Ezgo ST 400 48V Owner's Manual & Service Manual

OWNER'S MANUAL

&

SERVICE GUIDE

612307

400 48V

ELECTRIC POWERED VEHICLE

ISSUED MAY 2009

SAFETY

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

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

On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.

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

For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.

Vehicles equipped with Precision Drive System ™ (PDS) must be towed with the Run-Tow/Maintenance switch, located under the passenger seat, in the ‘Tow/Maintenance’ position.

Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.

BATTERY WARNING BATTERIES

AND RELATED PARTS

CONTAIN LEAD

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

WASH HANDS

AFTER HANDLING!

WASH HANDS

AFTER HANDLING!

WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Be sure that this manual remains as part of the permanent service record should the vehicle be sold.

!

< 14˚ 25%

DO NOT

DRIVE ACROSS

SLOPES IN

EXCESS OF 14˚

Throughout this guide

NOTE, CAUTION

and

WARNING will be used.

Observe these

NOTES, CAUTIONS

and

WARNINGS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous.

Improper service or repair may damage the vehicle or render it unsafe.

A NOTE indicates a condition that should be observed.

A CAUTION indicates a condition that may result in damage to the vehicle.

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

A WARNING indicates a hazardous condition that could result in severe injury or death.

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

OWNER’S MANUAL

AND SERVICE GUIDE

ELECTRIC POWERED

UTILITY VEHICLES

ST 400 E

Starting Model Year 2009

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

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

The E-Z-GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDEN-

TAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

TO CONTACT US

NORTH AMERICA:

TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124

SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175

INTERNATIONAL:

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

E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Owner’s Manual and Service Guide Page i

GENERAL INFORMATION

This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated.

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

Overfilling battery may void the warranty.

BATTERY PROLONGED STORAGE

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

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

For winter storage, the batteries must be clean, fully charged and disconnected from any source of electrical drain. The battery charger and the controller are both sources of electrical drain. Unplug the battery charger DC plug from the vehicle receptacle.

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

Page ii Owner’s Manual and Service Guide

TABLE OF CONTENTS

SAFETY ................................................................................................................ Inside covers

GENERAL INFORMATION ....................................................................................................... ii

SAFETY INFORMATION ........................................................................................................... v

GENERAL ................................................................................................................................. ix

BEFORE INITIAL USE .............................................................................................................. 1

Fig. 1 Initial Service Chart ......................................................................................................... 1

PORTABLE CHARGER INSTALLATION ............................................................................................................1

Fig. 2 Proper Charger Installation ............................................................................................. 2

Fig. 3 Charger Receptacle Location ......................................................................................... 2

CONTROLS AND INDICATORS ............................................................................................... 2

KEY/LIGHT SWITCH ...........................................................................................................................................2

Fig. 4 Key/Light Switch & State of Charge Meter ..................................................................... 3

DIRECTION SELECTOR .....................................................................................................................................3

Fig. 5 Direction Selector Types ................................................................................................. 3

STATE OF CHARGE METER .............................................................................................................................3

HOUR METER .....................................................................................................................................................3

ACCELERATOR PEDAL .....................................................................................................................................3

Fig. 6 Accelerator and Brake Controls ...................................................................................... 3

COMBINATION SERVICE BRAKE AND PARK BRAKE PEDAL ........................................................................4

RUN - TOW/MAINTENANCE SWITCH (PDS VEHICLES ONLY) ............................................. 4

Fig. 7 Run-Tow/Maintenance Switch ........................................................................................ 4

PLASTIC LOADBED ................................................................................................................. 4

MANUAL LIFT BED OPERATION .......................................................................................................................5

Fig. 8 Manual Bed Latch ........................................................................................................... 5

TAILGATE OPERATION .....................................................................................................................................5

OPERATING THE VEHICLE ..................................................................................................... 5

PRECISION DRIVE SYSTEM™ ..........................................................................................................................6

Regenerative Braking .............................................................................................................................6

Pedal-Up Braking ....................................................................................................................................6

Walk-Away Feature ................................................................................................................................7

Anti-Roll Back Feature ............................................................................................................................7

Anti-Stall Feature ....................................................................................................................................7

High Pedal Disable Feature ....................................................................................................................7

Default Mode Feature .............................................................................................................................7

STARTING AND DRIVING ..................................................................................................................................7

STARTING VEHICLE ON A HILL ........................................................................................................................8

COASTING ..........................................................................................................................................................8

LABELS AND PICTOGRAMS .............................................................................................................................8

SUN TOP AND WINDSHIELD .............................................................................................................................8

TOWING A TRAILER ..........................................................................................................................................8

