locking differentials. With the lever(s) in the forward position the selected differential is locked and power is distributed to both of the axle drive wheels; with the lever(s) in the rear position the differential is unlocked and power will be transferred to the wheel that is loosing traction, once the wheel regains traction the power will be transferred to both wheels.
B
15. Charger Receptacle
The polarized charger receptacle for the batteries is located on the panel below the driver seat. It is the receptacle for the charger cord when the batteries need to be charged.
Always check to be sure the receptacle is free from dirt and debris before connecting the charger cord.
16. Truck Bed Latch
A truck bed latch is located at the front of the manual lift truck bed. It is used to raise and lower the manual lift truck bed.
To release the latching mechanism, pull the handle upward then raise the front of the truck bed up.
16
17. Truck Bed
The truck bed provides space to transport cargo. A molded plastic bed is standard; some vehicles may be equipped with an optional aluminum bed.
18. Taillights
The taillights are located at the rear of the truck, below the truck bed.
17
18
13 Owner’s Manual
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
19. Head Protection
Rubber pads provide head protection while driving over rough terrain.
They are a standard safety feature on the vehicle and should not be altered or removed.
20. Side Nets
Side nets are a standard safety feature provided with the vehicle and must be properly secured before operating vehicle.
19 20
21. Rear Seat/Load Deck (if equipped)
The rear facing seat is designed for two occupants.The load deck is created by unfolding the rear facing seat.
21
14 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
OPERATING PROCEDURES
PIN AND SERIAL NUMBER LOCATION
The PIN plate is riveted to the frame below the seat wrap panel.
Two serial number and manufacture date code plates are on the vehicle. One is located on the steering column, the other is located on the chassis under the cowl on the driver’s side.
Design changes take place on an ongoing basis. In order to obtain correct components for the vehicle, the PIN number, manufacture date code, serial number and vehicle model, must be provided when ordering service parts.
Front of Vehicle
Serial Number
Part B
Serial Number
Part A
PIN Label
PIN Plate
Improper use of this vehicle could result in severe injury or death. The AMBUSH is a light duty utility vehicle, NOT an All Terrain Vehicle (ATV).
To reduce the possibility of severe injury or death resulting from loss of vehicle control the following warnings must be observed:
When driving vehicle, consider the terrain, traffic conditions and the environmental factors which affect the terrain and the ability to control the vehicle.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass or gravel.
Maintain a safe speed when driving up or down a hill. Use service brake to control speed when traveling down an incline. A sudden stop or change of direction may result in loss of control.
To prevent loss of control, do not move the vehicle direction selector while the vehicle is in motion. moving the direction selector will result in a sudden slowing of the vehicle.
Slow down before and during turns. All turns should be made at reduced speed.
Do not drive through water that is over 12 inches deep.
To prevent inadvertent movement when the vehicle is to be left unattended, engage the parking brake, turn key to OFF position and remove key.
Make sure the key switch/direction selector is set to the neutral position before attempting to start the vehicle.
Owner’s Manual 15
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Always bring the vehicle to a complete stop before shifting the direction selector.
Do not take vehicle out of gear while in motion (coast).
Check area behind vehicle before operating in reverse.
All occupants must be seated with seat belts fastened and front side nets latched. Keep entire body inside vehicle and hold on while vehicle is in motion.
This vehicle is not a toy and using it while engaging in horseplay is dangerous.
BEFORE INITIAL USE
Record the four digit key number and store in a safe place. Individual keys can only be replaced if the key number is known. Without a key number the entire ignition switch will have to be replaced if keys are lost.
Make a note of the key number in the event that new keys must be ordered. The key number is stamped into the key and into the face of the ignition switch. Both numbers must match.
Be sure you understand the vehicle, its equipment and how to use it safely. Read, understand and follow the safe operation labels in various location on the vehicle. Although the vehicle has been designed to provide safe and reliable operation, maintaining good performance depends, to a large extent, on the operator.
Before a new vehicle is put into operation, the items shown in the
INITIAL SERVICE CHART must be performed.
Battery Charger
Batteries
Seats
Brakes
Tires
Fuel
Item
Engine
General Vehicle
INITIAL SERVICE CHART
Service Operation
Remove from vehicle and read operating instructions.
Charge battery for gas engine and battery set for electric motor.
Remove protective plastic covering.
Check operation; adjust if necessary.
Check hydraulic fluid level; add if necessary.
Check air pressure; adjust if necessary.
See “WHEELS AND TIRES” on page 33 for tire
pressure.
Fill with correct fuel, regular unleaded, 10% or less Ethanol blend is permissible.
Check oil level (Initial change after 20 hours).
Check for oil or fuel leaks that could have developed during shipment.
Check for any loose or missing hardware.
Key Number
16 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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).
B
To reduce the chance of battery explosion that could result in severe injury or death, never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc.
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%.
Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation.
Five air exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water heaters and furnaces.
PORTABLE CHARGER
Use charger ONLY on 72 volt battery systems. Other usage may cause personal injury and damage. Lead acid batteries may generate explosive hydrogen gas during normal operation. Keep sparks, flames, and smoking materials away from batteries. Provide adequate ventilation during charging. Never charge a frozen battery. Study all battery manufacturers’ specific precautions such as recommended rates of charge and removing or not removing cell caps while charging.
Risk of electric shock. Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances. A grounded outlet is required to reduce risk of electric shock – do not use ground adapters or modify plug.
Do not touch uninsulated portion of output connector or uninsulated battery terminal.
Disconnect the DC supply before making or breaking the connections to the battery while charging. Do not open or disassemble charger. Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way – refer all repair work to qualified personnel. Not for use by children.
The portable charger is shipped with the vehicle. Prior to vehicle or charger operation, the charger must be removed from the vehicle. A dedicated circuit is required for the charger. Refer to the charger manual for appropriate circuit protection. For optimum performance and shortest charge times, place the charger in an area with adequate ventilation and relatively free of dirt, mud, or dust. If the charger is operated in an outdoor location, rain and sun protection must be provided. The charger may get hot during operation and must be placed such that risk of contact by people is reduced.
17 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Looping the DC cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging. The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away.
To reduce the possibility of a physical hazard that could result in an electrical shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle.
An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution.
Using the Charger
Before using, read the charger manufacturer’s operation manual that is supplied with the charger.
To prevent a physical hazard that could result in an electrical shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle.
An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution.
The charging (DC) cord is equipped with a polarized connector that fits into a matching receptacle on the vehicle. The receptacle is located in the seat panel below the seat on the driver’s side of the vehicle.
SEAT BELT OPERATION
Seat belts must be worn by all occupants whenever vehicle is in motion.
Charger
Receptacle
Ensure seat belts are free from twists and latch securely.
Position shoulder belt across the top of the shoulder; do not place shoulder belt under the arm.
Keep belts snug and positioned low on hips. Loose fitting belts significantly reduce protection.
The vehicle is equipped with seat belts for the number of occupants it is designed to carry; do not exceed the recommended number of occupants for the vehicle.
Seat belts are designed for one occupant per belt. Do not attempt to secure more than one person in a seat belt.
Seat belts must be worn at all times by all occupants when vehicle is in motion.
18 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
To keep seat belts in proper working condition, do the following:
• Inspect the seat belt webbing and hardware periodically. Check for cuts, frays or loose parts. Replace components if excessive wear or damage is noticed.
B
• Keep seat belts clean and dry. To clean, use mild soap and warm water. Do not use bleach, dye or abrasive cleaners as this will weaken the belt webbing material.
• Do not insert any foreign objects into the retractor mechanism.
• Periodically check for smooth operation and replace if the mechanism is not operating properly.
To properly secure the seat belts:
1.
Pull the metal tab on the seat belt across the body toward the appropriate buckle located near the center of the seat.
2.
Insert tab into buckle. (A click will be heard when the tab is securely latched).
3.
Position the lap belt as low as possible on the hips, not at the waist.
• Adjust to ensure a snug fit by pulling the shoulder portion upward.
The retractor will lock the belt during sudden stops. It may also lock if occupant leans forward quickly. Slow, easy motions allow the belt to travel freely.
To release the safety belt, press the buckle release button and allow the belt to retract. If the belt does not retract, check for twisted straps.
OPERATING THE VEHICLE
Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance.
Read the following warnings before attempting to operate the vehicle.
To reduce the possibility of severe injury or death resulting from loss of vehicle control, the following warnings must be observed:
When driving vehicle, consider the terrain, traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.
Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline. A sudden stop or change of direction may result in loss of control.
Slow down before and during turns. All turns should be made at reduced speed.
Never drive vehicle up, down, or across an incline that exceeds 14° (25% grade).
Refer to GENERAL SPECIFICATIONS for seating capacity.
To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings must be observed:
Owner’s Manual 19
B
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Pressing accelerator pedal may cause inadvertent vehicle movement. Turn the key to the
‘OFF’ position whenever the vehicle is parked.
To prevent inadvertent movement when the vehicle is to be left unattended, engage the park brake, turn key to ‘OFF’ position and remove key.
Always bring the vehicle to a complete stop before shifting the direction selector.
Do not take vehicle out of ‘gear’ while in motion (coast).
Check the area behind the vehicle before operating in reverse.
All occupants must be seated and wearing their seat belts, front side nets must be latched. Keep entire body inside vehicle and hold on while vehicle is in motion.
COMMON SENSE OPERATION
To prevent severe injury or death, observe the following:
Never transport loaded firearms on or in vehicle.
Check that firearms are unloaded with the safety engaged and are properly secured with muzzle pointing in a safe direction before operating vehicle. Be aware of other firearms in proximity to operator and passengers.
This vehicle is not a toy.
If not operated properly and responsibly, it can cause severe injury or death to the operator, passengers or bystanders. All operators should possess a valid driver’s license. Children should not be permitted to operate the vehicle. Children may not have the skill, judgement or strength to operate this or similar vehicles.
Alcohol, drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely.
Always review side effects of any medication with a doctor or pharmacist before operating vehicle.
Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when operating vehicle in rough or densely wooded terrain.
When driving at full speed on a dirt road, loose surfaces or wet grass, vehicle stopping distance will increase. If the vehicle is fully loaded, it will take longer to stop than with no load. When operating vehicle in wet weather conditions, remember that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit. If wet, the brakes will lose much of their effect.
Slow down when in unfamiliar terrain. Slow down when cresting a hill in an area that you are unfamiliar with.
Some hills are too steep to climb. If you attempt to climb a hill that is too steep or if you are unable to achieve adequate traction, do not attempt to turn around on the hill. Slowly back straight down the hill using the service brake to control speed.
ENVIRONMENTAL CONCERNS
As a responsible user, practice respect for all wildlife and their habitat. Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles. To prevent severe injury or death while driving, be aware of the following:
Environmental hazards such as steep slopes, overhanging limbs, etc.
Danger of fire when vehicle is operated over dry combustible organic material.
20 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
When driving, be aware of environmental hazards such as steep slopes, overhanging limbs, etc. Be aware of the danger of fire when the gasoline powered vehicle is operated over dry combustible organic material.
B
STARTING AND DRIVING
Operation of this vehicle is limited to persons who are licensed drivers.
This vehicle is to be operated by licensed drivers only. Do not attempt to operate the buggy under the influence of drugs or alcohol. Never turn the key switch to OFF while the buggy is in motion, this can cause loss of control and lead to serious injury or death.
Use caution when traveling uphill or downhill; on a downhill slope it is possible for the buggy to achieve speeds greater than if it were operating on flat terrain. Speed on an uphill slope should be limited to not more than 5 mph and in a downhill situation must be limited to 5 mph by using the service brake to slow the vehicle. If allowed to travel too fast on a downhill slope loss of control may occur, this can cause serious injury or death.
Use caution when traveling through water and never operate vehicle in water over 12 inches deep.
This vehicle has two separate powertrains that may be operated individually to provide two wheel drive or at the same time to provide four wheel drive. When the MODE switch is set to ELEC (top of switch pressed) only the front drive axle is engaged, drawing power from the battery set. With the MODE switch set to GAS (bottom of switch pressed) only the rear axle is engaged powered by the gas engine. With the MODE switch set to 4WD (switch in neutral position) both the electric and gas powertrains are engaged for four wheel drive.
While operating in GAS mode (rear wheel drive) the vehicle can be changed on the fly from 2 wheel rear drive to full time
4 wheel drive by setting the Mode Switch on the instrument panel to the 4WD (middle) position.
To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release service brake until engine has started.
Electric Powertrain
To operate the vehicle in electric only mode:
• Set the Mode Switch to ELEC.
• Place the key in the key switch and turn it to the ON/N position.
• Turn the key to the desired direction; F for forward or R for reverse.
• Press the brake pedal and hold it down.
• Release the parking brake.
• Slowly press the accelerator pedal to start the electric motor while releasing pressure on the brake pedal.
• When the accelerator pedal is released the motor will stop and the vehicle will slow down and eventually stop.
To stop the vehicle more quickly, press the brake pedal.
Gas Powertrain
To operate the vehicle in gas engine only mode:
• Set the Mode Switch to GAS.
• Place the key in the key switch and turn it to the ON/N position.
• Press the brake pedal and hold it down.
• Press and hold the start engine switch until the engine starts.
Owner’s Manual 21
B
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
• Release the parking brake.
• Turn the key to the desired direction; F for forward or R for reverse.
• Release the parking brake.
• Slowly press the accelerator pedal while releasing the pressure on the brake pedal.
• When the accelerator pedal is released the vehicle will slow down and the engine will idle. To stop the vehicle more quickly, press the brake pedal.
Do not allow the starter to operate continuously for more than 10 seconds. Allow 30 seconds between starting attempts. If the vehicle does not start on the third attempt, turn the key switch off and determine the cause of the problem.
If the vehicle had been running and the engine does not start within 10 seconds, use the choke.
Starting the Vehicle on a Hill
To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release service brake until engine has started.
Do not hold vehicle on hill by using accelerator and motor. This will cause premature and excessive wear to drive train components.
To reduce the possibility of permanent damage to the drive system, it is important to prevent excessive roll-back when starting the vehicle on a hill.
Place left foot on service brake and release the park brake. Depress accelerator with right foot and release the service brake by lifting left foot.
RUN-IN
Check for oil or fuel leaks that could have developed in shipment from the factory. Avoid full throttle starts and rapid acceleration until the engine has achieved operating temperature.
All engines consume more oil than normal during the first hours of operation. As internal moving parts are run-in, oil consumption should gradually decrease until the rate of consumption stabilizes.
Check the oil level per the Periodic Service Schedule. Add oil if the level on the dipstick indicates that oil is in the add oil range.
Fill Cold Engine to this Point
Add Oil
Safe
Operating Range
Hot Engine
Maximum Oil Level for Hot Engine
Do not Overfill
Check Oil Level on Dipstick
22 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.
B
The oil dipstick/fill cap must be in place before operating the engine. Failure to install the dipstick/fill cap will result in oil becoming contaminated and/or being discharged into the engine compartment.
STARTING THE VEHICLE WITH DISCHARGED BATTERY
Do not attempt to ‘jump start’ a vehicle using another vehicle.
The vehicle is equipped with a starter/generator. When starting the engine, the starter/generator functions as a starter and with the engine running, it functions as a generator. Since the engine stops when the accelerator is released, do not attempt jump starting .
With the running times associated with this kind of vehicle, the generator is more than adequate to maintain the battery charge level. The generator is not designed to charge a discharged battery.
If the vehicle is equipped with additional lights and/or a strobe light that is used when the vehicle is not in motion, the starter/generator may not be adequate to maintain battery charge. If the vehicle battery has become discharged, it must be charged using a 12V charger that is rated at 10 amps or less. Observe all instructions provided by the manufacturer of the charger.
COASTING
To reduce the possibility of severe injury or death from coasting at above recommended speeds, limit speed with service brake.
On steep hills, it is possible for the vehicle to coast at greater than normal speeds encountered on a flat surface. To reduce the possible loss of vehicle control and severe drivetrain damage, speeds should be limited to no more than the maximum governed speed on level ground (see GENERAL SPECIFICATIONS). Limit speed by applying pressure to the brake pedal.
23 Owner’s Manual
B
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
FUEL
To decrease the risk of severe injury or death from improper fuel handling:
Do not smoke near the fuel tank.
Do not add fuel near open flame or electrical items that can cause a spark.
Always handle gasoline in a well ventilated area.
Always wear eye protection to protect against splashed fuel and fuel vapors.
Inspect the fuel cap, tank and other components for leaks or damage that can cause a hazardous condition.
Oxygenated or reformulated gasoline, is mixed with alcohols or ethers. Excessive amounts of these blends can damage the fuel system or cause performance problems. If any operating problems occur, use gasoline with a lower percentage of alcohol or ether.
Use clean regular grade unleaded fuel. The Ethanol blend fuel up to 10% is permitted.
Do not use gasoline that contains methanol.
High altitude or heavy use/load applications can benefit from higher octane gasoline.
FUEL TANK
The fuel tank is found below the seat on the passenger side of the vehicle. Fill the tank with clean, automotive grade gasoline.
Early Production Fuel Tank
Always allow enough space for the expansion of gasoline. Leave at least 1-inch (2.5 cm) of space below bottom of filler neck.
Early production fuel tanks can be identified by the location of the fuel cap which is located in the middle of the top of the tank as shown.
Early production fuel tanks require enough space for the expansion of the gasoline. Leave at least 1-inch (2.5 cm) of space below the bottom of the filler neck.
Fuel
1" Min.
(2.5 cm)
Owner’s Manual
Early Production Fuel Tank
24
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Late Production Fuel Tank
Late production fuel tanks can be identified by the location of the fuel cap which is located in the rear of the top of the tank as shown.
Late production fuel tanks are designed to allow for fuel expansion and do NOT require space below bottom of filler neck.
B
BATTERY
Late Production Fuel Tank
If the gas engine starting battery has become discharged, it must be charged using a 12 volt charger that is rated at 10 amps or less and in accordance with all instructions provided by the manufacturer of the charger.
TOWING A TRAILER
The vehicle is equipped with a 2-inch receiver. The trailer and its load must not exceed 1200 lbs (544kg) and no more than 100 lbs (45 kg) tongue weight may be attached to the hitch. Remember that the overall capacity of the vehicle, operator, passenger, contents of load bed and accessories must be reduced to compensate for the trailer and load.
The range of motion of the trailer is limited by the ball and hitch. The trailer should not be used on rough trails or over objects such as logs, large rocks, holes, etc.
Never install baskets or extensions using the hitch receivers. Such items will change the performance characteristics of vehicle and result in unsafe handling, possible roll over or vehicle damage.
TERRAIN
The vehicle is NOT designed for use on public roads. The vehicle may be used on established trails or open terrain that is free from stumps, large rocks or holes. The vehicle should not be used to cross water that is more than 12 inches (30 cm) deep or fast moving water.