VEHICLE CLEANING AND CARE ............................................................................................ 9

VEHICLE CLEANING ..........................................................................................................................................9

REPAIR ...................................................................................................................................... 9

LIFTING THE VEHICLE ......................................................................................................................................9

Fig. 9 Lifting the Vehicle ......................................................................................................... 10

WHEELS AND TIRES ......................................................................................................................................10

Tire Repair ............................................................................................................................................10

Wheel Installation .................................................................................................................................11

Fig. 10 Wheel Installation ....................................................................................................... 11

LIGHT BULB REPLACEMENT ..........................................................................................................................11

Fig. 11 Headlight and Turn Signal Bulb Replacement ............................................................11

Fig. 12 Tail and Brake Light Bulb Replacement ..................................................................... 11

FUSE REPLACEMENT .....................................................................................................................................11

TRANSPORTING VEHICLE .................................................................................................... 12

TOWING ............................................................................................................................................................12

Owner’s Manual and Service Guide Page iii

Page iv

TABLE OF CONTENTS

HAULING .......................................................................................................................................................... 12

SERVICE AND MAINTENANCE .............................................................................................. 12

SERIAL NUMBER PLATE AND LOCATION .................................................................................................... 13

Fig. 13 Serial Number Plate and Location ............................................................................. 13

PERIODIC SERVICE SCHEDULE .................................................................................................................. 14

Fig. 14 Periodic Service Schedule ......................................................................................... 14

TIRE INSPECTION ........................................................................................................................................... 15

BRAKES ........................................................................................................................................................... 15

Periodic Brake Test for Mechanical Brakes ......................................................................................... 15

Fig. 15 Typical Brake Performance Test ................................................................................ 16

REAR AXLE ...................................................................................................................................................... 16

Checking the Lubricant Level ............................................................................................................... 16

LUBRICATION .................................................................................................................................................. 16

Fig. 16 Add, Check and Drain Axle Lubricant ........................................................................ 17

Fig. 17 Lubrication Points ....................................................................................................... 17

PDS SYSTEM TEST ......................................................................................................................................... 17

HARDWARE ..................................................................................................................................................... 17

CAPACITIES AND REPLACEMENT PARTS ................................................................................................... 17

Fig. 18 Capacities and Replacement Parts ............................................................................ 17

BATTERIES AND CHARGING ................................................................................................ 17

SAFETY ............................................................................................................................................................ 17

Fig. 19 Torque Specifications and Bolt Grades ....................................................................... 18

BATTERY ......................................................................................................................................................... 18

BATTERY MAINTENANCE .............................................................................................................................. 19

At Each Charging Cycle ....................................................................................................................... 19

Monthly ................................................................................................................................................. 19

Electrolyte Level and Water ................................................................................................................. 19

Fig. 20 Correct Electrolyte Level ............................................................................................ 19

Fig. 21 Water Purity Table ..................................................................................................... 20

Fig. 22 Automatic Watering Gun ............................................................................................ 20

Battery Cleaning ................................................................................................................................... 20

Battery Replacement ............................................................................................................................ 21

Fig. 23 Preparing Acid Neutralizing Solution .......................................................................... 21

Fig. 24 36V Battery Connections ........................................................................................... 21

Prolonged Storage ............................................................................................................................... 21

BATTERY CHARGING ..................................................................................................................................... 22

Fig. 25 Freezing Point of Electrolyte ...................................................................................... 22

AC Voltage ........................................................................................................................................... 23

TROUBLESHOOTING ...................................................................................................................................... 23

Hydrometer .......................................................................................................................................... 23

Fig. 26 Hydrometer ................................................................................................................ 24

Using A Hydrometer ............................................................................................................................. 24

Fig. 27 Hydrometer Temperature Correction ......................................................................... 24

GENERAL SPECIFICATIONS ................................................................................................. 27

ST 400 E ........................................................................................................................................................... 28

Fig. 28 Vehicle Dimensions .................................................................................................... 29

Fig. 29 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter ........... 30

LIMITED WARRANTIES .......................................................................................................... 31

(U.S. AND CANADA) ........................................................................................................................................ 32

LABELS AND PICTOGRAMS ............................................................................Appendix A - 1

DECLARATION OF CONFORMITY (EUROPE ONLY) ......................................Appendix B - 1

Owner’s Manual and Service Guide

SAFETY INFORMATION

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 20mph. When an E-Z-GO-manufactured vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER FED-

ERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer

MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for

LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in the places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final

Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.

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

The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPER-

ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE

REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-Z-

GO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this

SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has reason to believe may be operated in personal transportation applications.

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

49 of the Code of Federal Regulations (Transportation).