Be aware of steep slopes, overhanging limbs or danger of fire when the gas engine is operated over dry combustible material. Consult dealer for an available spark arrestor for this vehicle.
When traveling up or down steep slopes do not attempt to turn the vehicle around on the slope. Vehicle stopping distance increases when driving on wet gras, dirt roads or loose surfaces.
Owner’s Manual 25
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
DIFFERENTIAL LOCK
To reduce the possibility of severe injury or death from loss of control while vehicle is in motion, do not engage front differential lock while turning steering wheel. Lock engagement may force steering wheel to center abruptly, causing loss of grip on wheel and control of vehicle.
Do not drive vehicle on pavement or other hard surfaces with differentials in the locked position. Sharp maneuvers and turns can cause premature wear and damage to the CV shafts and tires.
Differential locks should only be used when additional traction is required. Continued use of rear differential lock may cause excessive wear to tires. Continued use of front differential lock may increase steering effort.
Vehicle must be completely stopped before engaging or disengaging differential lock. Failure to stop may damage differential.
Front and rear differentials are equipped with manually actuated locks. A locked differential distributes power to both tires on the axle at all times, which greatly increases traction. Locks are not intended to be engaged at all times. Their purpose is to free, or prevent vehicle from being stuck as terrain demands, ideally for short runs at slow speeds. Always disengage differential locks as terrain and conditions allow.
Push lever(s) to the forward position to engage the differential lock(s). Pull the levers into the rear position to disengage the lock(s).
DUMP BED
Passengers should never be allowed to ride in the dump bed. Severe injury or death could result if they should fall out or the vehicle is involved in an accident or sudden maneuver.
Be careful when loading the vehicle. Secure loads to prevent shifting. Do not overload vehicle. A dump bed warning label is affixed to the inside of the bed on the front panel.
This label must be understood and observed at all times for safe operation of the vehicle. The dump bed is limited to a maximum load of 500 lbs. The load must be positioned in the bed as far forward as possible, it’s center of gravity must not be higher than 12" above the bed floor, and securely fastened down. Failure to follow these instructions could cause personal injury, damage to the vehicle and/or cause the vehicle to tip over. Operate the vehicle with awareness of the load.
Do not drive the vehicle with the dump bed raised or with the tailgate unsupported.
When using the optional electric dump, be sure to avoid backing up to the edge of a drop off, such as a loading dock or ravine. A misjudgment of distance or an unstable surface could result in the vehicle falling backwards.
Always insure that no one is behind or close to the dump bed while the electric dump mechanism is being operated.
26 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
REAR FACING SEAT / LOAD DECK
B
Passengers should never be allowed to ride on the load deck. Severe injury or death could result if they should fall out or the vehicle is involved in an accident or sudden maneuver.
The rear facing seat will accommodate two passengers with a combined weight of less than 400 pounds or, the seat bottom may be folded out to form a load deck. When using the load deck, position the load as far forward as possible and securely fastened down. The maximum load is 250 lbs and the center of gravity must not be higher than 12” above the load deck.
WINCH OPERATION (IF EQUIPPED WITH WINCH)
This vehicle may be equipped with an optional winch. Read, understand and follow all of the information supplied with the winch on the operation and use of the winch before attempting to operate it.
Winch Application
A winch may be used for a number of purposes, including pulling the vehicle if it loses traction on unsuitable terrain.
Improper use of the winch could result in a number of conditions that could cause severe injury or death to operator, occupants of vehicle or bystander.
It is impossible to predict all conditions that the winch could be used, therefore the following warnings should not be considered as complete. Before operating the winch, consider the possible dangers and take precautions to protect yourself, your passenger and any bystanders.
To prevent severe injury or death to operator, occupants or bystanders, consider the following when selecting an object to attach the cable to:
Make sure the object cannot be pulled over or otherwise damaged.
The object the winch cable is attached to could fall on the vehicle and it’s occupants.
If attaching the winch to a dead tree, a section could fall.
When pulling vehicle with winch, pull straight only. Do not permit the cable to contact the side of the drum.
Do not pull vehicle at an angle. If the vehicle is pulled at an angle, it could turn over causing severe injury or death to anyone in the area. The winch cable could also become overstressed and break causing severe injury or death to anyone struck by the cable.
The rear drive axle is equipped with a manually operated locking differential. With the differential unlocked, if one drive wheel looses traction, all available power is transferred to that wheel until it regains traction. In normal driving this is not a problem. However, if the vehicle becomes ‘hung up’ on an object, the vehicle will stop. With the differential locked, power is distributed to both drive wheels at all times. If both drive wheels lose traction as a result of the vehicle becoming ‘hung
Owner’s Manual 27
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
up’ on an object, the vehicle will stop. If the vehicle cannot be pushed off the obstruction, it will have to be pulled off using
B the winch.
To prevent severe injury or death, read and understand the following warnings before attempting to use the winch:
The winch is not intended to be used in any hoisting operation.
The rolling load capacity of the winch decreases with the steepness of the slope.
The winch is designed for intermittent duty only.
The electric motor should not be allowed to become excessively hot. If the motor becomes uncomfortably hot to the touch, stop winching and allow the motor to cool.
Always wear thick leather gloves when handling the wire cable.
Replace frayed wire cable with a direct factory replacement only.
Never operate the winch with less than five (5) full turns of cable around the drum.
If the winch motor stalls from overloading, do not continue to activate the winch remote control. The wire cable may become overstressed.
Do not attempt to pull loads exceeding the manufacturers maximum load rating.
Have all persons and pets leave the area while operating winch. Never allow anyone to remain in the vehicle.
To prevent damage to the wire cable, never hook the cable to itself.Always use a nylon sling.
Damper
Nylon
Sling
Do Not Hook Cable to Itself
Use a Nylon Sling and Install a Damper when Winching
Stay clear of the winch, the cable and the cable hook. Place a heavy cloth, jacket or blanket over the cable to act as a damper should the cable break when operating the winch.
When operating the winch, keep the entire area in view.
Never release the free spool clutch while the cable is under load.
Never work around the winch drum or the winch cable while it is under tension.
Unplug the winch switch before working on the winch drum in order to prevent inadvertent operation.
When operating winch, take up slack slowly. Stop winch before cable becomes tight and inspect all winching connections. Check winch attachment, hook attachment, nylon sling (if required) and load attachment.
28 Owner’s Manual
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Incorrect
Correct
Do Not Pull at Angle
Do not pull at an angle. This will cause the wire cable to pile up on one end of the winch. This may jam the winch causing damage to the cable and/or the winch. Pulling the vehicle at an angle can cause damage to the front suspension and may cause the vehicle to overturn. When pulling vehicle, pull straight only.
If the vehicle is being used as an anchor to winch a load, it should have the parking brake applied and chocks installed on all wheels.
Never use the winch to lift people or other overhead loads.
Do not use the winch to secure loads. Use a tie down designed for the job.
Do not apply shock loads to the winch.
Do not attempt to modify or weld the winch.
Owner’s Manual 29
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
30 Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
MAINTENANCE
VEHICLE CLEANING AND CARE
To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.
When pressure washing exterior of vehicle, do not use pressure in excess of 700 psi and maintain a 12” minimum distance from spray nozzle to painted surface. To reduce the possibility of cosmetic damage, do not use any abrasive or reactive solvents to clean plastic parts.
It is important that proper techniques and cleaning materials be used. Using excessive water pressure may cause severe injury to operator or bystander, damage to seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi to wash exterior of vehicle.
Clean windshield with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish or Plexus
®
plastic cleaner available from the service parts department.
Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive appearance 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.
TRANSPORTING VEHICLE
Be sure vehicle and all contents are secure before transporting a vehicle.
Never ride on the vehicle being transported.
Always remove windshield (if equipped) before transporting.
Maximum speed with sun top installed is 70mph (112 kph).
If the vehicle is to be transported at highway speeds, the windshield must be removed and the seat bottom secured.
When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points.
The rated capacity of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load plus 1000 lbs. (454 kg).
Secure the vehicle using ratchet tie downs.
Owner’s Manual 31
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
ROUTINE MAINTENANCE
Preventive maintenance, applied at recommended intervals, is the best guarantee for keeping the vehicle dependable.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the PERIODIC
SERVICE SCHEDULE for appropriate service intervals.
LIFTING THE VEHICLE
Tool List Qty
Floor Jack.................................................................... 1
Jack Stands................................................................. 4
Wheel Chocks ............................................................. 4
To reduce the possibility of severe injury or death from a vehicle falling from a jack:
Always place chocks in front and behind the wheels not being raised.
Be sure the vehicle is on a firm and level surface.
Never get under a vehicle while it is supported by a jack.
Use jack stands and test the stability of the vehicle on the stands.
Use extreme care since the vehicle is extremely unstable during the lifting process.
When lifting the vehicle, position the jacks and jack stands at the areas indicated.
Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while lifting.
To raise the entire vehicle, install the wheel chocks in front and behind each front wheel.
Center the jack under the rear axle tube next to differential housing or under the skid plate. Raise the vehicle and position the jack stands under the frame where the leaf spring mounting bracket is welded to the frame.
Lower the jack and test the stability of the vehicle on the two jack stands.
Place the jack under the center front of the car just behind the bumper. Raise the vehicle and position the jack stands under the frame where the instrument panel support is attached to the frame.
Lower the jack and test the stability of the vehicle on all four jack stands. To raise only the front or rear of the vehicle, place the wheel chocks in front and behind the wheels that are not to be raised. The jack may be left under the center front of the frame while the front end of the vehicle is on the jack stands.
Lower the vehicle by reversing the lifting sequence.
32 Owner’s Manual
MAINTENANCE
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LIGHT BULB REPLACEMENT
B
To reduce the possibility of premature bulb failure, do not touch new bulbs with bare fingers. Use clean, dry tissue or paper towel to handle the glass portion of the bulb.
Headlight Bulb Replacement
Make sure that the vehicle key switch is in the OFF position and the key has been removed.
Locate the headlight bulb socket on the backside of the light assembly. Turn bulb socket a quarter turn counterclockwise to unlock. Pull out bulb and socket, remove old bulb from the socket. Insert new bulb in socket and position bulb socket into headlight housing and rotate socket a quarter turn clockwise to secure.
Inside of Cowl
Headlight
Bulb
Taillight Bulb Replacement
Make sure that the vehicle key switch is in the OFF position and the key has been removed.
The taillight contains an LED light board rather than a light bulb, if the LEDs burn out the whole light will have to be replaced.
WHEELS AND TIRES
A tire explosion can cause severe injury or death. Never exceed the inflation pressure rating on the tire sidewall.
To reduce the possibility of tire explosion, pressurize tire with small amounts of air applied intermittently to seat beads. Due to the low volume of the small tires, over inflation can occur in seconds. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face and eyes from escaping air when removing a valve core.
Use caution when inflating tires. Over inflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause severe injury.
To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for impact wrench use.
Tire Repair
Tool List Qty.
Lug Wrench, 3/4” or 17mm.......................................... 1
Impact Wrench ............................................................ 1
Tool List Qty.
Impact Socket, 3/4” or 17mm ...................................... 1
Torque Wrench, ft. lbs. ................................................ 1
Steel wheel rims will require the 3/4” lug wrench and aluminum wheel rims will require the 17mm lug wrench.
Generally, the most cost effective way to repair a flat tire resulting from a puncture in the tread portion is to use a commercial tire plug.
Owner’s Manual 33
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
If the tire is flat, raise vehicle and remove wheel. Refer to ‘Lifting the Vehicle’ for proper lifting procedure and safety information. Inflate tire to the maximum recommended pressure, immerse tire in water to locate the leak and mark the leak with chalk. Insert tire plug in accordance with manufacturer’s specifications.
Use caution when inflating tires. Due to the low volume of the small tires, over inflation can occur in seconds. Over inflation could cause the tire to separate from the wheel or cause the tire to explode.
See GENERAL SPECIFICATIONS section for recommended tire inflation pressure. Under no condition should inflation pressure be higher than recommended on tire sidewall. All four tires should have the same pressure for optimum handling characteristics. Be sure to install the valve stem dust cap after checking or inflating. The vehicle is fitted with low volume tubeless tires mounted on one piece rims.
Wheel Installation
Front of
Vehicle
Ro t a t io
To reduce the possibility of component damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.
1
It is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will assure even seating of the wheel against the hub.
With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger tighten the lug nuts (1) in a ‘cross sequence’ pattern. Tighten the lug nuts to 50 to 85 ft. lbs. (68 to 115 Nm) torque in 20 ft. lbs. (27 Nm) increments following the ‘cross sequence’ pattern.
Tire style may vary
Valve Stem Cap
1
Cross Sequence
Unidirectional Tires
Unidirectional tires may be identified by a directional arrow on the sidewall. Be sure to position the wheel on the hub correctly with the arrow indicating the direction of rotation when moving forward.
WHEEL ALIGNMENT
Driving over rough terrain may cause mis-alignment of the wheels. With four wheel independent suspension both front and rear wheels may need to be aligned.
Wheel Alignment
Tool List Qty.
Tape Measure.............................................................. 1
Open End Wrench, 17 mm.......................................... 1
Tool List Qty.
Open End Wrench, 12 mm.......................................... 1
Open End Wrench, 19 mm.......................................... 1
Park the buggy on a level surface, set the front wheels straight ahead. Turn the key switch to OFF, remove the key and set the parking brake.
With the buggy empty (no passengers or payload) measure the distance between the center of both the front and the rear sets of tires. Measure both in front and behind each tire set, keeping the tape measure parallel to the ground. The measurement behind the tires should be 1/4” less than the measurement taken at the front of the tires to produce a toeout condition.
34 Owner’s Manual
MAINTENANCE
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B
Adjust both tie rods equally to obtain the correct toe-out. Hold tie rod (2) with an open end wrench, loosen the jam nut (1) and turn the adjustment shaft (3) to move the wheel in the desired direction.
Recheck the measurement at the front and at the rear of the front tires, if the 1/4” toe-out has been achieved tighten the lock nut (1) on each tie rod.
3
1
2
BRAKES
This vehicle is equipped with four wheel hydraulic disc brakes. The parking brake is hand operated. Check the fluid level at intervals specified in the PERIODIC SERVICE
SCHEDULE; if fluid leaks are noticed or the brake pedal seems soft check the fluid level immediately. If the brake pedal is soft, the brake system should be bled to remove air from the brake lines. Instructions for bleeding the brake system are included in the vehicle repair manual.
Master Cylinder
The master cylinder is located under the front of the vehicle near the driver side front wheel well. Before removing the reservoir cap, clean any dirt or debris from around the reservoir and cap.
Check fluid level in the reservoir. The fluid level should be between the
MAX and MIN lines. Use fresh DOT 3 brake fluid only.
To fill the reservoir, remove the cap to expose the rubber diaphragm, remove the diaphragm, making sure to keep it clean. Add enough brake fluid to bring the level up to the MAX line. Collapse and replace the diaphragm and install the reservoir cap. Clean any spilled brake fluid from the area.
Owner’s Manual 35
MAINTENANCE
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Bleeding Brakes
Tool List Qty. Tool List
Hose ........................................................................ A/R
Brake Fluid, DOT 3.................................................. A/R
Qty.
Clean Container .......................................................... 1
Wrench, 1/4” box end .................................................. 1
The hydraulic brake system must be free of air to operate properly. Air can enter the system when hydraulic parts are disconnected for servicing or replacement, or when the fluid level in the master cylinder reservoir is very low. Air in the system will give the brake pedal a spongy feeling upon application.
An assistant will be necessary to perform this procedure.
1.
Use a clean cloth to wipe off the master cylinder reservoir and wheel cylinder bleeder valves. Clean each fitting before opening to prevent contaminating the system.
2.
Open the master cylinder reservoir and top off with standard automotive
DOT 3 brake fluid.
Bleeder
Hose
Never return brake fluid to the original container or reuse brake fluid due to the possibility of contamination by dirt, grease, moisture. Contaminated brake fluid could cause failure of the braking system. Dispose of brake fluid in accordance with Federal, state and local codes.
3.
Attach a short length of clear hose to the caliper bleed valve and insert the other end into a suitable clean container containing fresh, clean brake fluid.
Check the fluid level in the master cylinder frequently during this operation to prevent air from entering the lines.
4.
Starting with the passenger side rear brake, then driver side rear brake, passenger side front brake and driver side front brake last. Bleeding the brakes requires an assistant to pump the brake pedal and keep pressure on the pedal.
Bleed the brakes using the following procedure: a.
Build pressure in the brake system, if possible, by slowly pumping the brake pedal.
b.
Open the bleeder valve while an assistant holds pressure on the brake pedal as the pedal slowly goes through the full stroke.
c.
Close the bleeder valve and have the assistant slowly release the brake pedal. d.
Repeat the process until no bubbles can be seen leaving the bleeder valve. e.
Close the valve and move to the next brake.
Parking Brake Adjustment
The floor mounted parking brake has an adjustment knob on the end of the handle.
If the vehicle starts to roll when the parking brake is engaged on a hill, place one foot on the service brake pedal, turn the adjustment knob clockwise to increase tension on the brake, release the service brake and check to see if the parking brake is holding, repeat the process if necessary.
Adjustment
Knob
36 Owner’s Manual
MAINTENANCE
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GAS POWERTRAIN
Engine
This vehicle is powered by a 28hp Subaru V-Twin Cylinder OHV engine. For all maintenance procedures for the gas engine refer to the Subaru Manual located in Appendix A of this owner’s guide.
The 12 volt engine starter battery is located under the front of the vehicle. It is charged by the generator as the engine runs. See BATTERY MAINTENANCE on page 34.
B
ELECTRIC POWERTRAIN
To reduce the possibility of severe injury or death from improper servicing techniques:
DO NOT attempt any type of servicing operations before reading all notes, cautions and warnings in this manual.
Never press the accelerator pedal with drive wheels off the ground.
Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with all four drive wheels raised and vehicle properly supported on jack stands.
To reduce the possibility of motor damage, never operate vehicle at full throttle for more than 4 - 5 seconds while vehicle is in a ‘no load’ condition.
Reduce the possibility of accidental starting by disconnecting battery at negative terminal before servicing.
Wear eye protection when working on the vehicle. Use extra care when working around batteries, or using solvents or compressed air.
To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the battery before removing battery wires.
Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench ‘shorting out’ a battery, which could result in an explosion.
The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.
Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 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.
37 Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
System Test
At monthly intervals, test the controller by setting the MODE switch to ELEC and allowing the vehicle to roll down an incline with the accelerator pedal released. Braking force should be felt at approximately 2 mph (3 kph) indicating that the system is functioning. If vehicle speed continues to rise, press on the brake pedal to stop the vehicle and have the vehicle inspected by a trained mechanic.
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.
It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual. Preventative maintenance, applied at recommended intervals, is the best guarantee for keeping the vehicle both dependable and economical.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the PERIODIC
SERVICE SCHEDULE for appropriate service intervals.
AXLES
Front and Rear Axles
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.
Check/Fill
Plug
The front and rear axle do NOT use the same lubricant. Extreme care should be used when topping off or refilling the axles.
The axles use different lubricants. Do NOT mix oils in an axle. The front axle contains 14 ounces of 90 weight gear oil, the rear axle contains 22 ounces of SAE 80 weight gear oil.
Checking the Lubricant Level
Clean the area around the check/fill plug and remove the plug. The correct lubricant level is just below the bottom of the threaded hole. If lubricant is low, add lubricant as required. Add lubricant slowly until it starts to seep from the hole. Install the check/fill plug.
BATTERY CHARGING AND MAINTENANCE
Battery Safety
Always observe the following warnings when working on or near batteries.
To prevent battery explosion that could result in severe personal injury or death, keep all smoking materials, open flames or sparks away from the batteries.
38 Owner’s Manual
MAINTENANCE
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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.
B
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.
Battery Disposal
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling.
For neutralized spells, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.
Battery
A battery is defined as two dissimilar metals immersed in an acid. If the acid is absent or if the metals are not dissimilar, a battery has not been created. The batteries most commonly used in these vehicles are lead acid.
A battery does not store electricity, but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy. The chemical reaction takes place faster in warm conditions and slower in cold conditions. Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences.
As a battery ages, it 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.
39 Owner’s Manual
MAINTENANCE
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Battery Maintenance
Tool List Qty.
Insulated Wrench, 9/16” .............................................. 1
Insulated Wrench, 1/2” ................................................ 1
Battery Maintenance Kit P/N 25587-G01 .................... 1
Socket, 9/16” ............................................................... 1
Socket, 1/2” ................................................................. 1
Tool List Qty.
Battery Carrier............................................................. 1
Hydrometer ................................................................. 1
Battery Protective Spray ............................................. 1
Torque Wrench, in. lbs. ............................................... 1
Most of the battery set for the electric motor is located under the seat, two batteries are located under the cowl. The tow batteries located under the cowl are supplied with a battery fill system tube that is located in the passenger side glove box, the remaining batteries for the electric motor are accessed by raising an removing the seat bottom and the battery compartment cover. The single battery for starting the gas engine is located under the front of the vehicle between the front frame members.
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 battery pack, inspect the plug of the battery charger and vehicle receptacle housing for dirt or debris.
Charge the batteries after each day’s use.
Monthly
• Inspect all wiring for fraying, loose terminations, corrosion or deterioration of insulation.
• Check that the electrolyte level is correct and add suitable water as required.
• Clean the batteries and wire terminations.
• Torque battery terminal nuts to 95 - 105 in. lbs. (11 - 12 Nm).
• Coat battery terminals with commercially available protectant.
• Replace all terminal covers.
• Replace battery compartment covers.
40 Owner’s Manual
MAINTENANCE
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Temperature Affects Battery Capacity
Battery storage capacity is affected by the temperature; the colder it is, the less energy it is able to store; as temperature increases so does the storage capacity of the battery.
The ideal battery temperature for deep cycle batteries that are available today is 77°F (25°C). At 32°F (0°C) the storage capacity of the battery will be reduced by 20%, this means in cold weather the vehicle will not travel as far as it would in warm weather.
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.
65
60
55
50
45
40
35
F°
30
-40
C° -40
115
110
105
100
95
90
85
80
75
70
-22
-30
-4
-20
14
-10
32
0
50
10
68
20
T E M P E R A T U R E
86
30
104
40
122
50
140
60
B
DO NOT overfill batteries. The charging cycle will expel electrolyte and result in component damage.
If the battery electrolyte level is too high, the electrolyte will block the vent tube and the gas will force it out of the vent tube and battery cap. The water will evaporate but the sulfuric acid will remain where it can damage vehicle components and the storage facility floor. Sulfuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery.
Vent Cap
Gas Vent
Expansion
Space
Vent
1/4 to 3/8 inch
(6 mm to 10 mm)
Plates
1/2 inch
(13 mm)
Electrolyte level should be at least 1/2” (13 mm) above the plates and 1/4” to 3/8” (6 to 10 mm) below vent.
41 Owner’s Manual
MAINTENANCE
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Over the life of the battery, a considerable amount of water is consumed. It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction. The water must be distilled or purified by an efficient filtration system. Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it does not exceed the impurity levels specified in the table.
An Automatic Watering Gun or a Battery Watering Jug; available from many auto parts stores; may be used to fill the batteries, these watering devices are accurate, easy to use and allow for rapid filling. They also maintain the correct electrolyte level within the battery cells.
Impurity
Color
Suspended
Total Solids
Calcium & Magnesium Oxides
Iton
Ammonia
Organic & Volatile Matter
Nitrites
Nitrates
Chloride
Water Purity Table
Hand Held Watering Device
Parts Per
Million
Clear
Trace
100
40
5
8
50
5
10
5
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
The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates.
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 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liter) of water and flushed with water.
Always wear a safety shield or approved safety goggles when adding water or charging batteries.
42 Owner’s Manual
MAINTENANCE
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Cleaning Batteries
When cleaning the outside of the batteries and terminals, do not use a water hose without first spraying the batteries with a solution of baking soda (sodium bicarbonate) and water to neutralize any acid deposits. Use of a water hose without first neutralizing the acid will move the acid from the top of the batteries to another area of the vehicle or storage facility, where it will attack the metal structure or the concrete/asphalt floor.
After hosing down the batteries, a residue will be left on the batteries, which is conductive and will contribute to the discharge of the batteries.
1 quart
(1 liter)
Clear Water
2 Teaspoons
(10 ml)
Sodium
Bicarbonate
(Baking Soda)
Plastic
Spray
Bottle
B
.
To prevent battery damage, be sure that all battery caps are tightly installed.
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.
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 plastic spray bottle. The solution should consist of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liter) of 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.
Most of the battery set for the electric motor is located under the seat, two batteries are located under the cowl. The tow batteries located under the cowl are supplied with a battery fill system tube that is located in the passenger side glove box, the remaining batteries for the electric motor are accessed by raising an removing the seat bottom and the battery compartment cover. The single battery for starting the gas engine is located under the front of the vehicle between the front frame members.
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.
Cleaning should take place once a month or more often under 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.
Battery Removal and Installation
Improper handling of high voltage wiring, batteries, or control systems could result in serious or fatal injury by electric shock. Only qualified technicians should repair or access high voltage wiring, battery packs, and associated systems.
To prevent battery explosion that could result in severe personal injury or death, 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.
Owner’s Manual 43
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
If the batteries are replaced, make sure they are the exact type and model originally supplied with the vehicle.
Failure to follow this caution can result in damage to the vehicle’s electrical system.
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 areas 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.
Electric Motor
Battery Pack
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.
Gas Engine
Starter Battery
BATTERY CONFIGURATION
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.
44 Owner’s Manual
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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Storage
During periods of storage, the batteries will need attention to keep them maintained and prevent discharge.
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.The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge.
The battery charger may be left connected to the vehicle to maintain a full charge on the batteries, provided the charger is plugged into an active electrical source. If power to the electrical source is disconnected or interrupted the battery charger will continue to check the charge on the battery pack, this will draw power from the battery pack and eventually drain the batteries if power is not restored in a timely manner.
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:
O F O C
E
R
A
T
T
E
M
P
U
R
E
T
R
O
L
E
L
E
C
Y
T
E
+15 -9
+5 -15
-5 -21
-15 -26
-25 -32
-35 -37
-45 -43
-55 -48
-65 -54
-75 -60
-85 -65
-95 -71
1.100
1.140
1.120
1.180
1.160
1.220
1.200
1.260
1.240
1.280
SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT
1.300
B
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.
BATTERY FAULT DIAGNOSIS
In general, fault diagnosis 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
Owner’s Manual 45
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
result in a vehicle that runs slowly or in a vehicle that is unable to operate for the time required.
A new battery must mature before it will develop its maximum capacity. Maturing may take up to 100 charge/discharge cycles. After the maturing phase, the older a battery gets, the lower the capacity. The only way to determine the capacity of a battery is to perform a load test using a discharge machine following manufacturer’s recommendations.
A cost effective way to identify a poorly performing battery is to use a hydrometer to identify a battery in a set with a lower than normal specific gravity. Once the particular cell or cells that are the problem are identified, the suspect battery can be removed and replaced. At this point there is nothing that can be done to salvage the battery; however, the individual battery should be replaced with a good battery of the same brand, type and approximate age.
HYDROMETER
A hydrometer is used to test the state of charge of a battery cell. This is performed by measuring the density of the electrolyte, which is accomplished by measuring the specific gravity of the electrolyte. The greater the concentration of sulfuric acid, the more dense the electrolyte becomes. The higher the density, the higher the state of charge.
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.
Specific gravity is the measurement of a liquid that is compared to a baseline. The baseline is water which is assigned a base number of 1.000. The concentration of sulfuric acid to water in a new golf car battery is 1.280 which means that the electrolyte weighs 1.280 times the weight of the same volume of water. A fully charged battery will test at 1.275 - 1.280 while a discharged battery will read in the 1.140 range.
Subtract from Float
Reading
Hydrometer
Weight
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.
46 Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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).
As a battery ages the specific gravity of the electrolyte will decrease at full charge. This is not a reason to replace the battery providing all cells are within fifty points of each other.
Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should be recharged and the test repeated. If the results indicate a weak cell, the battery or batteries should be removed and replaced with a good battery of the same brand, type and approximate age.
ELECTROLYTE
TEMPERATURE
°F °C
160 71
150 65
140 60
130 54
120 49
110 43
100 37
90 32
80 26
70 21
60 15
50 10
40 4
30 -1
20 -6
10 -12
+.010
+.008
+.006
+.004
+.002
0
-.002
-.004
-.006
-.008
-.010
-.012
-.014
-.016
-.018
-.020
-.022
-.024
-.026
-.028
+.032
+.030
+.028
+.026
+.024
+.022
+.020
+.018
+.016
+.014
+.012
EXAMPLE #1
ELECTROLYTE TEMPERATURE
Above 80 °F (27 °C)
AMBIENT TEMPERATURE
Above 80 °F (27 °C)
ELECTROLYTE TEMPERATURE
Above 90 °F (32 °C)
HYDROMETER READING 1.250
1.250 + .004 = 1.254
CORRECTED SPECIFIC GRAVITY
READING
EXAMPLE #2
ELECTROLYTE TEMPERATURE
Above 80 °F (27 °C)
AMBIENT TEMPERATURE
Above 80 °F (27 °C)
ELECTROLYTE TEMPERATURE
Above 70 °F (21 °C)
HYDROMETER READING 1.250
1.250 - .004 = 1.246
CORRECTED SPECIFIC GRAVITY
READING
B
PROLONGED STORAGE
Hydrometer Temperature Correction
Battery Set and Gas Starting Battery
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 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.
47 Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Gas Engine
To reduce the possibility of severe injury or death resulting from a possible explosion:
Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.
Store vehicle in a clean, dry area. Do not store in same area as a stove, furnace, water heater, or other appliance that uses a pilot light or has a device that can create a spark.
When refueling, inspect the fuel cap for leaks or breaks that could result in fuel spillage.
Always wear safety glasses while refueling to prevent possible eye injury from gasoline or gasoline vapor.
Keep hands, clothing and jewelry away from moving parts. Use care not to contact hot objects.
Raise the rear of the vehicle and support on jack stands before attempting to run the engine.
Preparing the engine for a prolonged storage period (30 days or more) calls for a few simple steps to prevent a build up of varnish and gum in the throttle body and corrosion in the engine.
• Perform all routine maintenance per the Periodic Service Schedule.
• Add commercially available fuel stabilizer to the fuel tank. Follow the manufacturer’s instructions.
• Start the engine and allow to run for several minutes in a well ventilated area to allow the fuel stabilizer to be mixed through the fuel system.
• Turn the fuel shut-off valve to the closed (OFF) position at the fuel tank
• With proper ventilation, run the engine until the remaining fuel in the system is depleted and the engine stalls.
• Remove both spark plug wire boots from the spark plugs.
• Remove both spark plugs.
• Use a conventional cylinder fogging oil or add one ounce of 30 weight oil to each spark plug hole.
• Inspect the spark plugs prior to installation. Replace if needed.
Fuel Shut-off
Valve
Turn to “OFF”
Position
• Rotate the engine several times with the starter prior to reinstalling the spark plug wire boots onto the spark plugs.This will allow the fogging oil to coat the cylinders.
• Reinstall the spark plug wire boots onto the spark plugs.
• Turn the Key Switch to OFF position, and remove the key.
• Secure the vehicle to prevent rolling while in storage.
HARDWARE
Periodically, the vehicle should be inspected for loose fasteners. Use care when tightening fasteners, refer to the Technician’s Repair and Service Manual for specific torque values.
Generally, three classes of standard hardware and two classes of metric hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hex head and grade 8 hardware is identified by six marks on the head. metric hardware is marked on the head with 8.8 or 10.9. Unmarked hardware is Grade 2.
48 Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
BOLT SIZE
Grade 2
Grade 5
Grade 8
1/4"
4
(5)
6
(8)
6
(8)
5/16"
8
(11)
13
(18)
18
(24)
3/8"
15
(20)
23
(31)
35
(47)
7/16"
24
(33)
35
(47)
55
(75)
1/2"
35
(47)
55
(75)
80
(108)
9/16"
55
(75)
80
(108)
110
(149)
5/8"
75
(102)
110
(149)
170
(230)
3/4"
130
(176)
200
(271)
280
(380)
7/8"
125
(169)
320
(434)
460
(624)
1"
190
(258)
480
(651)
680
(922)
BOLT SIZE
Class 5.8
(Grade 2) 5.8
Class 8.8
(Grade 5) 8.8
Class 10.9
(Grade 8) 10.9
M4
1
(2)
2
(3)
3
(4)
M5
2
(3)
M6
4
(6)
M8
10
(14)
M10
20
(27)
M12
35
(47)
M14
55
(76.4)
4
(6)
6
(8)
7
(10)
10
(14)
18
(24)
25
(34)
35
(47)
49
(66)
61
(83)
86
(117)
97
(131)
136
(184)
Torque Specifications and Bolt Grades
CAPACITIES AND REPLACEMENT PARTS
Front Axle Oil
Rear Axle Oil
Brake Fluid
Fuel Tank (Early Production
Fuel Tank (Late Production
CAPACITIES
13.8 oz. 90 wt. Gear Oil
13.8 oz. 90 wt. Gear Oil
DOT 3
5.3 Gallons (20 Liters)
5.6 Gallons (21.3 Liters)
B
REPLACEMENT PARTS
LED Headlight Bulb
Headlight Bulb
P/N 619101
P/N 619100
ATC Type Fuse 10 Amp
ATC Type Fuse 15 Amp
ATC Type Fuse 20 Amp
P/N 35212G07
P/N 35212G01
P/N 35212G02
49 Owner’s Manual
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
50 Owner’s Manual
PERIODIC SERVICE SCHEDULE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE
CH - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE
REMARKS
Tires - pressure, condition of tires & rims
Hardware - loose or missing
Overall Vehicle Condition
Batteries - state of charge, condition, loose terminals, corrosion, hold downs & hardware
Batteries* - check electrolyte level, fill after charging if required (if plates are exposed before charging, add only enough water to cover any exposed plates and fill after charging)
Brakes - Check fluid level in master cylinder
Brakes - smooth operation of pedal, stopping distance
CH
CH
CH
CH
CH
CH
CH
C&A
CH
CH
CH
CH
CH
CL
C&A
CH
CH
CH
CH
CH
CL
C&A
CH
CH
CH
CH
CH
CL
C&A
CH
CH
3000 miles/
5000 kms
CH
Park Brake - ability to hold on a hill
Accelerator - smooth operation
Wiring - loose connections, broken or missing insulation
Charger Receptacle - inspect and clean receptacle at each charge
Direction Selector - attachment and mechanism
Steering Assembly - excessive play, loose or missing hardware
Tie Rods - excessive play, bent rods, loose or missing hardware
Front and Rear Axle - oil leakage, noise, loose or missing hardware
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
C&A
CH
CH
CL
C&A
CH
CH
CH
Front and Rear Axle - drain and replace fluid
5000 miles/
8000 kms
Front Suspension - strut oil leakage, excessive play in hubs or kingpins, worn bushings, loose or missing hardware
Rear Suspension - strut oil leakage, worn bushings, loose or missing hardware
Front Wheel Alignment - unusual tire wear
CH CH
CH
C&A
CH
CH
C&A
CH
CH
C&A
* Use only distilled or purified water that is free from contaminates to fill batteries.
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.
Owner’s Manual 51
PERIODIC SERVICE SCHEDULE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
52 Owner’s Manual
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
APPENDIX A
SUBARU ENGINE OPERATORS MANUAL
Safety Precautions .............................................................................................................................................................................1
Components .......................................................................................................................................................................................4
Pre-operation Checks.........................................................................................................................................................................5
Battery Installation ..............................................................................................................................................................................7
Operating Your Engine .......................................................................................................................................................................9
Easy Troubleshooting.......................................................................................................................................................................11
Spark Arrestor (Optional) .................................................................................................................................................................13
Maintenance Schedule .....................................................................................................................................................................14
“How-To” Maintenance .....................................................................................................................................................................16
Preparations for Storage ..................................................................................................................................................................20
Specifications ...................................................................................................................................................................................21
The Subaru Owner’s Manual (2ZZ9990168 issue EMD-EU6943) is included in this manual (without changes or editing) with the permission of Subaru Industrial Power Products. Copying or reprinting of this manual is prohibited.
Owner’s Manual A
ISSUE EMD-EU6943
EH72 FI
PRINTED IN USA
December 2009
2ZZ9990168
(英・仏・西)
OHV Gasoline Engines
EH72FI us̲EU6943 09.12.21 3:07 PM ページ001
(California Proposition 65)
WARNING :
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
(California only)
AIR INDEX
To show compliance with California emission regulations, a hangtag has been provided displaying the Air Index level and durability period of this engine.
The Air Index level defines how clean an engine’s exhaust is over a period of time. A bar graph scaled from “0” (most clean) to “10” (least clean) is used to show an engine’s Air Index level. A lower Air Index level represents cleaner exhaust from an engine.
The period of time (in hours) that the Air Index level is measured is known as the durability period. Depending on the size of the engine, a selection of time periods can be used to measure the Air Index level (see below).