GENERAL

Many vehicles are 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 warnings can take the place of good common sense and prudent driving practices.

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

If you have any questions regarding this vehicle, contact your closest representative or write to the address on the back cover of this publication, Attention: Product Service Department.

The manufacturer reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.

The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

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

Owner’s Manual and Service Guide Page v

SAFETY INFORMATION

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 the battery (-) post.

Never use the chassis or body as a ground connection.

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

Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

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

GENERAL OPERATION

Always:

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

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

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

• Reduce speed to compensate for poor terrain or conditions.

• Apply service brake to control speed on steep grades.

• Maintain adequate distance between vehicles.

• Reduce speed in wet areas.

• Use extreme caution when approaching sharp or blind turns.

• Use extreme caution when driving over loose terrain.

• Use extreme caution in areas where pedestrians are present.

MAINTENANCE

Always:

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

• Ensure that repairs are performed by those that are trained and qualified to do so.

• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

Page vi

SAFETY INFORMATION

• Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material.

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

• Use specified replacement parts. Never use replacement parts of lesser quality.

• Use recommended tools.

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

• 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. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic.

• Replace damaged or missing warning, caution or information labels.

• Keep complete records of the maintenance history of the vehicle.

The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury, refer the repair or maintenance to a qualified mechanic.

VENTILATION

Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air exchanges per hour is considered the minimum requirement.

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

Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the receptacle when the charger is in operation.

Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable electrical code (whichever is higher).

Page vii

SAFETY INFORMATION

GENERAL

The following text is provided as recommended by part II of ANSI/ITSDF B56.8 - 2006. The manufacturer strongly endorses the contents of this specification.

6 GENERAL SAFETY PRACTICES

6.1 Introduction

6.1.1

Like other machines, carriers can cause injury if improperly used or maintained. Part II contains broad safety practices applicable to carrier operation. Before operation, the user shall establish such additional specific safety practices as may reasonably be required for safe operation.

6.1.2

Premise review — The user shall periodically review their premises, and as conditions warrant, identify areas where carriers should not be operated and to identify possible hazards such as the following examples: a) Steep Grade — In areas where steep grades exist, carrier operation should be restricted to the designated vehicle’s pathways where possible, and shall be identified with a suitable warning giving the following information:

“Warning, steep grade.” b) Wet Areas — Wet areas could cause a carrier to lose traction and could affect steering, stability and braking. c) Sharp Turns, Blind Spots, Bridge Approaches — Sharp turns, blind spots, bridge approaches, and other potentially hazardous areas shall be identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard.

d) Loose Terrain — Loose terrain could cause a carrier to lose traction and could affect steering, stability, and braking.

6.2 Operation

Experience has shown that carriers, which comply with the provisions, stated in paragraph 9

.

3.9 are stable when properly operated and when operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard. Some of the conditions which may affect stability are failure of the user to follow safety practices; also, ground and floor conditions, grade, speed, loading, the operation of the carrier with improper loads, battery weight, dynamic and static forces, and the judgment exercised by the carrier operator. a) The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard. b) The user shall survey specific operating conditions and environment, and establish and train carrier operators to comply with additional, specific safety practices.

6.3 Nameplates, Markings, Capacity, and Modifications

6.3.1

The user shall maintain in a legible condition all nameplates, warnings, and instructions, which are supplied by the manufacturer.

6.3.2

Except as provided in 6.3.4, no modifications or alterations to a carrier, which may affect the capacity, stability, or safe operation of the carrier, shall be made without the prior written approval of the original carrier manufacturer or a successor thereof. When the carrier manufacturer or its successor approves a modification or alteration, appropriate changes shall be made to capacity plates, decals, tags, and operation and maintenance manuals

6.3.3

As required under paragraphs 6.3.1 or 6.3.2, the manufacturer shall be contacted to secure new nameplates, warnings, or instructions, which shall then be affixed in their proper place on the carrier.

6.3.4

In the event that the carrier manufacturer is no longer in business and there is no successor in interest to the business, the user may arrange for a modification or alteration to a carrier, provided however, the controlling party shall:

Owner’s Manual and Service Guide Page ix

SAFETY INFORMATION

(1) Arrange for the modification or alteration to be designed, tested, and implemented by an engineer(s) expert in carrier(s) and their safety;

(2) Maintain a permanent record of the design, test(s), and implementation of the modification or alteration;

(3) Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals;

(4) Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been modified or altered together with the date of the modification or alteration, and the name of the organization that accomplished the tasks.

6.4 Fuel Handling and Storage

6.4.1

The user shall supervise the storage and handling of liquid fuels (when used) to be certain that it is in accordance with ANSI/NFPA 505 and ANSI/NFPA 30 or as required by local ordinance.