Descriptive Term Applicable to Emissions Durability Period
Moderate - 50 hours (engine from 0 to 80 cc)
125 hours (engine greater than 80 cc)
Intermediate -
Extended -
125 hours (engine from 0 to 80 cc)
250 hours (engine greater than 80 cc)
300 hours (engine from 0 to 80 cc)
500 hours (engine greater than 80 cc)
1000 hours (225 cc and greater)
Notice : This hangtag must remain on this engine or piece of equipment, and only be removed by the ultimate purchaser before operation.
Notice : FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA EMISSION CONTROL
WARRANTY are applicable to only those engines/ generators complied with EPA (Environmental
Protection Agency) and CARB (California Air Resources Board) emission regulations in the U.S.A.
Notice : To the engines/generators exported to and used in the countries other than the U.S.A., warranty service shall be performed by the distributor in each country in accordance with the standard Robin engine/generator warranty policy as applicable.
EH72FI us̲EU6943 09.12.21 3:07 PM ページ002
EH72FI us̲EU6943 09.12.21 3:07 PM ページ01
FOREWORD
Thank you very much for purchasing a ROBIN ENGINE .
Engine
Emission label
Engine serial No.
Your ROBIN ENGINE can supply the power to operate various sorts of machines and equipment.
Please take a moment to familiarize yourself with the proper operation and maintenance procedures in order to maximize the safe and efficient use of this product.
Due to constant efforts to improve our products, certain procedures and specifications are subjected to change without notice.
When ordering spare parts, always give us the MODEL,
SPECIFICATION and SERIAL NUMBER of your engine.
Please fill in the following blanks after checking the specification number on your engine.
SPEC NO.
E H
SERIAL NO.
For your nearest ROBIN distributor (and/or dealer), you are able to check at our ROBIN website of the following URL; http://www.subaru-robin.jp
EH72FI us̲EU6943 09.12.21 3:07 PM ページ02
CONTENTS
1. SAFETY PRECAUTIONS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 1
2. COMPONENTS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 4
3. PRE OPERATION CHECKS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 5
4. BATTERY INSTALLATION ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 7
5. OPERATING YOUR ENGINE ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 9
6. EASY TROUBLESHOOTING ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 11
7. SPARK ARRESTER (OPTIONAL) ・ ・ ・ ・ ・ ・ ・ ・ 13
8. MAINTENANCE SCHEDULE ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14
9. "HOW TO" MAINTENANCE ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 16
10. PREPARATIONS FOR STORAGE ・ ・ ・ ・ ・ ・ ・ ・ 20
11. SPECIFICATIONS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 21
EH72FI us̲EU6943 09.12.21 3:07 PM ページ03
SYMBOLS
EH72FI us̲EU6943 09.12.21 3:07 PM ページ1
1. SAFETY PRECAUTIONS
Please make sure you review each precaution carefully.
EXHAUST PRECAUTIONS
■
Never inhale exhaust gas.
It contains carbon monoxide, a colorless, odorless and extremely dangerous gas which can cause unconsciousness or death.
■
Never operate the engine indoors or in a poorly ventilated area, such as tunnel, cave, etc.
■
Exercise extreme care when operating the engine near people or animals.
■
Keep the exhaust pipe free of foreign objects.
REFUELING PRECAUTIONS
■
Be sure to stop the engine prior to refueling.
■
Do not overfill the fuel tank.
■
If fuel is spilt, wipe it away carefully and wait until the fuel has dried before starting the engine.
■
After refueling, make sure that the fuel cap is secured to prevent spillage.
FIRE PREVENTION
■
Do not operate while smoking or near an open flame.
■
Do not use around dry brush, twigs, cloth rags, or other flammable materials.
■
Keep the engine at least 3 feet
(1 meter) away from buildings or other structures.
■
Keep the engine away from flammables and other hazardous materials (trash, rags, lubricants, explosives).
− 1 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ2
− 2 −
PROTECTIVE COVER
■
Place the protective covers over the rotating parts.
If rotating parts such as the drive shaft, pulley, belt, etc. are left exposed, they are potentially hazardous.
To prevent injury, equip them with protective covers or shrouds.
■
Be careful of hot parts .
The muffler and other engine parts become very hot while the engine is running or just after it has stopped.
Operate the engine in a safe area and keep children away from the running engine.
■
Never make adjustments on the machinery while it is connected to the engine, without first removing the ignition cable from the spark plug.
Turning the crankshaft by hand during adjusting or cleaning might start the engine, and the machinery with it, causing serious injury to the operator.
■
Never run the engine with governor disconnected, or operate at speeds in excess of 3600 rpm load.
SURROUNDINGS
■
Operate the engine on a stable, level surface free of small rocks, loose gravel, etc.
NOTE
Operating the engine at a steep incline may cause seizure due to improper lubrication even with a maximum oil level.
EH72FI us̲EU6943 09.12.21 3:07 PM ページ3
■
Drain the fuel when transporting the engine.
■
Do not move the engine while in operation when it has been removed from the equipment.
■
Keep the unit dry (do not operate it in rainy conditions).
PRE-OPERATION CHECKS.
■
Carefully check fuel hoses and connections for looseness and fuel leakage. Leaking fuel creates a potentially dangerous situation.
■
Check bolts and nuts for looseness.
A loose bolt or nut may cause serious engine trouble.
■
Check the engine oil daily and refill if necessary.
■
Check the fuel level and refill if necessary.
Do not overfill the tank.
■
Wear snug fitting working clothes when operating the engine.
Loose aprons, towels, belt, etc., may be caught in the engine or drive train, causing a dangerous situation.
− 3 −
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2. COMPONENTS
Speed control lever
Air cleaner cover
Key switch
Control box
Warning lamp
Spark plug cap
Fuel filter
Blower housing
Fuel pump
Oil cooler
Throttle body Oil filler cap
Hook
Spark plug cap
Engine emission label
Governor lever
Voltage regulator
Oil gauge
Electric starter
Oil drain plug (On both sides)
Oil filter
PTO shaft
REMARKS :
■
Fuel tank, valve (sediment bowl type is recommended), fuel hoses, and fuel filter are required for connecting fuel source to throttle body.
■
A battery rated at 12V-36AH or larger with the specified cable are required for electric starter operation. Make the proper electrical wiring arrangements before normal engine operation.
(See Section 4 Battery Installation for instructions.)
− 4 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ5
3. PRE-OPERATION CHECKS
STD-type Option
Oil gauge
CHECK ENGINE OIL
(DAILY)
Before checking or refilling engine oil, be sure the engine is not running and is located on a stable, level surface.
■
If the oil level is below the lower level line on the oil gauge, refill with the proper oil (see table) to the upper level.
OIL CAPACITY : 1.55 liter
Oil gauge
Upper level
Lower level
Oil gauge
Upper level
Lower level
Oil gauge
Upper level
Lower level
5W
10W
Single grade
20W
#20
#30
#40
Multi grade
Ambient temperature
10W-30
10W-40
-20 -10
-4 14
0
32
10
50
20
68
30
86
40
104
■
When filling oil in the engine, keep the engine level and fill the oil up to the upper mark of the oil gauge. Measure the oil level with the oil gauge plugged in position.
■
After an oil change, run the engine, and recheck the oil level. The oil level may drop a little as the oil fills the oil filter. Fill the oil up to the upper mark of the oil gauge.
■
Change oil if it is contaminated.
(See Section 8 Maintenance Schedule.)
■
Use 4-stroke automotive detergent oil of API service class SE or higher grade
(SG, SH or SJ is recommended).
■
If multi-grade oil is used, oil consumption tends to increase when the ambient temperature is high.
− 5 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ6
Rubber pipe
Fuel filter
Fuel inlet
Fuel pump
CHECK FUEL
WARNING
Do not refuel while smoking, near an open flame or other potential hazards.
NOTE :
THIS ENGINE IS CERTIFIED TO OPERATE
ON AUTOMOTIVE UNLEADED GASOLINE.
■
The fuel tank shall be provided separately, because the engine is not equipped with a fuel tank.
A fuel valve and fuel filter should be connected between the fuel tank and fuel pump.
Securely connect with fuel hoses to the fuel pump to prevent leakage.
■
Fuel tanks may be mounted up to 0.66
meters (2 feet) below the throttle body.
If the fuel tank is mounted above the throttle body, a fuel shut off valve must be connected between the fuel tank and fuel pump. The fuel valve must be shut off when the engine is not operating to prevent fuel from flooding the throttle body.
■
A serious accident may occur if the fuel hose comes off. Properly secure the fuel line connections by completely inserting the hose onto the fittings and securing the connection with a hose clamp.
■
Use automotive unleaded gasoline only.
■
Stop the engine and close the fuel valve before filling the fuel tank.
■
Wipe off any spilled fuel before starting the engine.
− 6 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ7
4. BATTERY INSTALLATION
For electric starter operation, proper electric wiring arrangements are needed before normal engine operation.
PARTS NEEDED
■
Use a battery rated 12V-36AH or larger.
■
Use a proper cable and ground wire to connect battery and key switch and electric starter.
CABLE
LA406 LA408
25mm
EARTH (GROUND) WIRE
BATTERY CABLE
CABLE
LENGTH
CABLE
DIA.
WIRE GAUGE
AWG (BS)
BWG
SAE JIS
Less than
1.5 m
7.3 mm 1 6 AV15
1.5 m to 2.5 m
2.5 m to 4.0 m
8.5 mm 0
10.8 mm 3/0
4
2
AV20
AV30
GROUND WIRE, use a flat braided wire of 0.03 sq. in. or larger sectional area.
(SAE GAUGE 4)
KEY SWITCH CABLE
WIRE GAUGE
CABLE
LENGTH
CABLE
DIA.
AWG (BS) BWG JIS
Less than
1.5 m
1.5 m to 3.0 m
3.0 m to 5.0 m
1.5 mm
1.9 mm
2.4 mm
14
12
10
16
14
13
AV1.25
AV2
AV3
− 7 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ8
Cable
+
Battery
-
Electric starter terminal
Earth wire
WIRING
■
Connect positive terminal of electric starter and positive terminal of the battery with battery cable.
■
Ground negative terminal of the battery to the body of engine or machine with ground wire.
NOTE
Tighten bolts and nuts on terminals securely so they will not be loosened by vibration.
WIRING DIAGRAM
W
Grn, R
(Covering: Blk)
THROTTLE
BODY
Blk
Blk
Blk
Blk
R
Blk
(Covering: Blk)
Blk
R
ELECTRIC
FUEL PUMP
Gry
OIL
PRESSURE
SWITCH
R
Blk
Blk (Covering: Gry)
Blk
Gry
Grn, R
(Covering: Gry)
Blk Blk
IGNITION
COIL #2 SPARK
PLUG
IGNITION
COIL #1 SPARK
PLUG
OIL WARNING LAMP
W
R
Y
R
R
Y
W
TACHO /
HOUR METER
(OPTION)
Y
Blk / W
Blk : BLACK
Grn : GREEN
Gry : GRAY
Blk
OFF
RUN
START
G M B L S
KEY SWITCH
TEMPERATURE
SENSOR (MBC) REGURATOR
CHARGE
COIL
Grn
ELECTRIC
STARTER
BATTERY
12V
Optional hardware shown by dotted lines. Select wires of proper gauge and connect battery as shown by the dotted line in the wiring diagram.
− 8 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ9
5. OPERATING YOUR ENGINE
NOTE
Following operating method is for the STD type speed control lever.
As to the fixed type speed control lever (exp. Generator spec.), do not move it otherwise the generator component such as voltage regulator may be damaged.
STARTING
FUEL VALVE
1
(Provided by the equipment manufacturer)
ELECTRIC STARTER
3
OFF
RUN
RUN
WARNING
LAMP
(Light up)
START
If there is a control box mounted, turn the key switch and set it to the
"RUN" position. Check to make sure that the warning and other lights illuminate (red).
■
When the key switch is set to the drive position (RUN) the operating noise of the fuel pump may be audible for two or three seconds
(this is not a malfunction).
Open the fuel valve.
2
SPEED CONTROL LEVER
Set the speed control lever 1/3 of the way towards the high speed position.
− 9 −
4
ELECTRIC STARTER
OFF
RUN
START
START
Turn the key switch to the "START" position.
■
Do not operate the electric starter continuously for more than 5 seconds, even if the engine dose not start.
■
If the engine failed to start, set the key to the "RUN" position and wait for about 10 seconds before retrying.
■
Never turn the key switch to the
"START" position while engine is running.
EH72FI us̲EU6943 09.12.21 3:07 PM ページ10
RUNNING
SPEED CONTROL LEVER
STOPPING
1
SPEED CONTROL LEVER
After the engine starts, set the speed control lever at the low speed position and warm it up without load for a few minutes.
Set the speed control lever at the low speed position and allow the engine to run at low speed for 2 or
3 minutes before stopping.
2
ELECTRIC STARTER
STOP
OFF
RUN
START
Gradually move the speed control lever toward the high speed position and set it at the required engine speed.
Turn the key switch to the "STOP" position.
NOTE :
Whenever high speed operation is not required, slow the engine down (idle) by moving the speed control lever to save fuel and extend engine life.
− 10 −
FUEL VALVE
3
Close the fuel valve.
EH72FI us̲EU6943 09.12.21 3:07 PM ページ11
6. EASY TROUBLESHOOTING
WHEN ENGINE WILL NOT START:
■
Perform the following checks before you take the engine to your Robin dealer.
■
If you still have trouble after completing the checks, take the engine to your nearest Robin dealer.
Is there enough compression?
If the spark plug is loose, tighten it.
Is the spark plug wet with gasoline?
1. Slowly start the engine for 2 or 3 seconds.
Remove the plug and check if its electrode is wet. If the electrode is wet, fuel is well supplied to your engine.
2.When the electrode is dry, check to find where the fuel is restricted.
(Check the fuel intake of the throttle body and fuel strainer intake.)
3. In case the engine does not start with well supplied fuel, try using fresh fuel.
WARNING
Wipe off spilled fuel carefully before checking the spark plug.
Place spark plug as far away from spark plug hole as possible.
Do not hold spark plug by hand while checking.
Is there a strong spark across the electrode?
1. Remove the spark plug and connect it to the plug cap.
Turn key switch to START position while grounding spark plug against engine body.
2. Try with a new spark plug if the spark is weak or there is no spark.
3. The ignition system is faulty if there is no spark with a new spark plug.
Take your engine to your nearest
Robin dealer.
− 11 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ12
About the Warning Lamp
■
Check the oil if the warning lamp illuminates while driving.
(Refer to Section "3. PRE-OPERATION CHECKS" for instructions.)
■
Have the vehicle inspected at a dealer or maintenance shop if the warning light is flashing while driving.
Is your battery well charged ?
Check the battery, it may be discharged and unable to operate the electric starter.
Consult your nearest dealer or service shop.
− 12 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ13
7. SPARK ARRESTER (OPTIONAL)
In a dry or wooded area, it is recommendable to use the product with a spark arrester. Some areas require the use of a spark arrester. Please check your local laws and regulations before operating your product.
The spark arrester must be cleaned regularly to keep it functioning as designed.
A clogged spark arrester :
●
●
●
Prevents the flow of exhaust gas
Reduces engine output
Increases fuel consumption
●
Makes starting difficult
If the engine has been running, the muffler and the spark arrester will be very hot.
Allow the muffler to cool before cleaning the spark arrester.
MUFFLER
SPARK
ARRESTER
SCREEN
How to remove the spark arrester
1. Remove the flange bolts from the muffler cover and remove the muffler cover.
2. Remove the special screw from the spark arrester and remove the spark arrester from the muffler.
MUFFLER COVER
SPARK ARRESTER SCREEN
Clean the spark arrester screen
Use a brush to remove carbon deposits from the spark arrester screen.
Be careful to avoid damaging the screen.
The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged.
Install the spark arrester, and muffler protector in the reverse order of disassembly.
− 13 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ14
8. MAINTENANCE SCHEDULE
MAINTENANCE, REPLACEMENT, OR REPAIR OF EMISSION CONTROL DEVICES
AND SYSTEMS MAY BE PERFORMED BY ANY NONROAD ENGINE REPAIR
ESTABLISHMENT OR INDIVIDUAL.
DAILY INSPECTION
Before running the engine, check the following service items.
Enough gasoline
Excessive vibration,noise
Clean air cleaner element
Safe surroundings
Enough clean engine oil
Leakage of gasoline and engine oil
Loose or broken bolts and nuts
PERIODIC MAINTENANCE
Periodic maintenance is vital to safe and efficient operation of your engine.
Check the table below for periodic maintenance intervals.
IT IS ALSO NECESSARY FOR THE USER OF THIS ENGINE TO CONDUCT
THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION-RELATED
PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL SYSTEM
EFFECTIVE.
The emission control system consists of the following parts:
(1) Throttle body and internal parts
(2) Cold start enrichment system, if applicable
(3) Intake manifold, if applicable
(4) Air cleaner elements
(5) Spark plug
(6) Magneto or electronic ignition system
(7) Spark advance/retard system, if applicable
(8) Exhaust manifold, if applicable
(9) Hoses, belts, connectors, and assemblies
The maintenance schedule indicated in the following table is based on the normal engine operation. Should the engine be operated in extremely dusty condition or in heavier loading condition, the maintenance intervals must be shortened depending on the contamination of oil, clogging of filter elements, wear of parts, and so on.
− 14 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ15
Periodic Maintenance Schedule table
Maintenance Items
Clean engine and check bolts and nuts
Check and refill engine oil
Change engine oil (*Note 1)
Replace engine oil filter (*Note 1)
Check battery electrolyte fluid level
Clean spark plug
Clean air cleaner
Spark arrester (optional part)
Replace air cleaner element
Clean fuel strainer
Clean and adjust spark plug and electrodes
Replace spark plug
Remove carbon from cylinder head
Clean throttle body (*Note 2)
Clean engine base (oil pan)
Check and adjust valve clearance
Every 8 hours
(Daily)
● (Daily)
Every
50 hours
Every
200 hours
Every
500 hours
● (Refill daily to upper level)
●
(Initial 20 hours)
●
(Initial 20 hours)
● (Every 100 hours)
●
●
●
●
● (Every 100 hours)
●
●
●
●
●
●
●
●
Replace fuel lines
Overhaul engine (*Note 2)
Every
1000 hours
●
(Yearly)
●
* Note 1 : Initial oil change and oil filter replacement should be performed after 20 hours of operation.
Thereafter change oil every hundred (100) hours and replace oil filter 200 hours.
Before changing oil, check for a suitable way to dispose of old oil. Do not pour it down into sewage drains, onto garden soil or into open streams. Your local zoning or environmental regulations will give you more detailed instructions on proper disposal.
*Note 2 : As to the procedures, please refer to the Service Manual or consult your nearest
ROBIN service dealer.
*Note 3 : More frequent oil changing, oil filter replacement and air cleaner service on replacement may be necessary depending on operating conditions.
This would include dusty environment, high ambient temperature, heavy engine loading.
− 15 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ16
9. "HOW-TO" MAINTENANCE
0.7 to 0.8 mm
(0.03 in)
INSPECTING THE SPARK
PLUG
■
Clean off carbon deposits on the spark plug electrode using a plug cleaner or wire brush.
■
Check electrode gap.
Adjust gap to :
0.7mm to 0.8mm (0.03 inches)
■
Use a proper spark plug :
BPR5ES (NGK) or BPR4EY (NGK)
Oil drain plug
(On both sides)
ENGINE OIL CHANGE
■
Initial oil change
・・・・・ After 20 hours of operation
■
Thereafter
・・・・・ Every 100 hours of operation
1. When changing oil, stop the engine and loosen the drain plug.
2. Re install the drain plug before refilling oil.
3. Refer to the recommended oil table.
(See Section 3 Pre-operation Checks)
4. Always use the best grade and clean oil. Contaminated oil, poor quality oil and shortage of oil cause damage to engine or shorten the engine life.
OIL CAPACITY : 1.55 liter
− 16 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ17
Oil filter
ENGINE OIL FILTER
REPLACEMENT
■
Initial engine oil filter replacement should be performed after 20 hours of operation. Thereafter replace the engine oil filter every 200 hours.
■
When installing a new oil filter, apply oil to O-ring, attach the oil filter in position and tighten 2/3 turns by hand or with wrench after touching the O-ring to the sealing surface of engine.
■
Run the engine for a minute ; stop the engine and check for oil leakage around the oil filter and recheck the oil level.
CAUTION
To prevent injury, pay attention to the spilled hot engine oil when replacing engine oil filter.
Base
Knob
Urethane foam
Air cleaner cover
Grommet
Element
CLEANING AIR CLEANER
A dirty air cleaner element will cause starting difficulty, power loss, engine malfunctions, and shorten engine life extremely.
Always keep the air cleaner element clean. Replaced the air cleaner element set more often in dusty environments.
The air cleaner paper inner element and urethane foam outer element can be removed after removing knob and air cleaner cover. When installing, set the paper element and urethane foam on the air cleaner base. Check that the grommet is in position, and then install the cover with knob tightened securely.
■
Urethane Foam cleaning
Wash and clean the urethane foam in kerosene. Saturate in a mixture of 3 parts kerosene and 1 part engine oil, and then squeeze to remove excess oil. Clean or replace the urethane foam element every 50 hours. (more often in dusty environments)
− 17 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ18
■
Paper element
Clean by tapping gently to remove dirt and blow off dust. Never use oil.
Clean or replace the paper element every 50 hours of operation, and replace element set every 200 hours or once a year.
Clean and replace air cleaner elements more often when operating in dusty environments.
CHECKING BOLTS, NUTS
AND SCREWS
Retighten loose bolts and nuts.
Check for fuel and oil leaks.
Replace damaged parts with new ones.
Keep safety in your mind.
Fuel hose
(RETURN)
To fuel tank
To throttle body
Fuel hose
FUEL AND OIL HOSE
REPLACEMENT
WARNING
Take extreme caution when replacing fuel hose ; gasoline is flammable.
Replace the fuel and oil hose every
1,000 hours or every year.
If fuel and oil hose leak is found, replace the fuel hose immediately.
Oil hose
− 18 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ19
CHECKING BATTERY
WARNING
Battery electrolyte is an acid and is poisonous and corrosive.
Serious injury results from contact with the skin, eyes or clothing.
If the electrolyte fluid is below level line, refill battery with distilled water.
HIGH ALTITUDE ENGINE OPERATION
The FI system is installed in this engine.
The air/fuel ratio when driven at the high ground is corrected automatically by this FI system.
The automatic correction is possible up to 3000m(9800ft).
− 19 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ20
10. PREPARATIONS FOR STORAGE
USE UP THE FUEL
WARNING Flame Prohibited
If you will not use the engine for more than 1 month, run the engine until there is no fuel left, and then store the equipment in a location with low humidity in order to prevent start-up problems and operation trouble due to deterioration of the fuel.
ENGINE OIL
■
Change the engine oil with fresh oil.
■
Remove the spark plug, pour about 5 cc of engine oil into the cylinder, slowly start the engine for 2 or 3 seconds, and re install the spark plug.
CLEAN AND STORE
■
Remove the spark plug wires from the spark plugs.
■
Slowly turn the crankshaft until resistance is felt and leave it in that position.
■
Clean the engine thoroughly with an oiled cloth, cover the engine, and store the engine indoors in a well ventilated, low humidity area.
− 20 −
EH72FI us̲EU6943 09.12.21 3:07 PM ページ21
11. SPECIFICATIONS
Type
MODEL
Bore x stroke mm(in)
Displacement cm 3 (cu. in)
Continuous Output kW (HP) / rpm
Maximum Output kW (HP) / rpm
Max. Torque
N ・ m (kgf ・ m) / rpm
Direction of Rotation
EH72 FI
Air-Cooled, 4-Stroke, V-Twin Cylinder, Horizontal P.T.O. shaft,
OHV Gasoline Engine
2-84 x 65 (3.31 x 2.56)
720 (43.9)
14.9 (20.0) / 3600
2
.
(2
8
.0) /
40
00
52.2 (5.32) / 2800
Lubricant
Counterclockwise as viewed from P.T.O. shaft side
Automotive Engine Oil SAE #20, #30 or 10W-30 ;
Class SE or higher (SG, SH or SJ is recommended)
Capacity of Lubricant liter (U.S. gal)
Fuel
Spark plug
Starting System
Dry Weight kg (lb)
Dimension
(L x W x H) mm (in)
Valve Clearance
(Intake & Exhaust)
Emissions Durability Period
(California only)
1.55 (0.41)
Automotive Unleaded Gasoline
BPR5ES (NGK) or BPR4EY (NGK)
Electric Starter
46 (101.3)
317 x 477 x 480
(12.5 x 18.8 x 18.9)
0.1 ± 0.02 mm (0.0039 ± 0.0008 in)
Note : Adjust the valve clearance while the engine is cold.
250 hours
− 21 −
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ01
(Proposition pour la Californie 65)
AVERTISSEMENT:
L'échappement du moteur de ce produit contient des produits chimiques connus par l'État de la Californie comme étant capables de causer le cancer, des défauts de naissance ou tout autre défaut de reproduction.
(Seulement pour la Californie)
INDICE D'AIR
Pour indiquer la conformité aux règlements d'émission de la Californie, une étiquette du fabriquant a été fournie indiquant le niveau d'indice d'air et la période de durabilité du moteur.
Le niveau d'indice d'air définit la propreté de l'échappement d'un moteur sur une certaine période de temps. Une barre analogique mesurée de "0" (l’air le plus propre) à "10" (l’air le moins propre) est utilisée pour indiquer le niveau d'indice de l'air du moteur. Un niveau plus bas d'indice d'air représente un échappement plus propre d'un moteur.
La période (en heures) pour laquelle le niveau d'indice d'air est mesuré est connue comme période de durabilité. Selon la taille du moteur, un choix des périodes de temps peut être utilisé pour mesurer le niveau d'indice d'air (voir ci-dessous).
Limite descriptive
Modéré -
Intermédiaire
Applicable aux émissions Période de durabilité
50 heures (moteur de 0 à 80 cm 3 )
125 heures (moteur supérieur à 80 cm 3 )
- 125 heures (moteur de 0 à 80 cm 3 )
250 heures (moteur supérieur à 80 cm 3 )
Prolongé - 300 heures (moteur de 0 à 80 cm 3 )
500 heures (moteur supérieur à 80 cm 3 )
1000 heures (225 cm 3 ou plus)
Notification : Cette étiquette du fabriquant doit rester sur le moteur ou la pièce d'équipement, et sera enlevée seulement par l'acheteur final avant son fonctionnement.
Notification : LA GARANTIE FÉDÉRALE CONTRE DÉFAUTS DE COMPOSANTS D'ÉMISSION et la GARANTIE DE CONTRÔLE
D'ÉMISSION DE LA CALIFORNIE sont applicables seulement aux moteurs/générateurs qui sont conformes aux règlements d’émission des États-Unis de l'EPA (Agence de Protection de l'Environnement, Environmental
Protection Agency) et de la CARB (Comité des Ressources de l'Air de la Californie, California Air Resources Board).
Notification : Le service de garantie sera assuré aux moteurs/générateurs exportés vers et utilisés dans les pays autres que les
États-Unis par le distributeur dans chaque pays selon la police d’assurance applicable du moteur/générateur standard Robin.
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ02
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ03
PREAMBULE
Nous vous remercions d'avoir acquis un MOTEUR ROBIN .
Étiquette d'émission du moteur
Nº DE SÉRIE DU MOTEUR
Prenez le temps de vous familiariser avec les procédures de mise en marche, de fonctionnement et de maintenance, pour utiliser votre moteur dans les meilleures conditions de
SECURITE et de PERFORMANCES.
Dans le souci constant d'améliorer la QUALITE de nos produits, certaines procédures et certaines spécifications sont succeptibles de changer sans préavis.
Lors de la commande de piéces détachées, préciser le
MODELE et le NUMERO DE SERIE de votre moteur.
Veuillez inscrire dans les cases blanches le numéro de série de votre moteur.
SPEC NO.
E H
N
O
DE SERIE.
Pour avoir des renseignements sur votre distributeur ROBIN (et/ou le concessionnaire) le plus proche, consultez en cliquant sur l’adresse
(URL) du site ROBIN suivant: http://www.subaru-robin.jp
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ04
SOMMAIRE
1. SECURITE ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 1
2. DESCRIPTION ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 4
3. VERIFICATION AVANT DEMARRAGE ・ ・ ・ ・ ・ ・ 5
4. INSTALLATION DE LA BATTERIE ・ ・ ・ ・ ・ ・ ・ 7
5. UTILISATION ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 9
6. RECHERCHE DES PANNES ・ ・ ・ ・ ・ ・ ・ ・ ・ 11
7. PARE-ÉTINCELLES (OPTIONNEL) ・ ・ ・ ・ ・ ・ ・ 13
8. TABLEAU DE MAINTENANCE ・ ・ ・ ・ ・ ・ ・ ・ ・ 14
9. COMMENT REPARER ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 16
10. STOCKAGE ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 20
11. SPÉCIFICATIONS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 21
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ05
SYMBOLES
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ1
1. SECURITE
Veuillez suivre ces conseils pour une utilisation correcte et s û re de votre moteur.
ECHAPPEMENT
■
Ne jamais respirer les gaz d'échappement.
Ceux-ci contiennent de l'oxyde de carbone, un gaz incolore, inodore et extrêmement dangereux pouvant entraîner la perte de conscience ou la mort.
■
Ne jamais utiliser le moteur dans un endroit confiné ni un endroit insuffisament ventilé, tel que : cave, tunnel, etc....
■
Etre très prudent lors de l'utilisation du moteur près d'enfants ou d'animaux, ou de quelconques tres vivants.
■
Eviter d'obstruer le pot d'échappement.
PLEIN DE CARBURANT
■
Arrêter le moteur avant de faire le plein.
■
Ne pas faire déborder le carburant lors du remplissage.
■
Essuyer soigneusement toute trace de carburant sur le moteur et attendre que tout soit évaporé avant le démarrage.
■
Lors des vidanges d'huile s'assurer que le bouchon du réservoir est bien fermé.
− 1 −
PREVENTION DES INCENDIES
■
Ne pas approcher du moteur avec une cigarette ou toute autre flamme.
■
Ne pas utiliser le moteur près d'un stockage de matières inflammables.
■
Utiliser le moteur à un mètre de tout obstacle : mur meuble, porte, ....
■
Tenir le moteur à l’écart de tout matériau inflammable ou dangereux
(ordures, chiffons, lubrifiants, explosifs).
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ2
PROTECTIONS
■
Installer des protections sur les pièces en mouvement.
Si vous utilisez des équipements tels que poulies, courroies, etc..., protégez-les avec un cache pour
éviter tout accident.
■
Faire attention aux pièces brulantes.
Le pot d'échappement et d'autres pièces du moteur sont très chaudes lors de la marche ou juste après l'arrêt du moteur.
Utilisez donc le moteur dans un endroit sûr et à l'écart des enfants.
■
Ne jamais réglar la machine lorsque le moteur tourne.
Il faut débrancher le fil de bougie avant toute intervention. Le fait de tourner le vilebrequin à la main pour régler la machine peut suffire à faire démarrer le moteur.
■
Ne jamais utiliser le moteur sans son régulateur ou à un régime excédent
3600t / mn. en charge.
ENVIRONNEMENTS
■
Utiliser le moteur sur un sol plan et exempt de tout défaut.
− 2 −
NOTE
Utiliser le moteur sur un plan inchiné peut provoquer un bris du vilebrequin par défaut de lubrification.
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ3
■
Vidanger le carburant avant de transporter le moteur.
■
Ne pas déplacer le moteur lorqu'il est en marche.
■
Garder le moteur au sec (ne pas l’utiliser sous la pluie).
− 3 −
VERIFICATIONS AVENT LE
DEMARRAGE
■
Vérifier le bon serrage et l'absence de fuites aux flexibles de carburant et aux raccords. Toute fuite de carburant présente un danger potentiel.
■
Vérifier le bon serrage des boulons et des écrous. Tout boulon ou écrou desserré peut entraîner des problèmes sérieux du moteur.
■
Vérifier quotidiennement le niveau de l'huile moteur et faire l'appoint si nécessaire.
■
Vérifier le niveau du carburant et faire le plein si nécessaire. Ne pas remplir le réservoir au-delà de la limite maxi.
■
Eviter de porter des vêtements lâches pour utiliser le moteur.
Tabliers, serviettes, ceintures et autres peuvent être pris dans le moteur ou le train moteur et être à l'origine d'un accident grave.
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2. DESCRIPTION
Levier de
Commande de regime
Couvercle du filtre a air
Ecartement dela bougie
Filtre à carburant
Pumpe de carburant
Refroidisseur d’huile
Contacteur à cl
Boîte de commande
Témoin d’alarme
Carter du ventilateur
Corps de commande des gaz
Chapeau de remplissage d'huile
Crochet
Ecartement dela bougie
Étiquette d'émission du moteur
Manette du regulateur
Regulateur de tension
Jauge d'huile
Demarreur electrique
Filtre à huile
Arbre de prise de force
Bouchon de vidange
(des-deux cotes)
REMARQUES :
■
Le réservoir de carburant, la soupape (le type à cuvette de dépôt est recommandé), les durites à carburant et le filtre de carburant sont requis pour connecter la source de carburant au corps de commande des gaz.
■
Prévoir une batterie de 12V-36AH ou plus et des câbles appropriés.
Procéder au cablage nécessaire pour garantir le bon fonctionnement du moteur.
(Voir la Section 4 Installation de la Batterie pour des instructions.)
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3. VERIFICATION AVANT DEMARRAGE
Type STD Option
Jauge d'huile
VERIFICATION DU NIVEAU
D'HUILE (QUOTIDIENNE)
Avant de procéder au contrôle du niveau d'huile ou à l'appoint d'huile, vérifier que le moteur est à l'arrêt et qu'il se trouve sur une surface stable et horizontale.
■
Refaire le niveau si nécessaire avec une qualité d'huile appropriée.
Capacité d'huile : 1,55 litre
Jauge d'huile
Jauge d'huile
Niveau maxmum
Niveau minimum
Niveau maxmum
Niveau minimum
Jauge d'huile
Niveau maxmum
Niveau minimum
5W
10W
Monograde
20W
#20
#30
#40
Multigrade
Températures ambiantes
10W-30
10W-40
-20 -10 0 10 20 30 40
-4 14 32 50 68 86 104
■
Pour faire le plein d'huile moteur, placer celui-ci à l'horizontale et faire le plein jusqu'au repère de niveau maxi de la pige. Procéder au contrôle du niveau après avoir remis la pige de niveau en place.
■
Après une vidange de l'huile, faire tourner le moteur et revérifier le niveau. Le niveau de l'huile risque de baisser dans le réservoir une fois le filtre à huile plein. Faire l'appoint en huile jusqu'au repère de niveau maxi.
■
Changer l'huile dés qu'elle est dégradée.
(Voir la Section 8 le tableau de maintenance)
■
Utiliser l’huile détersive pour véhicules à moteur à 4 temps de la Classe de service API SE ou de qualité supérieure
(SG, SH ou SJ est recommandé).
■
Si vous utilisez une huile multigrade la consommation d'huile sera légèrement augmentée, quand la température ambiante augmentera.
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EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ6
Tuyau en caoutchouc
Filtre à carburant
Arrivee du carburant
Pumpe de carburant
VERIFICATION DU CARBURANT
ATTENTION
Ne pas remplir le réservoir lorsque le moteur est en marche, près d'une cigarette ou près d'une flamme.
NOTE :
CE MOTEUR EST CERTIFIÉ POUR
L’USAGE AVEC L’ESSENCE SANS
PLOMB POUR AUTOMOBILE.
■
Le moteur n’étant pas pourvu d’un réservoir de carburant, prévoir un réservoir à part.
Raccorder un robinet et un filtre à carburant entre le réservoir et la pompe. Fixer soigneusement les flexibles de carburant à la pompe pour
éviter toute fuite.
■
Disposer le réservoir à environ 66 cm en-dessous du corps de commande des gaz. Si le réservoir est installé dans une position supérieure par rapport au corps de commande des gaz, installer un robinet de coupure entre le réservoir et la pompe. Fermer ce robinet quand le moteur n'est pas en fonction pour éviter de noyer le corps de commande des gaz.
■
Tout débranchement des flexibles de carburant peut entraîner un accident grave. Bien raccorder toutes les canalisations de carburant en insérant à fond le flexible sur l'embout et en fixant en place à l'aide d'un collier.
■
Utilisez seulement l’essence sans plomb pour automobile.
■
Couper le moteur et fermer le robinet de carburant avant de refaire le plein du réservoir.
■
Avant le démarrage du moteur I'essuyer soigneusement.
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4. INSTALLATION DE LA BATTERIE
Pour garantir le bon fonctionnement du moteur de démarrage, procéder à la mise en place du câblage électrique avant de mettre le moteur en fonction normalement.
PIECES NECESSAIRES
■
Utiliser une batterie de 12V-36AH ou plus si possible.
■
Raccorder la batterie, le contacteur à clé et le démarreur électrique à l'aide d'un câble approprié et d'un fil de mise à la terre.
CABLE
LA406 LA408
25mm
FIL DE TERRE (MASSE)
CÂBLE DE BATTERIE
LONGUEUR
DE CABLE
DIAETRE
DE
CABLE
TYPE DE CABLE
AWG (BS)
BWG
SAE JIS
Inf. à 1,5 m 7,3 mm 1 6 AV15
Entre 1,5 m et 2,5 m
8,5 mm 0
Entre 2,5 m et 4,0 m
10,8 mm 3/0
4
2
AV20
AV30
Pour la mise à la terre utilisez une tresse métallique de largeur mini 25 mm.