6.4.2

Storage and handing of liquefied petroleum gas fuels shall be in accordance with ANSI/NFPA 505 and ANSI/

NFPA 58 or as required by local ordinance. If such storage or handling is not in compliance with these standards, the user shall prevent the carrier from being used until such storage and handling is in compliance with these standards.

6.4.3

Prevent fire and explosion caused by static electric discharge. Use only non-metal, portable fuel containers approved by the Underwriter’s Laboratory (U.L.) or the American Society for Testing & Materials (ASTM). If using a funnel, make sure it is plastic and has no screen or filter.

Static electric discharge can ignite gasoline vapors in an ungrounded fuel container. Remove the fuel container from the bed of a carrier or the trunk of a car ban place on the ground away from the carrier before filling. Keep nozzle in contact with container opening while filling. When practical, remove equipment from trailers or truck beds and re -fuel them on the ground. If this is not possible, use a portable, plastic fuel container to refuel equipment on a truck bed or trailer.

6.5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers

6.5.1

The user shall require battery changing and charging facilities and procedures to be in accordance with ANSI/

NFPA 505 or as required by local ordinance.

6.5.2

The user shall periodically inspect facilities and review procedures to be certain that ANSI/NFPA 505 or as required by local ordinance, are strictly complied with, and shall familiarize carrier operators with it.

6.5.3

Maintenance and storage areas for carriers shall be properly ventilated to avoid fire hazards in accordance with applicable fire codes and ordinances.

Ventilation for internal combustion engine powered carriers shall be provided to remove flammable vapors (gases), fumes and other flammable materials. Consult applicable fire codes for specific levels of ventilation.

Ventilation for electric powered carriers shall be provided to remove the accumulation of flammable hydrogen gas emitted during the battery charging process. The amount of hydrogen gas emitted depends upon a number of factors such as the condition of the batteries, the output rate of the battery charger and the amount of time the batteries are on charge. Because of the highly volatile nature of hydrogen gas and its propensity to accumulate in pockets, a minimum number of air changes per hour is required during charging.

Consult applicable fire and safety codes for the specific ventilation levels required as well as the use of explosion proof electrical apparatus. SAE J1718 can be followed to check for hydrogen gas levels.

6.6 Hazardous Locations

6.6.1

The user shall determine the hazard classification of the particular atmosphere or location in which the carrier is to be use in the accordance with ANSI/NFPA 505.

6.6.2

The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI/NFPA

505.

Page x

SAFETY INFORMATION

6.7 Lighting for Operating Area

The user, in accordance with his responsibility to survey the environment and operating conditions, shall determine if the carrier requires lights and, if so, shall equip the carrier with appropriate lights.

6.8 Control of Noxious Gases and Fumes

When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be maintained within limits specified in the American Conference of Governmental Industrial Hygienists publication,:Threshold

Limit Values for Chemical Substances and Physical Agents in the Workroom Environment.” This may be accomplished by ventilation maintenance of emission control equipment recommended or provided by the manufacturer of the equipment.

6.9 Warning Device(s)

6.9.1

The user shall make periodic inspections of the carrier to be certain that the sound-producing and/or visual device(s) if so equipped are maintained in good operating condition.

6.9.2

The user shall determine if operating conditions require the carrier to be equipped with additional sound-producing or visual devices or both and be responsible for providing and maintaining such devices, in accordance with the manufacturer’s recommendations.

6.10 Safety Interlocks

The user shall make periodic inspections of the carrier to be certain that the safety interlock system, if so equipped, is operating properly.

7 OPERATING SAFETY RULES AND PRACTICES

7.1 Personnel and Burden Carrier Operator Qualifications

Only persons whoa are trained in the proper operation of the carrier shall be authorized to operate the carrier. Operators shall be qualified as to visual, auditory, physical, and mental ability to safely operate the equipment according to

Section 7, all other applicable parts of this Standard and the operators’ manual.

7.2 Personnel and Burden Carrier Operators’ Training

7.2.1

The user shall conduct an operators’ training program.

7.2.2

Successful completion of the operators’ training program by the operator shall be required before operation of the carrier. The program shall be presented in its entirely to all-new operators and not condensed for those claiming previous experience.

7.2.3

The user shall include as a minimum in the operators’ training program the following.

a) Instructional material provided by the manufacturer including the operators; manual; b) Emphasis on safety of passengers, material loads, carrier operator, and other person(s); c) General safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard, and why they were formulated; d) Introduction of equipment, control locations of the environment which could affect carrier operation; e) Operator competency evaluations.

7.3 Personnel and Burden Carrier Operator Responsibility

7.3.1 General Operator Responsibility

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SAFETY INFORMATION

7.3.1.1

Read and follow operators’ manual

7.3.1.2

Do not operate carrier under the influence of drugs and alcohol.

7.3.1.3

Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger other persons

.

7.3.1.4

Riding on the carrier by persons other than the operator is authorized only on personnel seat(s) provided by the manufacturer. All parts of each person’s body shall remain within the plan view outline of the carrier.

7.3.1.5

When a carrier is to be left unattended, stop the carrier, apply the parking brake, stop the engine or turn off power, turn off the control or ignition circuit, and remove the key if provided. Additionally, for the electric carriers, the forward and reverse directional controls, should be neutralized if a means is provided. Block the wheels if the carrier is on a n incline.

7.3.1.6

A carrier is considered unattended when the operator is 7.6m (25 ft.) or more from the carrier which remains in his view, or whenever the operator leaves the carrier and it is not within his view. When the operator is dismounted and within

7.6m (25 ft.) of the carrier still in his view, he still must have controls neutralized, and the parking brake(s) set to prevent movement.

7.3.1.7

Maintain a safe distance from potential hazards, such as edges of ramps and platforms.

7.3.1.8

Use only approved carriers in hazardous locations, as defined in the appropriate safety standards.

7.3.1.9

Report all accidents to the user.

7.3.1.10

Do not add to, or modify, the carrier.

7.3.1.11

Carriers shall not be parked or left unattended such that they block or obstruct fire aisles, access to stairways, or fire equipment.

7.3.1.12

Only operate carrier while within operator’s station.

7.3.2 Traveling

7.3.2.1

Observe all traffic regulations, including authorized speed limits. Under normal traffic conditions keep to the right. Maintain a safe distance, based on speed of travel, from a carrier or vehicle ahead, and keep the carrier under control at all times.

7.3.2.2

Yield the right of way to pedestrians, ambulances, fire trucks, or other carriers or vehicles in emergency situations.

7.3.2.3

Do not pass another carrier or vehicle traveling in the same direction at intersections, blind spots, or at other dangerous locations.

7.3.2.4

Keep a clear view of the path of travel, observe other traffic and personnel, and maintain a safe clearance.

7.3.2.5

Slow down or stop, as conditions dictate, and activate the sound-producing warning device at cross aisles and when visibility is obstructed at other locations.

7.3.2.6

Ascend or descend grades slowly.

7.3.2.7

Avoid turning, if possible, and use caution on grades, ramps, or inclines, normally travel straight up and down.

7.3.2.8

Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop in a safe manner.

7.3.2.9

Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift the load, endanger passengers, or lose control of the carrier.

7.3.2.10

Do not operate carrier in a dangerous manner.

7.3.2.11

Slow down when approaching, or on, wet or slippery surfaces.

7.3.2.12

Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power, and set parking brakes. It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit.

7.3.2.13

Avoid running over loose objects, potholes, and bumps.

7.3.2.14

Reduce carrier speed to negotiate turns.

7.3.2.15

Avoid any action verbal or physical by an operator or passenger, which could cause the operator to be distracted.

7.3.3 Loading

7.3.3.1

Refer to operators’ manual for loading instruction.

Page xii

SAFETY INFORMATION

7.3.3.2

Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered, operate with extra caution.

7.3.3.3

Handle only loads within the capacity of each cargo area of the carrier as specified by the manufacturer.

7.3.3.4

Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manufacturer.

7.3.4 Operator Care of Personnel and Burden Carriers

7.3.4.1

Read and follow operators’ manual.

7.3.4.2

At the beginning of each shift during which the carrier will be used, the operator shall check the carrier condition and inspect the tires, warning devices, lights, battery(s), speed and directional controllers, brakes, safety interlocks, and steering mechanism. If the carrier is found to be in need of repair, or in any way unsafe, the matter shall be reported immediately to the user and the carrier shall not be operated until it has been restored to safe operating condition.

7.3.4.3

If during operation the carrier becomes unsafe in any way, the matter shall be reported immediately to the user, and the carrier shall not be operated until it has been restored to safe operating condition.

7.3.4.4

Do not make repairs or adjustments unless specifically trained and authorized to do so.

7.3.4.5

Before refueling, the engine shall be stopped and allowed to cool. The operator and passengers shall leave the carrier before refueling.

7.3.4.6

Spillage of hazardous materials shall be contained immediately and addressed via appropriate hazardous materials regulations.

7.3.4.7

Do not operate a carrier with a leak in the fuel system or battery(s). Battery(s) shall be charged and serviced per manufacturer’s instructions.