(SAE TYPE 4)
FIL DE CONTACT
TYPE DE CABLE
LONGUEUR
DE CABLE
DIAETRE
DE
CABLE AWG (BS) BWG JIS
Inf. à 1,5 m 1,5 mm
1,5 m et 3,0 m
3,0 m et 5,0 m
1,9 mm
2,4 mm
14
12
10
16 AV1,25
14
13
AV2
AV3
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EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ8
Cable
RESEAU ELECTRIQUE
■
Raccorder le plot positif du démarreur électrique et le plot positif de la batterie à l'aide d'un câble de batterie.
■
Brancher la borne négative de la batterie sur le corps du moteur ou sur la machine qui lui est accouplée.
+
Batterie
-
Plot du demarreur
Electrique
Fil de terre (Masse)
NOTE
Bien bloquer les écrous pour éviter tout désserrage par vibration.
SCHEMA ELECTRIQUE DU DEMARREUR
W
Grn, R
(Revêtement: Blk)
CORPS DE
COMMANDE
DES GAZ
Blk
Blk Blk
R
POMPE
À CARBURANT
ÉLECTRIQUE
Gry
Blk
Blk
PRESSOSTAT
D'HUILE
R
R
Blk
Blk
(Revêtement: Blk)
Blk (Revêtement: Gry)
Blk
Gry
TEMOIN D'HUILE
W
R
Y
Grn, R
(Revêtement: Gry)
BOBINE
D'ALLUMAGE
#2
Blk Blk
BOUGIE
BOBINE
D'ALLUMAGE
#1
BOUGIE
Y
Blk : NOIR
Grn : VERT
Gry : GRIS
R
Blk / W
R
Y
W
TACHIMÈTRE /
COMPTEUR
HORAIRE
(OPTION)
Blk
ARRÊT
RUN
START
G M B L S
CONTACTEUR À CLÉ
SONDE
DE TEMPÉRATURE
(MBC)
REGULATEUR
BOBINE
DE CHARGE Grn
DEMARREUR
ELECTRIQUE
BATTERIE
12V
L'équipement facultatif est indiqué en pointillé. Choisir des câbles de section appropriée et raccorder la batterie comme indiqué par les traits en pointillé sur le schéma de câblage.
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5. UTILISATION
NOTE
La méthode de fonctionnement suivante concerne le levier de commande de vitesse de type STD.
Quant au levier de commande de vitesse de type fixé (exemple spéc.
du générateur), ne le déplacez pas sinon le composant du générateur tel que régulateur de tension risque de s’endommager.
MISE EN MARCHE
1
ROBINET DE CARBURANT
(Fourni par le fabricant de l'équipement)
3
TIRETTE DU STARTER
MARCHE
OFF
RUN
TÉMOIN
D’ALARME
(s’allume)
START
Si une boîte de commande est installée, tourner le contacteur à clé et le régler à la position
(MARCHE). Vérifier que le témoin d’alarme et autres témoins sont bien illuminés (en rouge).
■
Quand le contacteur à clé est réglé à la position de marche
(MARCHE), un bruit de fonctionnement de la pompe à carburant peut être produit pendant deux ou trois secondes (ceci ne représente pas un défaut de fonctionnement).
Ouvrir le robinet de carburant.
2
LEVIER DE COMMANDE
DE REGIME
4
CONTACTEUR A CLE
OFF
RUN
Réglez le levier de comamnde de régime sur un point à 1/3 de la position de regine maximum.
− 9 −
START
DÉMARRAGE
Insérer la clé dans le contacteur et mettre sur la position (DÉMARRAGE) pour démarre le moteur.
■
Méme si le moteur ne part pas, n'actionnez pas le démarreur plus de cinq secondes de suite.
■
■
Mettre la clé en position (MARCHE) et attendre 10 secondes avant de refaire un essai.
Ne jamais faire fonctionner le démarreur pendant que le moteur tourne.
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MARCHE
LEVIER DE COMMANDE
DE REGIME
ARRET
1
LEVIER DE COMMANDE
DE REGIME
Après le démarrage du moteur mettre le levier en position ralenti pour faire chauffer pandant quelques minutes le moteur.
Mettre le levier enposition de ralenti et faire tourner le moteur ainsi pendant 2 à 3 minutes, avant de l'arrêter.
2
CONTACTEUR A CLE
ARRET
OFF
RUN
Puis régler progréssivement le régime jusqu'à la vitesse requise.
START
NOTE :
Quand un régime maxi n’est pas nécessaire, réduire la vitesse du moteur (ralenti) par réglage de la manette de commande pour
économiser le carburant et garantir une plus longue durée de vie du moteur.
Mettre la clé sur la position
(ARRET).
− 10 −
3
ROBINET DE CARBURANT
Refermer le robinet d’essence
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6. RECHERCHE DES PANNES
QUAND LE MOTEUR NE PART PAS
■
Vérifiez ces quelques points avant de contacter votre revendeur ROBIN.
■
Si cela ne suffit pas, n'hésitez pas à porter votre moteur chez le revendeur
ROBIN le plus proche.
Est-ce que la bougie est mouillée avec de l’essence?
Si la bougie est desserrée, revissez-la.
La bougie est-ell humide d'essence?
1. Fermer le starter et faire tourner le moteur lentement pendant 2 ou 3 secondes.
Enlever la bougie et vérifier si l’électrode est humide. Si c’est le cas, l’alimentation en carburant s’effectue correctement.
2. Si l'électrode est sèche, chercher l'endroit où le passage du carburant est obturé. (Vérifier la prise de carburant du corps de commande des gaz et la prise du filtre de carburant)
3. Dans le cas où le moteur ne dèmarrerait pas avec une bonne alimentation d'essence, essayez en refaisant le plein avec de l'essence neuve.
ATTENTION
Avant de procéder au contrôle de la bougie, nettoyer soigneusement toute trace de carburant. Eloigner la bougie de son trou de bougie.
Ne pas tenir la bougie directement
à la main pendant le contrôle .
Y a t'il une étincelle assez forte à l'électrode ?
1. Démonter la bougie et la brancher sur son antiparasite.
Tirer la poignée du lanceur en maintenant la bougie sur le corps du moteur pour la mettre au contact de la masse.
2. Si l'étincelle est trop faible ou inexistante, essayez avec une bougie neuve.
3. Si la bougie neuve ne donne pas de meilleurs résultats, cela signifie que l'allumage est endommagé.
Dans ce cas apportez votre moteur chez un réparateur ROBIN.
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A propos du témoin d’alarme
■
Vérifier l'huile pour voir si la lampe d'alarme est illuminée durant la conduite.
(Voir la Section “3. VERIFICATION AVANT DEMARRAGE” pour les instructions.)
■
Faire inspecter le véhicule par l’atelier du concessionnaire ou un centre d'entretien si le témoin d'alarme clignote durant la conduite.
Votre batterie est-elle bien chargée?
Vérifier la batterie. Elle est peut-être déchargée et dans l'impossibilité de commander le démarreur électrique.
Veuillez vérifier le niveau de charge de votre batterie.
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7. PARE-ÉTINCELLES (OPTIONNEL)
Dans une région sèche et boisée, il est recommandé de doter le produit d’un pare-
étincelles. Certaines zones requièrent l’utilisation d’un pare-étincelles. Consultez les lois et recommandations en vigueur localement avant de mettre votre produit en fonction.
Le pare-étincelles doit être nettoyé rapidement pour qu’il puisse continuer à fonctionner normalement. Un pare-étincelles encrassé :
●
●
●
●
Bloque la circulation des gaz d’échappement
Réduit la puissance du moteur
Augmente la consommation de fuel
Rend le démarrage difficile
Si le moteur a été en fonctionnement, le silencieux et le pare-étincelles chaufferont beaucoup. Laisser refroidir le silencieux avant de nettoyer le pare-étincelles.
SILENCIEUX
GRILLE
DU PARE-
ÉTINCELLES
Comment enlever le pare-étincelles
1. Enlever les écrous de bride du capot recouvrant le silencieux et retirer le capot.
2. Enlever la vis spéciale du pare-
étincelles et retirer le pare-étincelles du silencieux.
CAPOT
DE SILENCIEUX
GRILLE DU PARE-ÉTINCELLES
Nettoyer la grille du pare-étincelles
Se servir d’une brosse pour nettoyer les dépôts de charbon. Faites attention à ne pas endommager la grille.
Le pare-étincelles ne doit avoir aucune fracture ou aucun trou. Le remplacer s’il est endommagé.
Installer le pare-étincelles et la protection du silencieux dans l’ordre inverse du démontage.
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8. TABLEAU DE MAINTENANCE
L’ENTRETIEN, LE REMPLACEMENT OU LA RÉPARATION DES DIPOSITIFS ET
SYSTÈMES ANTIPOLLUTION PEUVENT ÊTRE EXÉCUTÉS PAR TOUT ÉTABLISSEMENT
OU PROFESSIONNEL DE LA RÉPARATION DES MOTEURS NON ROUTIERS.
VERIFICATION QUOTIDIENNE
Avant d'utiliser le moteur vérifier les points suivants.
Assez d'essence
Pas de bruits arormaux
Filtre à air
Environnement correct
Assez d'huile moteur
Fuites de toute nature
Ecrous et boulons
INSPECTION PERIODIQUE
Une inspection régulière est vitale pour la vie et les performances de votre moteur.
Veuillez vous référer à la table ci-dessous pour les périodes d'entretien.
La table est basée sur une utilisation normale du moteur.
IL EST AUSSI NÉCESSAIRE QUE L’UTILISATEUR DE CE MOTEUR EFFECTUE
DES OPÉRATIONS DE MAINTENANCE ET DE RÉGLAGE SUR LES PIÈCES
ASSOCIÉES AU CONTRÔLE DES ÉMISSIONS POLLUANTES CI-DESSOUS
POUR PRÉSERVER L’EFFICACITÉ DU SYSTÈME ANTIPOLLUANT.
Le système anti-polluant est constitué des pièces suivantes :
(1) Corps de commande des gaz et pieces internes et pièces internes
(2) Système d’enrichissement de démarrage à froid, le cas
échéant
(4) Éléments de l’épurateur d’air
(5) Bougie d’allumage
(6) Dispositif d’allumage
Magnétique ou électronique
(7) Système d’avancement / retard, le cas échéant
(8) Collecteur d’échappement, le cas échéant
(3) Collecteur d’admission, le cas échéant
(9) Tuyaux, courroies, connecteurs et assemblages
Le calendrier de maintenance indiqué dans le tableau suivant s’applique pour fonctionnement normal du moteur. Si celui-ci est utilisé en environnement extrêmement poussiéreux ou en situation de charge plus pressante, les intervalles pour les opérations de maintenance devront être raccourcis en fonction du degré de contamination de l’huile, de l’encrassement des éléments de filtrage, de l’usure des parties, etc.
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EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ15
Tableau d'entretien périodique
Points d’entretien
Nettoyer le moteur et verifier ecrous et boulons
Toutes les
8 heures
(Chaque jour)
● (Chaque jour)
Toutes les 50 heures
Toutes les 200 heures
Toutes les 500 heures
Toutes les 1000 heures
Verifier et refaire plein d'huile
Vidanger l'huile moteur (*Note 1)
Changer le filtre à huile moteur (*Note 1)
Contrôle du niveau d'électrolyte de batterie
● (remplir au niveau supérieur tous les jours)
● (20 premières heures)
● (20 premières heures)
● (Toutes les 100 heures)
●
●
Verifer la bougie
Nettoyer le filtre a air
Pare-étincelles (partie en option)
Changement de l'élément du filtre à air
●
●
● (Toutes les 100 heures)
●
● Nettoyer le filtre a essence
Nettoyage et réglage des bougies et des
électrodes
Remplacer la bougie d’allumage
●
Nettoyer le charbon sur la tête de cylindre
Nettoyer le Corps de commande des gaz
(*Note 2)
Nettoyage du bloc-moteur (carter d'huile)
●
●
●
Verifier et regler jeu du poussoir de soupape
●
●
Remplacer les canalisations d’essence
Révision du moteur (*Note 2)
● (tous les ans)
●
* Note 1 : Au départ, le changement d’huile et le remplacement du filtre à huile doivent être effectués après 20 heures de fonctionnement.
Après quoi, changer l’huile toutes les cent (100) heures et remplacer le filtre à huile toutes les 200 heures. Avant de changer l’huile, disposer comme il convient de l’huile usée. Ne pas l’écouler dans les égouts ou dans les cours d’eau. Les règlements en vigueur localement pour les diverses zones et environnements vous donneront des instructions plus détaillées sur les modes appropriés d’élimination des déchets.
*Note 2 : En ce qui concerne les procédures, voir le Manuel d’Entretien et de Réparation ou consulter votre centre ROBIN de service le plus proche.
*Note 3 : Il pourra être nécessaire d’augmenter la fréquence des changements d’huile, des remplacements du filtre à huile et des interventions d’entretien de l’épurateur d’air selon les conditions de fonctionnement.
Par exemple, en cas d’un environnement poussiéreux, de températures ambiantes
élevées et de charges élevées du moteur.
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9. COMMENT REPAPER
0,7 à 0,8 mm
(0,03 pouces)
VERIFICATION DE LA
BOUGIE
■
Nettoyer la bougie à la brosse métallique.
■
Contrôler l’intervalle des électrodes.
Régler l’intervalle sur :
0,7mm à 0,8mm (0,03 pouces)
■
Utiliser une bogie adaptée :
BPR5ES (NGK) ou BPR4EY (NGK)
Bouchon de vidange
(Des-deux cotes)
VIDANGE MOTEUR
■
Première vidange après 20 heures de marche.
■
Vidanges successives toutes les 100 heures.
1. Pour vidanger, arrêter le moteur et dévisser le boulon de vidange.
2. Revisser le bouchon de vidange lorsque le carter est vide.
3. Se référer au tableau d’huile recommandée.
(Voir la Section 3 Verification avant demarrage)
4. Toujours utiliser le bon grade et une huile propre.
Tout écart peut entrainer de graves dommages pour le moteur.
CONTENANCE EN HUILE : 1,55 litre
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EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ17 filtre à huile
PRECAUTION
Pour éviter tout accident, ne pas renverser d’huile sur le moteur chaud pendant le remplacement du filtre à huile.
Molette
Mousse d'urethane
Base
Couvercle du filtre à air
Virole
Élément
CHANGEMENT DU FILTRE
A HUILE MOTEUR
■
Le premier remplacement du filtre à huile moteur doit être effectué au bout de 20 heures de marche. Procéder ensuite à ce remplacement toutes les
200 heures d’utilisation.
■
A l’installation d’un filtre à huile moteur neuf, enduire le joint torique d’huile, mettre le filtre à huile en position et visser de 2/3 de tour à la main ou à l’aide d’une clé depuis la position de contact du joint torique et de la surface d’étanchéité.
■
Faire tourner le moteur pendant une minute : couper le moteur puis vérifier l'absence de fuites d'huile autour du filtre
à huile et vérifier le niveau de l'huile.
NETTOYAGE DU FILTRE A AIR
Un élément de filtre à air sale peut provoquer des difficultés au démarrage, une perte de puissance, des pannes du moteur et réduit de beaucoup la vie du moteur.
Toujours maintenir l'élément filtrant propre.
L'élément interne en papier et l'élément externe en mousse d'uréthane du filtre à air sont démontables après dépose de la molette et du couvercle du filtre à air.
A la repose, installer l'élément en papier et la mousse d'uréthane sur la base du filtre à air. Vérifier que la virole est en bonne position, reposer le couvercle et le fixer soigneusement à l'aide de la molette.
■
Nettoyage de la mousse d'uréthane
Laver et nettoyer la mousse d'uréthane à l'aide de kérosène. Laisser tremper dans une solution 3/4 kérosène et 1/4 huile moteur puis essorer soigneusement.
Nettoyer ou changer l'élément en mousse d'uréthane toutes les 50 heures
(ou plus souvent en cas d'utilisation en environnement poussiéreux).
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EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ18
■
Elément en papier
Nettoyer en tapotant doucement le papier et en soufflant pour enlever la poussière. Ne jamais utiliser d’huile. Nettoyer l'élément en papier toutes les 50 heures de marche et changer cet élément toutes les 200 heures ou tous les ans.
Nettoyer et changer plus souvent les éléments du filtre à air en cas d'utilisation en environnement poussiéreux.
VERIFIER LES VIS, LES
BOULONS ET LES ECROUS.
Revisser les boulons et écrous dévissés.
Vérifier s'il n'y a pas de fuite. Remplacer les piéces endommagées.
SOYEZ SUR DE VOTRE MOTEUR.
Tuyau de carburant
(RETOUR)
Vers le réservoir de carburant
Tuyau de huile
Vers le corps de commande des gaz
Tuyau de carburant
CHANGEMENT DU
FLEXIBLE DE CARBURANT
AVERTISSEMENT
Prendre les plus grande précautions au changement d'un flexible de carburant : l'essence est un produit inflammable.
Remplacez le tuyau de carburant et d’huile toutes les 1.000 heures ou chaque année. En cas de fuite, changer immédiatement le flexible.
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VERIFICATION DE LA BATTERIE
AVERTISSEMENT
L'électrolyte de batterie est un acide et, à ce titre, un produit dangereux et corrosif.
Des blessures graves peuvent résulter d'un contact avec la peau ou les vêtements.
Si le niveau d'électrolyte est trop bas, refaire le plein avec de l'eau distillée.
FONCTIONNEMENT DU MOTEUR À HAUTE ALTITUDE
Ce moteur est doté du système FI.
Le rapport air/carburant durant la conduite à haute altitude est corrigé automatiquement grace à ce système FI.
La correction automatique est possible jusqu'à 3000 mètres (9800 pieds).
− 19 −
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ20
10. STOCKAGE
UTILISEZ TOUT LE
CARBURANT JUSQU’À
SON ÉPUISEMENT
AVERTISSEMENT
Interdit de faire du feu
Si vous n'utilisez pas le moteur pour plus d'un mois, faites le marcher jusqu’à ce que le carburant soit complètement
épuisé, puis rangez l'équipement dans un endroit présentant une basse humidité afin d'éviter tous problèmes de démarrage et de fonctionnement dû à la détérioration du carburant.
HUILE
■
Mettre de l'huile neuve dans le moteur.
■
Enlever la bougie et verser lentement environ 5 cm
3 d'huile moteur dans le cylindre.
Faire tourner le moteur pendant 2 ou
3 secondes et reposer la bougie.