7.3.4.8

Do not use open flames for checking electrolyte level in storage battery(s) or liquid level in fuel tanks.

8 MAINTENANCE PRACTICES

8.1 Introduction

Carriers may become hazardous if maintenance is neglected. Maintenance facilities, trained personnel, and procedures shall be provided. Such facilities may be on or off the premises.

8.2 Maintenance Procedures

Maintenance and inspection of all carriers shall be performed in conformance with the following practices and should follow the manufacturer’s recommendations.

a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed.

b) Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect carriers.

c) Before undertaking maintenance or repair follow the manufacturer’s recommendations for immobilizing the carrier.

d) Chock wheels and support carrier, before working underneath it.

e) Before disconnecting any part of the engine fuel system, be sure the shutoff valve, if so equipped, is closed and follow carrier manufacturer’s recommended practice.

f) Operation to check performance of the carrier shall be conducted in an authorized area where suitable conditions exist, free of vehicular and pedestrian traffic.

g) Before returning carrier to service, follow the manufacturer’s instructions and recommended procedure.

h) Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte, or coolant.

i) Properly ventilate the work area in accordance with applicable regulations or local ordinance.

j) Handle fuel cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken the tank and make it unsafe for use.

Page xiii

SAFETY INFORMATION k) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s recommendations.

l) Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved safe operating features. m) Fuel systems shall be checked for leaks and condition of parts. If a leak is found, action shall be taken to prevent the use to the carrier until the cause of the leak has been repaired. n) The carrier manufacturer’s capacity, operation, and maintenance instruction plated, tags, or decals shall be maintained in legible condition. o) Batteries, motors, speed and directional controllers, limit switches, protective devices, electrical conductors/ insulators, and connections shall be inspected and maintained per carrier manufacturer’s recommendation. p) Carriers shall be kept in a clean condition to minimize hazards and facilitate detection of components needing service.

q) Modifications and additions which affect capacity and safe carrier operation shall not be performed without manufacturer’s prior written authorization; where authorized modifications have been made, the user shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or safety labels are changed accordingly. r) Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. s) Disconnect batteries, negative connection(s) first. When reconnecting, connect positive connection first. t) Hydraulic systems, if so equipped, shall be checked for leaks, for condition of parts. Keep body and hands away from pin-holes or nozzles that eject fluids under high pressure. Use paper or cardboard, not hands, to check for leaks.

ANSI/ITSDF B56.8 - 2006

Page xiv

OPERATION AND SERVICE INFORMATION

Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

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

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

This vehicle has been designed and manufactured as a

‘World Vehicle’. Some countries have individual requirements to comply with their specifications; therefore, some sections may not apply in your country.

Most of the service procedures in this guide can be accomplished using common automotive hand tools.

Contact your service representative on servicing the vehicle in accordance with the Periodic Service Schedule.

Service Parts Manuals and Technician’s Repair and Service Manuals are available from a local Distributor, an authorized Branch or the Service Parts Department.

When ordering parts or requesting information for your vehicle, provide vehicle model, serial number and manufacture date code.

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.

Before a new vehicle is put into operation, the items shown in the INITIAL SERVICE CHART must be performed (Ref Fig. 1 on page 1).

Vehicle batteries must be fully charged before initial use.

Check for correct tire inflation. See GENERAL SPECIFI-

CATIONS.

Determine and record braking distance required to stop vehicle for future brake performance tests.

Remove the protective clear plastic, that protect the seat bottom and back rest during shipping, before placing the vehicle in service.

ITEM SERVICE OPERATION

BEFORE INITIAL USE

Read, understand and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle, its equipment and how to use it safely.

Maintaining good performance depends to a large extent on the operator.

Seats

Brakes

Remove protective plastic covering

Check operation and adjust if necessary

Establish acceptable stopping distance (mechanical brakes only)

Tires

Check hydraulic brake fluid level if equipped

Check air pressure (see SPECIFICATIONS)

Portable Remove from vehicle and properly mount

Ref Isc 5

Fig. 1 Initial Service Chart

PORTABLE CHARGER INSTALLATION

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

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

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

Because hydrogen gas is lighter than air, it will collect in

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

Owner’s Manual and Service Guide Page 1



Provide Protection From Elements

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.

Do Not Block Louvered Airways

NEMA 15 - 5R Grounded AC Receptacle

110 - 120 VAC. Dedicated 15 AMP Circuit

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

Ref Pci 1

Fig. 2 Proper Charger Installation

Portable chargers are shipped with the vehicle. Prior to vehicle or charger operation, chargers must be removed and mounted on a platform or wall above the ground to permit maximum air flow around and underneath the charger. If the charger is operated in an outdoor location, rain and sun protection must be provided (Ref Fig. 2 on page 2). A dedicated circuit is required for the charger.

Refer to the charger manual for appropriate circuit protection. The charger may remain plugged in to the AC outlet. To charge the vehicle, refer to the instruction labels on the charger. Insert the polarized DC plug completely into the vehicle receptacle (Ref Fig. 3 on page 2).

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

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

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

If vehicle is to be charged with a non E-Z-GO charger, refer to the instructions supplied with the charger.

Front of

Vehicle

Charger

Receptacle

Ref Crl 1

Fig. 3 Charger Receptacle Location

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

Page 2

CONTROLS AND INDICATORS

Vehicle controls and indicators consist of:

• key/light switch

• direction selector

• state of charge meter

• hour meter

• accelerator pedal

• combination service and park brake pedal

• horn

KEY/LIGHT SWITCH

Located on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key. To prevent inadvertent operation of the vehicle when left unattended, the key should be turned to the ‘OFF’ position and removed (Ref Fig. 4 on page 3).




Direction Selector (PDS only)

State of Charge Meter

FWD

REV

Reverse

Neutral

OFF

ON

Ref Kes 1 Key/Light Switch

Fig. 4 Key/Light Switch & State of Charge Meter

If the vehicle is equipped with lights, the key switch has a position to operate them, indicated by the light icon.

ef Dsl 1

FWD

REV

Forward

Reverse

Neutral, as sho wn

Fig. 5 Direction Selector Types

STATE OF CHARGE METER

Located in the dash, the state of charge meter indicates the amount of usable power in the batteries (Ref Fig. 4 on page 3).

HOUR METER

The hour meter indicates total hours of operation.

ACCELERATOR PEDAL

If the vehicle is equipped with manufacturer installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’ position.

DIRECTION SELECTOR

To prevent loss of control, do not move Precision Drive System (PDS) vehicle direction selector while the vehicle is in motion. Moving the selector will result in a sudden slowing of the vehicle and the beeping of a warning device.

Unintentional movement of the accelerator pedal will release the park brake and may cause the vehicle to move which could result in severe injury or death.

With the key switch ‘ON’, depressing the accelerator pedal starts the motor. When the pedal is released, the motor will stop (Ref Fig. 6 on page 3). To stop the vehicle more quickly, depress the service brake.

Park

Brake

Service

Brake

PARK

To reduce the possibility of component damage, the vehicle must be completely stopped before moving the direction selector.

On PDS models, if the direction selector is shifted before the vehicle comes to a complete stop, a warning beeper will activate.

Located on the seat support panel, this switch permits the selection of either ‘F’ (forward), ‘R’ (reverse) or neutral (the position between forward and reverse). Vehicle should be left in neutral with park brake applied/locked when unattended (Ref Fig. 5 on page 3).

Accelerator

Ref Abc 1

Fig. 6 Accelerator and Brake Controls

If key switch is ‘ON’ and park brake is set, depressing the accelerator inadvertently will release the park brake and will cause the vehicle to move which could cause severe injury or death.




Depressing the accelerator pedal will release the park brake if it is engaged. This is a feature to assure the vehicle is not driven with the park brake engaged. Depressing the accelerator pedal is not

the preferred method of releasing the park brake.

WARNING

RUN l

ANCE' posit ion before towing.

MAINTENANCE

Before removing/connect ing batteries or electrical

To disable electrical system position and remove battery wire.

components

place switch in 'TOW/MAI ing 'RUN' position

ANCE' position.

After reconnecting batteries, allow a mini before select

73340G01

Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure the longest service life of brake components.

COMBINATION SERVICE BRAKE AND PARK

BRAKE PEDAL

The brake pedal incorporates a park brake feature (Ref

Fig. 6 on page 3). To engage, push down on the upper section of the pedal until it locks in place. The park brake will release when the service brake pedal is depressed.

Use the lower section of the brake pedal to operate the service brake system.

RUN - TOW/MAINTENANCE SWITCH

(PDS VEHICLES ONLY)

Fig. 7 Run-Tow/Maintenance Switch

With the switch in ‘TOW/MAINTENANCE’ position:

• the controller is deactivated

• the electronic braking system is deactivated which allows the vehicle to be towed or roll freely

• the warning beeper is deactivated

With the switch in ‘RUN’ position:

• the controller is activated

• the electronic braking system and warning beeper features are activated

To reduce the possibility of severe injury or death resulting from loss of vehicle control, consider the grade of the terrain the vehicle is on and set vehicle’s park brake accordingly before switching the Run - Tow/Maintenance switch to the ‘Tow/Maintenance’ position. When in the ‘Tow/Maintenance’ position, the Anti-Roll

Back and Walk-Away safety features of the

PDS system no longer function.