NETTOYEGE ET
ENTREPOSAGE
■
Déposer les fils des bougies.
■
Faire tourner lentement le vilebrequin jusqu'à sentir une résistance et le laisser dans cette position.
■
Nettoyer soigneusement le moteur à l'aide d'un chiffon imbibé d'huile, couvrir le moteur et le ranger à l'abri, dans un endroit bien aéré et sans humidité excessive.
− 20 −
EH72FI̲fr̲EU6943 09.12.21 2:48 PM ページ21
11. SPÉCIFICATIONS
MODÉLE
Type
Course x alésage mm(pouces)
Cylindrée cm 3 (cu. pouces)
Puissance continue kW (CV) / tr/mn
Puissance maximum kW (CV) / tr/mn
Couple Max.
N ・ m (kgf ・ m) / tr/mn
Sens de rotation
Lubriflant
Contenance en lubrifiant litre (U.S. gal)
Carburant
Bougie
Démarrage
Poide à vide kg (livre)
Dimensions
(Lo x La x H) mm (pouces)
Jeu de soupapes
(Admission & Échappement)
Période de durabilité des émissions
(Californie seulement)
EH72 FI
Moteur à essence à ACT, arbre de prise de mouvement horizontal, double cylindre en V, 4 temps, refroidi par air
2-84 x 65 (3.31 x 2.56)
720 (43,9)
14,9 (20,0) / 3600
20
,
9
(2
8
,0) /
40
00
52,2 (5,32) / 2800
Sens inverse des aiguilles d'une montre face à l'arbre de prise de force
Huile pour moteur automobile SAE #20, #30 ou 10W-30,
Classe SE, SF ou mieux (SG, SH ou SJ est recommandé)
1,55 (0,41)
Essence sans plomb pour automobile
BPR5ES (NGK) ou BPR4EY (NGK)
Démarreur électrique disponible
46 (101,3)
317 x 477 x 480
(12,5 x 18,8 x 18,9)
0,1 ± 0,02 mm (0,0039 ± 0,0008 pouces)
Note : Régler le jeu de soupapes à moteur froid.
250 heures
− 21 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ01
(Propuesta California 65)
AVISO:
Los gases de escape de este producto contienen agentes químicos que, según el Estado de California, causan cáncer, defectos de nacimiento u otros efectos perjudiciales reproductivos.
(California solamente)
ÍNDICE DE AIRE
Para mostrar el cumplimiento de las regulaciones sobre las emisiones de California, se ha colocado una etiqueta que muestra el nivel de Índice de aire y el período de durabilidad de este motor.
El nivel del Índice de aire define el grado de limpieza de las emisiones de escape del motor en un período de tiempo. Se emplea un gráfico de barras escalado desde "0" (más limpio) a "10" (menos limpio) para indicar el nivel del Índice de aire del motor. Un nivel de Índice de aire más bajo representa unas emisiones de escape más limpias del motor.
El período de tiempo (en horas) que se mide el nivel del Índice de aire se denomina período de durabilidad. Dependiendo del tamaño del motor, puede emplearse una selección de períodos de tiempo para medir el nivel del Índice de aire (vea más abajo).
Término descriptivo
Moderado -
Intermedio
Extendido
Aplicable al período de durabilidad de las emisiones
50 horas (motores de 0 a 80 cc)
125 horas (motores de más de 80 cc)
- 125 horas (motores de 0 a 80 cc)
250 horas (motores de más de 80 cc)
- 300 horas (motores de 0 a 80 cc)
500 horas (motores de más de 80 cc)
1000 horas (225 cc o más)
Observación : Esta etiqueta deberá quedar en este motor o pieza de equipo, y sólo podrá extraerla el comprador final antes de la operación.
Observación : La GARANTÍA POR DEFECTOS DE COMPONENTES DE EMISIONES FEDERAL y la GARANTÍA DE CONTROL DE
EMISIONES DE CALIFORNIA son aplicables sólo a los motores/generadores que satisfacen las regulaciones de emisiones de EPA (Environmental Protection Agency) y de CARB (California Air Resources Board) en los EE.UU.
Observación : El servicio de garantía de los motores/generadores exportados y que se empleen en países que no sean los
EE.UU. deberá efectuarlo el distribuidor de cada país de acuerdo con la política de garantía estándar de motores/generadores de Robin según sea aplicable.
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ02
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ03
INTRODUCCIÓN
Muchas gracias por comprar un MOTOR ROBIN .
Etiqueta de emisiones del motor
Nº. de seire del motor
Este motor ROBIN suministrará la energía necesaria para poder alimentar diferentes máquinas y equipos.
Tómese el tiempo necesario para familiarizarse con los procedimientos apropiados de operación y mantenimiento a fin de lograr la máxima seguridad y rendimiento de este producto.
Debido a los constantes esfuerzos para mejorar nuestros productos, ciertos procedimientos y especificaciones están sujetos a cambios sin previo aviso.
Cuando solicite piezas de repuesto, indique siempre el
MODELO, ESPECIFICACIÓN y el NÚMERO DE SERIE del motor. Rellene los siguientes espacios en blanco después de comprobar el número de su motor.
Nº DE ESPEC.
E H
Nº. SERIE
Para encontrar al distribuidor (y/o concesionario) ROBIN que le quede más cercado, búsquelo en nuestro sitio en la Web en la URL siguiente; http://www.subaru-robin.jp
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ04
ÍNDICE
1. MEDIDAS DE SEGURIDAD ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 1
2. COMPONENTES ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 4
3. CONTROLES PREVIOS AL FUNCIONAMIENTO ・ ・ ・ ・ ・ 5
4. INSTALACIÓN DE LA BATERÍA ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 7
5. FUNCIONAMIENTO DEL MOTOR ・ ・ ・ ・ ・ ・ ・ ・ 9
6. LOCALIZACIÓN Y REPARACIÓN FÁCIL DE AVERÍAS ・・ 11
7. PARACHISPAS (OPCIONAL) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 13
8. PLAN DE MANTENIMIENTO ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14
9. COMPROBACIONES Y MANTENIMIENTO FÁCILES ・ ・ ・ 16
10. PREPARATIVOS PARA EL ALMACENAMIENTO ・ ・ ・ ・ 20
11. ESPECIFICACIONES TÉCNICAS ・ ・ ・ ・ ・ ・ ・ ・ 21
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ05
SÍMBOLOS
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ1
1. MEDIDAS DE SEGURIDAD
Por favor siga cada una de las si-guientes indicaciones :
CON LOS GASES DE ESCAPE
■
No inhale nunca los gases de escape.
Éstos contienen monóxido de carbono, un gas incoloro, inodoro y extremadamente peligroso, que puede causar la pérdida de conocimiento e incluso la muerte.
■
No utilice nunca el motor en lugares cerrados o mal ventilados: túneles, cuevas, etc.
■
Tenga mucho cuidado cuando utilice el motor cerca de personas y animales.
■
Mantenga el tubo de escape libre de objetos extraños.
AL REPOSTAR COMBUSTIBLE
■
Asegúrese de apagar el motor antes de repostar.
■
No llene demasiado el depósito de combustible.
■
En caso de salpicaduras de combustible, límpielo cuidadosamente y espere a que se seque antes de poner en funcionamiento el motor.
■
Después de repostar, asegúrese de que la tapa del depósito esté bien cerrada para evitar salpicaduras.
PREVENCION CONTRA
INCENDIOS
■
No utilice el motor cuando fume ni cerca de llamas.
■
No utilice el motor cerca de cepillos, ramas, trapos ni otros materiales inflamables.
■
Mantenga el motor al menos a 1 metro de edificios u otras estructuras.
■
Mantenga el motor alejado de materiales inflamables y peligrosos (basura, alfombras, lubricantes, explosivos).
− 1 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ2
CUBIERTA PROTECTORA
■
Coloque las cubiertas protectoras sobre las piezas giratorias.
Si las partes giratorias (eje, polea, correa, etc.) están al descubierto, suponen un peligro potencial.
Para evitar riesgos personales, equípelas con cubiertas protectoras.
■
Tenga cuidado con las piezas calientes.
El silenciador y otras partes del motor están calientes cuando el motor está en marcha o inmediatamente después de haberlo apagado.
Utilice el motor en un área segura y lejos de niños.
■
Nunca ajuste la maquinaria mientras esté conectada al motor, sin haber quitado antes el cable de encendido de la bujía. Girar el cigüeñal manualmente durante el ajuste puede encender el motor y la maquinaria conectada al mismo, provocando serios daños al usuario.
■
Nunca encienda el motor con el regulador conectado ni sobrepase la carga de 3600 r.p.m.
− 2 −
SURROUNDINGS
ALREDEDORES
■
Utilice el motor sobre una superficie nivelada y estable, exenta de piedras, grava, etc.
NOTA
Utilizar el motor en una superficie inclinada puede causar daños por falta de lubricación, aunque el depósito de aceite esté lleno.
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ3
■
Vacíe el depósito de combustible antes de transportar el motor.
■
No mueva el motor si está encendido cuando haya sido sacado del equipo.
■
Mantenga la unidad seca. (No opere el motor bajo la lluvia).
COMPROBACIONES PREVIAS AL
FUNCIONAMIENTO
■
Compruebe cuidadosamente que los tubos y juntas no estén flojos y que no haya fugas de combustible.
El combustible derramado crea situaciones potenciales de peligro.
■
Compruebe que no haya tuercas ni tornillos flojos. Un tornillo suelto puede causar serios daños al motor.
■
Compruebe el nivel de aceite todos los días y rellene si fuese necesario.
■
Compruebe el nivel de combustible y rellene si fuese necesario.
Tenga cuidado de no llenar de más el depósito.
■
Utilice ropa ajustada al utilizar el motor. Las chaquetas abiertas, toallas, cinturones, etc., pueden se enganchadas por el motor y crear una situación de peligro.
− 3 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ4
2. COMPONENTES
Tapa filtro aire
Palanca acelerador
Contacto
Panel de control
Lámpara de alarma
Capuchón bujía
Filtro del combustible
Conductor aire
Bomba combustible
Enfriador de aceite
Cuerpo de la mariposa
Tapón llenado aceite
Enganche
Capuchón bujía
Etiqueta de emisiones del motor
Regulador voltaje
Palanca regulador
Filtro aceite
Cala aceite
Eje
Arrancador eléctrico
Tapón drenaje (en los dos lados)
OBSERVACIONES :
■
Para conectar la fuente de combustible al cuerpo de la mariposa se requieren el depósito de combustible, la válvula (se recomienda el tipo de taza de sedimentos), las mangueras de combustible, y el filtro de combustible.
■
Para la operación de encendido del motor hace falta una batería de 12V-36AH o más, con su cable específico. Haga las conexiones de cableado necesarias antes del funcionamiento normal del motor. Vea la sección 4 de este manual de instrucciones.
(Para ver las instrucciones, consulte la Sección 4 Instalación de la batería.)
− 4 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ5
3. CONTROLES PREVIOS AL FUNCIONAMIENTO
Tipo estándar Opcional
Cala aceite
NIVEL DE ACEITE (DIARIO)
Antes de rellenar o comprobar el nivel de aceite, asegúrese de que el motor esté apagado y sobre una superficie nivelada.
■
Si el nivel de aceite está por debajo de la línea inferior de la cala, rellene con el aceite apropiado (ver tabla) hasta el nivel superior.
CAPACIDAD DE ACEITE : 1,55 LITROS
Cala aceite
Nivel superior
Nivel inferior
Cala aceite
Nivel superior
Cala aceite
Nivel superior
Nivel inferior
Nivel inferior
5W
10W
Grado
único
20W
#20
#30
#40
Multigrado
Temperatura ambiental
10W-30
10W-40
-20 -10
-4 14
0
32
10
50
20
68
30
86
40
104
■
Cuando llene el depósito de aceite, mantenga el motor nivelado y llene hasta la marca superior de la cala de aceite. Mida el nivel de aceite con la cala acoplada en su sitio.
■
Después de un cambio de aceite, encienda el motor y compruebe su nivel. Éste puede bajar un poco al llenarse el filtro. Llénelo hasta la marca superior de la cala.
■
Cambie el aceite cualdo esté sucio
(vea la Sección 8 para el plan de mantenimiento).
■
Utilice aceites detergentes para motor de 4 tiempos o de la categoría API SE o superior (SG, SH o SJ recomendados).
■
Si utiliza un aceite multigrado, el consumo de aceite tiende a aumentar cuando la temperatura ambiente es alta.
− 5 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ6
Tubo de goma
Filtro del combustible
Entrada combustible
Bomba combustible
CONTROL DEL COMBUSTIBLE
¡CUIDADO!
No reposte mientras fume ni cerca de llamas u otros peligros potenciales.
NOTA :
ESTE MOTOR ESTÁ CERTIFICADO PARA
FUNCIONAR CON GASOLINA SIN PLOMO
PARA AUTOMÓVILES.
■
Se puede proporcionar el tanque de combustible por separado ya que el motor no está equipado con dicho depósito.
La válvula de combustible y el filtro deberán conectarse entre el depósito y la bomba.
Asegure las gomas a la bomba, para prevenir fugas de combustible.
■
El depósito de combustible puede montarse hasta a 0,66 metros por debajo del cuerpo de la mariposa.
Si se monta el depósito por encima del cuerpo de la mariposa, deberá instalarse entre el depósito y la bomba una válvula que corte el fluido de gasolina.
Esta válvula deberá cerrarse cuando el motor esté apagado para evitar que el combustible rebose y encharque el cuerpo de la mariposa.
■
Si la goma de combustible se sale de su sitio se puede producir un grave accidente. Asegure las conexiones de la línea de combustible introduciendo ls gomas en su sitio hasta el fondo y asegurándolas con una grapa.
■
Emplee sólo gasolina sin plomo para automóviles.
■
Apague el motor y cierre la válvula del combustible antes de repostar.
■
Limpie bien el combustible derramado antes de encender el motor.
− 6 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ7
4. INSTALACIÓN DE LA BATERÍA
Para el encendido del motor, es necesario realizar una instalación de cables antes del funcionamiento normal del motor.
PIEZAS NECESARIAS
■
Utilice una batería de 12V-36AH o más.
■
Emplee un cable adecuado y un cable de toma de tierra para conectar la batería, el interruptor de la llave y el motor de arranque eléctrico.
CABLE
25mm
LA406
CABLE A TIERRA
LA408
CABLES DE LA BATERÍA
LONGITUD
CABLE
DIAM.
CABLE
CALA CABLE
AWG (BS)
BWG
SAE JIS menos de
1,5 m
7,3 mm 1 6 AV15
1,5 m a
2,5 m
2,5 m a
4,0 m
8,5 mm
10,8 mm
0
3/0
4
2
AV20
AV30
TOMA A TIERRA : utilice un cable plano con terminales de sección de 0,03 pulgadas cuadradas o más.
(CALA SAE 4)
CABLE DEL INTERRUPTOR
DE LA LLAVE
LONGITUD
CABLE
DIAM.
CABLE
CALA CABLE
AWG (BS)
BWG
SAE JIS menos de
1,5 m
1,5 mm 14 16 AV1,25
1,5 m a
3,0 m
3,0 m a
5,0 m
1,9 mm
2,4 mm
12
10
14
13
AV2
AV3
− 7 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ8
CABLEADO
■
Conecte el terminal positivo del automático al terminal positivo de la batería, con cable de batería.
■
Conecte el terminal negativo de la batería al cuerpo del motor o de la máquina con cable a tierra.
Cable
+
Batería
-
Terminal encendido del motor
Cable a tierra
NOTA
Apriete los tornillos y tuercas de los terminales para que no se suelten con las vibraciones.
DIAGRAMA DE CABLEADO
Grn, R
(Recubrimiento: Blk)
CUERPO DE
LA MARIPOSA
Blk
Blk
Blk
Blk
Blk
R
R
BOMBA DE
COMBUSTIBLE
ELÉCTRICO
Gry
INTERRUPTOR
DE LA PRESIÓN
DEL ACEITE
Blk
R
Blk
Blk
(Recubrimiento: Blk)
Blk (Recubrimiento: Gry)
Gry
Grn, R
(Recubrimiento: Gry)
W
BOBINA DE
ENCENDIDO
#2
Blk Blk
BUJÍA
BOBINA DE
ENCENDIDO
#1
BUJÍA
LÁMPARA DE ALARMA
DE ACEITE
W
R
Y
R
Blk / W
R
Y
Y
W
TACÓMETRO /
CONTADOR
DE HORAS
(OPCION)
Blk
Blk : NEGRO
Grn : VAERDE
Gry : GRIS
G M B L S
OFF
RUN
START
INTERRUPTOR
SONDA DE
TEMPERATURA REGURATOR
BOBINA DE
CARGA Grn
ARRANCADOR
ELÉCTRICO
BATERÍA
12V
Equipamiento opcional en líneas discontínuas. Seleccione cables de cala apropiada y conecte la batería según se muestra en la línea discontínua del diagrama de cableado.
− 8 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ9
5. FUNCIONAMIENTO DEL MOTOR
NOTA
Para la palanca de control del tipo estándar, se emplea el siguiente método de operación.
En cuanto a la palanca de control de la velocidad del tipo fijo
(véanse las especificaciones del generador), no la mueva, porque de lo contrario podría dañar componentes del generador tales como el regulador de tensión.
ARRANQUE
1
VÁLVULA COMBUSTIBLE
(Proporcionada por el fabricante)
TIRADOR AIRE
3
MARCHA
OFF
RUN
LÁMPARA
DE ALARMA
(se illumina)
START
Si una caja de mando está instalada, girar el interruptor y ajustarlo a la posición “MARCHA” (RUN).
Comprobar que se ilumina la lámpara de alarma y otras lámparas (de rojo).
■
Al ajustar el interruptor a la posición de marcha (RUN), un ruido de funcionamiento de la bomba de combustible puede producirse por dos o tres segundos (esto no representa un defecto de funcionamiento).
Abra la válvula de combustible.
2
PALANCA ACELERADOR
4
ARRANCADOR ELÉCTRICO
OFF
RUN
Sitúe la palanca del acelerador a
1/3 de distancia hacia la posición de máxima velocidad.
− 9 −
START
ARRANQUE
Gire el interruptor a la posición
"ARRANQUE".
■
No active el arranque eléctrico durante más de 5 segundos, aunque el motor no encienda.
■
Si el motor no arranca, sitúe el interruptor en la posición "RUN" y espere 10 segundos antes de intentar de nuevo el arranque.
■
Nunca sitúe el interruptor a la posición “ARRANQUE” con el motor encendido.
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ10
FUNCIONAMIENTO
PALANCA ACELERADOR
PARADA
1
PALANCA ACELERADOR
Una vez encendido el motor, sitúe la palanca del acelerador en la posición de baja velocidad y deje que se caliente el motor sin carga durante unos minutos.
Sitúe la palanca del acelerador en la posición de baja velocidad y deje que el motor funcione durante 2 ó 3 minutos sin carga.
2
ARRANCADOR ELÉCTRICO
PARADA
OFF
RUN
Mueva gradualmente la palanca hacia la posición de alta velocidad y sitúela en la velocidad requerida.
START
Gire el interruptor a la posición
"PARADA".
NOTA :
Cuando no necesite velocidad alta, redúzcala hasta ralentí para reducir el consumo de combustible y alargar la vida del motor.
− 10 −
3
VÁLVULA COMBUSTIBLE
Cierre la válvula de combustible.
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ11
6. LOCALIZACIÓN Y REPARACIÓN FÁCIL DE AVERÍAS
CUANDO EL MOTOR NO ARRANCA
■
Realice las siguientes comprobaciones antes de llevar el motor a su distribuidor
ROBIN.
■
Si después de comprobar estos puntos sigue teniendo problemas, lleve el motor a su distribuidor ROBIN.
¿Hay suficiente compresión?
Si la bujía esta floja, apriétela.
¿Está la bujía humedecida con gasolina?
1. Lentamente encienda el motor duante 2 ó 3 segundos.
Extraiga la bujía y compruebe si el electrodo está húmedo. Si es así, hay un buen suministro de combustible al motor.
2. Si el electrodo está seco, mire dónde se corta el suministro de combustible.
(Revise la admisión de combustible del cuerpo de la mariposa y la entrada en la llave de paso).
3. Si el motor no arranca con una circulación correcta de combustible, inténtelo utilizando gasolina nueva.
¡CUIDADO!
Limpie bien el combustible derramado antes de comprobar la bujía.
Sitúe la bujía lo más lejos posible de su hueco.
No sujete la bujía con la mano mientras la prueba.
¿Hay suficiente chispa en el electrodo?
1. Extraiga la bujía y conéctela al capuchón.
Gire la llave a la posición
"ARRANQUE" haciendo masa con la bujía contra el cuerpo del motor.
2. Cambie la bujía si no hay chispa o si
ésta es demasiado débil.
3. El sistema de encendido está dañado si no hay chispa con una bujía nueva.
Lleve el motor a su distribuidor ROBIN más próximo.
− 11 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ12
Acerca de la lámpara de alarma
■
Comprobar el aceite para ver si la lámpara de alarma se ilumina durante la conducción del vehículo. (Véase la Sección “ 3. CONTROLES PREVIOS AL
FUNCIONAMIENTO ” para las instrucciones.
■
Hacer examinar el vehículo por el taller del concesionario o un servicio de manutención si la lámpara de alarma parpadea durante la conducción del vehículo.
¿Está cargada la batería?
Revise la batería. Puede estar descargada y no podrá activar el arranque eléctrico. Consúltelo con su proveedor más cercano.
− 12 −
EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ13
7. PARACHISPAS (OPCIONAL)
En zonas secas o boscosas es recomendable utilizar el producto con un parachispas.
Algunas zonas exigen el uso de parachispas. Infórmese sobre las normas y leyes locales antes de utilizar el producto.
Es necesario limpiar el parachispas regularmente para garantizar su funcionamiento correcto. Un parachispas atascado :
●
●
●
Impide el flujo del gas de escape
Reduce el rendimiento del motor
Aumenta el consumo de combustible
●
Dificulta el arranque
Si el motor ha estado funcionando, el silenciador y el parachispas estarán muy calientes. Espere que el silenciador se enfríe antes de limpiar el parachispas.
SILENCIADOR
PANTALLA DEL
PARACHISPAS
Cómo quitar el parachispas
1. Quite los pernos de la tapa del silenciador y quite la tapa del silenciador.
2. Quite el tornillo especial del parachispas y quite el parachispas del silenciador.
TAPA DEL
SILENCIADOR
PANTALLA DEL PARACHISPAS
Cómo limpiar la pantalla del parachispas
Con un cepillo quite los depósitos de carbón de la pantalla del parachispas.
Tenga cuidado de no dañar la pantalla.
El parachispas no debe presentar roturas ni agujeros. Sustituya el parachispas si está dañado.
Instale el parachispas y la tapa del silenciador en el orden inverso al desensamblaje.
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8. PLAN DE MANTENIMIENTO
EL MANTENIMIENTO, LA SUSTITUCIÓN Y LA REPARACIÓN DE LOS SISTEMAS Y
DISPOSITIVOS DE CONTROL DE EMISIONES DEBEN SER REALIZADOS POR UN
INDIVIDUO O UN ESTABLECIMIENTO REPARADOR DE MOTORES NONROAD.
INSPECCIÓN DIARIA
Antes de encender el motor, compruebe los puntos siguientes.
Nivel de gasolina
Vibración excesiva, ruido
Filtro de aire limpio
Alrededores seguros
Suficiente aceite limpio
Fugas de combustible y aceite
Tornillos y tuercas flojos o rotos
INSPECCIÓN PERIÓDICA
Realizar un mantenimiento periódico es imprescindible para lograr un funcionamiento seguro y eficaz del motor.
Para los intervalos de mantenimiento periódico, consulte la siguiente tabla.
ES NECESARIO QUE EL USUARIO DE ESTE MOTOR REALICE EL MANTEN-
IMIENTO Y LOS AJUSTES DE LAS PIEZAS RELACIONADAS CON LA EMISIÓN,
LISTADAS A CONTINUACIÓN, PARA MANTENER LA EFICIENCIA DEL
SISTEMA DE CONTROL DE EMISIONES.
El sistema de control de emisiones está compuesto por las siguientes piezas:
(1) cuerpo de la mariposa y piezas internas
(4) Elementos del filtro de aire
(5) Bujía
(8) Colector de escape, si corresponde
(2) Circuito enriquecedor para arranque en frío, si corresponde
(6) Sistema de ignición magnético o electrónico
(9) Manguitos, cintas, conectores y ensamblajes
(3) Colector de admisión, si corresponde
(7) Sistema adelanto/atraso de chispa, si corresponde
El programa de mantenimiento indicado en la siguiente tabla está referido al uso normal del motor. Si el motor se utiliza en ambientes muy polvorientos o con cargas pesadas, los intervalos de mantenimiento deben abreviarse en función de la contaminación del aceite, el atascamiento de los elementos filtrantes, el desgaste de las piezas, etc.
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Tabla de mantenimiento periódico
Elementos de mantenimiento
Limpieza de motor y estado de tuercas y tornillos
Controle y restablezca el aceite del motor
Cada
8 horas
(Diariamente)
● (Diario)
Cada
50 horas
Cada
200 horas
Cada
500 horas
Cada
1000 horas
Cambio de aceite (*Nota 1)
Limpieza del filtro de aceite (*Nota 1)
Nivel de líquido en la batería
Limpieza de bujía
Limpieza del filtro de aire
Parachispas (opcional)
Cambio del elemento del filtro
Limpie el filtro del combustible.
Limpieza y ajuste de los electrodos de la bujía
Sustituya la bujía
Quite el carbón de la cabeza del cilindro
Limpie el cuerpo de la mariposa (*Nota 2)
Limpieza de la base del motor (bandeja de aceite)
Ajuste distancias de válvulas
● (A diario, hasta el nivel superior)
●
(Inicial, 20 horas)
●
(Inicial, 20 horas)
● (Cada 100 horas)
●
●
●
●
● (Cada 100 horas)
●
●
●
●
●
●
●
●
Sustituya las líneas de combustible
Revise el motor (*Nota 2)
●
(Anual)
●
* Nota 1 : El primer cambio de aceite y la primera sustitución del filtro de aceite deberían realizarse a las 20 horas de funcionamiento.
En lo sucesivo cambie el aceite cada 100 horas y sustituya el filtro cada 200 horas. Antes de cambiar el aceite encuentre una forma adecuada de eliminar el aceite usado. No lo deseche en el sumidero de aguas negras, en el jardín o en cursos de agua abiertos. Las normas locales de zonificación o medio ambiente le proporcionarán instrucciones más detalladas sobre la eliminación correcta.
*Nota 2 : En cuanto a los procedimientos, remítase al Manual de Servicio o consulte a su centro de asistencia ROBIN más cercano.
*Nota 3 : Según las condiciones de uso, puede ser necesario realizar con mayor frecuencia el cambio de aceite, la sustitución del filtro de aceite y la revisión del filtro de aire, especialmente si el ambiente es polvoriento, si la temperatura ambiente es alta o si la carga del motor es muy pesada.
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9. COMPROBACIONES Y MANTENIMIENTO FÁCILES
0,7 a 0,8 mm
(0,03 pulgadas)
INSPECCIÓN DE LA BUJÍA
■
Limpie el electrodo de la bujía de depósitos de carbonilla utilizando un limpiador de bujías o un cepillo de alambre.
■
Compruebe el espacio entre los electrodos.
Ajuste el espacio de :
0,7 a 0,8 mm (0,03 pulgadas)
■
Tipo de bujía recomendado :
BPR5ES (NGK) o BPR4EY (NGK)
Tapón drenaje
(a ambos lados)
CAMBIO DE ACEITE DEL MOTOR
■
Cambio inicial . . . . . .a las 20 horas.
■
Siguientes cambios . .cada 100 horas.
1. Al cambiar el aceite, pare el motor y saque el tapón de drenaje.
2. Vuelva a colocar el tapón de drenaje antes de rellenar el aceite.
3. Consulte la tabla del aceite recomendado.
(Vea la Sección 3 Controles previos al funcionamiento)
4. Utilice siempre aceite limpio del grado recomendado. Aceite sucio, de mala calidad o escaso puede dañar el motor, acortando su vida.
CAPACIDAD DE ACEITE : 1,55 LITROS.
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Filtro aceite
CAMBIO DEL FILTRO DE ACEITE
■
Cambio inicial: a las 20 horas.
■
Siguientes cambios: cada 200 horas.
■
Al instalar un nuevo filtro, ponga aceite en la arandela, coloque el filtro en su sitio y apriételo 2/3 de vuelta, a mano o con una llave, una vez que la arandela toque la superficie de sella-do del motor.
■
Haga funcionar el motor durante un minuto; apague el motor y verifique que no hay fugas de aceite alrededor del filtro. Revise el nivel de aceite.
¡CUIDADO!
Para evitar lesiones, tenga cuidado con derrames de aceite caliente al cambiar el filtro
Puño Cubierta filtro
Espuma uretano
Base
Tapón
Elemento
LIMPIEZA DEL FILTRO DE AIRE
Un filtro de aire sucio causará problemas de arranque, pérdida de potencia, funcionamiento irregular y reducción de la vida del motor.
Asegúrese de limpiar periódicamente el filtro. Cambie los elementos con más frecuencia si se opera en un entorno excesivamente polvoriento.
Los elementos de papel y de espuma de uretano pueden extraerse tras sacar el puño y la cubierta del filtro de aire. Al instalarlos, sitúe el elemento de papel y el de espuma en la base del filtro.
Asegúrese de que el tapón esté en su sitio y después coloque la cubierta con el puño asegurado en su sitio.
■
Limpieza de la espuma de uretano
Lavar la espuma en keroseno.
Empapar en una mezcla de 3 partes de keroseno y 1 de aceite del motor, oprimiendo para eliminar el exceso de líquido. Limpie o cambie la espuma cada 50 horas (menos en ambientes polvorientos).
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EH72FI̲es̲EU6943 09.12.21 3:01 PM ページ18
■
Limpieza del elemento de papel
Limpie golpeando suavemente y soplándole el polvo. Nunca utilice aceite.
Limpie o cambie el elemento cada 50 horas y cámbielo cada 200 o una vez al año.
Limpie y cambie el filtro de aire con más frecuencia si trabaja en ambientes polvorientos.
REVISIÓN DE TUERCAS Y
TORNILLOS
Apriete tornillos y tuercas flojos. Revise posibles fugas de aceite y combustible.
Cambie las piezas dañadas por nuevas. Tenga siempre presente la seguridad.
Mangueras de combustible
(REGRESO)
Hacia el tanque de combustible
Mangueras de aceite
Hacia el cuerpo de la mariposa
Mangueras de combustible
CAMBIO DE GOMA DE
COMBUSTIBLE
¡CUIDADO!
Extreme el cuidado al cambiar la goma. La gasolina es inflamable.
Reemplace las mangueras de combustible y de aceite cada 1.000
horas o cada año.
Si aparece una fuga, cambie la goma inmediatamente.
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REVISIÓN DE LA BATERÍA
¡CUIDADO!
El líquido de la batería es un ácido venenoso y corrosivo.
Se pueden producir serios daños si hay contacto con la piel, ojos y ropa.
Si el nivel del líquido de la batería es bajo, rellénela con agua destilada.
FUNCIONAMIENTO DEL MOTOR A ALTA ALTITUD
Este motor está dotado con el sistema FI.
La razón aire/carburante durante la conducción a alta altitud está corregida automáticamente por este sistema FI.
La corrección automática es posible hasta 3000 metros (9800 pies).
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10. PREPARATIVOS PARA EL ALMACENAMIENTO
UTILICE TODO EL
COMBUSTIBLE HASTA SU
AGOTAMIENTO
CUIDADO Prohibido fumar
Si no se utiliza el motor para más de un mes, operar el motor hasta que el combustible esté agotado completamente, luego almacenar el equipo en un lugar que presenta baja humedad con el fin de evitar todos los problemas de arranque y funcionamiento debido al deterioro del combustible.
ACEITE DEL MOTOR
■
Cambie el aceite por uno nuevo.
■
Quite la bujía, ponga 5cc. de aceite de motor en cada cilindro, encienda el motor lentamente durante 2 ó 3 segundos y vuelva a instalar la bujía.
LIMPIEZA Y ALMACENAMIENTO
■
Quite los cables de la bujía.
■
Gire lentamente el cigüeñal hasta que ofrezca resistencia y déjelo en esa posición.
■
Limpie el motor con un trapo mojado en aceite y almacénelo bajo cubierta en una zona bien ventilada y seca.
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11. ESPECIFICACIONES TÉCNICAS
Tipo
MODELO
Diámetro x carrera mm(pul.)
Desplazamiento cm 3 (Cúbico-pul.)
Potencia contínua kW (HP) / rpm
Potencia máxima kW (HP) / rpm
Par de torsión máximo
N ・ m (kgf ・ m) / rpm
EH72 FI
Enfriamiento de aire, 4 tiempos, cilindro doble en V,
árbol de toma de fuerza horizontal (P.T.O.), motor de gasolina OHV
2-84 x 65 (3,31 x 2,56)
720 (43,9)
14,9 (20,0) / 3600
20
,
9
(2
8
,0) /
40
00
52,2 (5,32) / 2800
Sentido de la rotación
Lubricante
Contrario al sentido de las agujas del reloj
Aceite para automóvil tipo SAE #20, #30 ó 10W-30 ; clase SE, SF o superior (SG, SH o SJ recomendados)
Capacidad del lubricante litros (U.S. gal)
Combustible
1,55 (0,41)
Gasolina sin plomo para automóvil
Bujía BPR5ES (NGK) o BPR4EY (NGK)
Sistema de arranque
Peso en seco kg (libras)
Dimensiones
(L x An x Al)
Juego de la válvula
(admisión y escape) mm (pul.)
Período de duración de las emisiones (sólo California)
Eléctrico
46 (101,3)
317 x 477 x 480
(12,5 x 18,8 x 18,9)
0,1 ± 0,02 mm (0,0039 ± 0,0008 pul.)
Nota: Ajuste el juego de la válvula mientras el motor esté frío.
250 horas
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ISSUE EMD-EU6943
EH72 FI
PRINTED IN USA
December 2009
2ZZ9990168
(英・仏・西)
OHV Gasoline Engines
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
B Owner’s Manual
Read the following warnings before operating vehicle:
To prevent personal injury or death, observe the following:
When vehicle is to be left unattended, engage park brake, move direction selector to neutral, turn key to OFF position and remove from key switch.
Drive vehicle only as fast as terrain and safety considerations allow. Consider environmental factors which effect the terrain and the ability to control the vehicle.
Avoid driving fast down hill. Sudden stops or change of direction may result in loss of control. Use service brake to control speed when traveling down an incline.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.
All travel should be directly up or down hills; use extra care if ever forced to drive across an incline.
Stay in designated areas and avoid steep slopes. Activate the park brake when the vehicle is parked.
Keep feet, legs, hands and arms inside vehicle at all times.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in reverse.
Make sure direction selector is in desired position before starting the vehicle.
Slow down before and during turns.
A l l t u r n s s h o u l d b e e x e c u t e d a t reduced speed.
Always bring vehicle to a complete stop before shifting direction selector.
See GENERAL SPECIFICATIONS for vehicle load and seating capacity.
Read the following information and warnings before operating vehicle:
In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible component failures or the manner in which they may fail.
A vehicle requiring repair indicates that it is no longer functioning as designed and therefore should be considered potentially hazardous.
Use extreme care when working on vehicle. When diagnosing, removing or replacing any components that are not operating properly, take time to consider the safety of yourself and others around you should the component move unexpectedly.
Some components are heavy, spring loaded, highly corrosive, explosive, may produce high amperage or reach high temperatures. Battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders if not treated with utmost caution. Be careful not to place hands, face, feet or body in a location that could expose them to injury should an unexpected situation occur.
Always use the appropriate tools listed in the tool list and wear approved safety equipment.
Before working on vehicle, remove all jewelry (rings, watches, necklaces, etc.).
Be sure no loose clothing or hair can contact moving parts.
Use care not to touch hot objects.
Raise rear of vehicle and support on jack stands before running or adjusting powertrain.
Wear eye protection when working on or around the vehicle. In particular, use care when working around batteries, using solvents, or compressed air.
Hydrogen gas forms when charging batteries.
Do not charge batteries without adequate ventilation.
Do no permit open flame or smokers in an area being used for charging batteries. A concentration of 4% hydrogen gas or more is explosive.
CONTACT US:
Bad Boy Buggies
1451 Marvin Griffin Road
Augusta, Georgia 30906-3852 USA
FAX: 855-256-9900
E-mail: [email protected]
For parts and repair, contact local dealer. Dealers can be located at www.BADBOYBUGGIES.com
Copyrighted Material
This manual may not be reproduced in whole or in part without the express permission of
E-Z-GO Division of Textron Inc.,
Technical Communications Department
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Key Features
- 4 X 4 drive for all-terrain capability
- Hybrid powertrain for improved fuel efficiency
- Rugged construction for durability in tough conditions
- Comfortable seating for up to four passengers
- Large cargo bed for hauling gear and equipment
- Towing capacity for pulling trailers and other loads
- Easy-to-use controls and intuitive dashboard
- Advanced safety features for peace of mind
- Versatile design for both work and play
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