PDS vehicles operate only in the ‘RUN’ position.

The PDS is a low power consumption unit but it will drain the vehicle batteries over a period of time. If the vehicle is to be stored for a prolonged period of time, the PDS should be disconnected from the batteries. (Refer to Prolonged Storage on page 21)

Before attempting to tow vehicle, move the Run-Tow/

Maintenance switch to the ‘Tow/Maintenance’ position.

Failure to do so will damage the controller or motor.

PLASTIC LOADBED

The manual lift bed is the standard bed for the vehicle.

The bed may be equipped with an optional electric lift switch.

Before disconnecting or connecting a battery, or any other wiring, move the Run-Tow/Maintenance switch to the

‘Tow/Maintenance’ position.

After connecting a battery, or any other wiring, wait a minimum of 30 seconds before moving the Run-Tow/

Maintenance switch to the ‘Run’ position.

The PDS vehicle is equipped with a two position switch located under the passenger side of the seat on the controller environmental cover (Ref Fig. 7 on page 4).

Page 4

Failure to follow these instructions may result in personal injury, damage the vehicle and/or cause the vehicle to tip over. Operate the vehicle with awareness of the load. Read, understand and follow the Danger label affixed to the front of the loadbed.

Do not permit anyone to ride in the bed.




Before operating, check to ensure no one is behind the vehicle.

A loadbed warning label is affixed to the inside front of the bed (see Appendix A). This label must be understood and observed at all times for safe operation of the vehicle. See the loadbed warning label for maximum load.

The load must be positioned in the bed as far forward as possible, distributed in such a way that its center of gravity must not be higher than height noted on label, and securely fastened down. Failure to follow these instructions may result in severe personal injury, damage the vehicle and/or cause the vehicle to tip over. Operate the vehicle with awareness of the load.

Do not permit anyone to ride in the bed.

Do not drive the vehicle with the loadbed raised or with the tailgate unsupported.

When using the electric lift, be sure to avoid backing up to the edge of a drop off, such as a loading dock or ravine. A misjudgment of distance or an unstable surface could result in the vehicle falling backwards.

Before operating, check to ensure no one is behind the vehicle.

..

Front of Vehicle

Ref Mbl 3

Manual Load Bed Latch

Pull Up to Release

Fig. 8 Manual Bed Latch

To lower the manual lift bed, grasp the bed handle and lower the bed to the rest position.

Be sure hands are not trapped by the bed.

TAILGATE OPERATION

To open the tailgate, lift tailgate straight up with a sharp upward pull to lift out of the closed position and pivot out for open position. To remove the tailgate, remove the side cables from the loadbed and open tailgate until it is straight down, move tailgate panel straight up to remove from pins and remove from the loadbed. Reassemble in reverse order.

Never fill a gas can in the bed of a vehicle.

Static discharge could ignite gasoline vapor and cause an explosion.

Always place a gas can on the ground before filling.

Never fill a gas can in the bed of the vehicle. Static electricity is built up during the fueling process and could discharge causing the gasoline vapor to ignite.

MANUAL LIFT BED OPERATION

OPERATING THE VEHICLE

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

Read and understand the following warnings before attempting to operate the vehicle.

Exercise caution while operating the manual lift bed to ensure the bed is not released during lifting or lowering procedure. Severe injury could result if bed is released and traps fingers or other body parts.

To lift the manual lift bed, pull back on the latch release handle immediately behind the driver seat (Ref Fig. 8 on page 5). Raise the bed using the handle on the side of the bed.

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



Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.

S t a y i n d e s i g n a t e d a r e a s a n d a v o i d extremely rough terrain.

Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline. A sudden stop or change of direction may result in loss of control.

To prevent loss of control, do not move the direction selector of a PDS vehicle while the vehicle is in motion. Moving the selector will result in a sudden slowing of the vehicle and the beeping of a warning device.

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

Never drive vehicle up, down, or across an incline that exceeds 14° (25% grade).

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

Refer to GENERAL SPECIFICATIONS for seating capacity.

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

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

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

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

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

Check the area behind the vehicle before operating in reverse.

All occupants must be seated. Keep entire body inside vehicle and hold on while vehicle is in motion

PRECISION DRIVE SYSTEM

™

Regenerative Braking

To prevent the possibility of loss of control that could cause severe injury or death, use service brake to control speed. The PDS system is not a substitute for the service brake.

PDS models are equipped with a regenerative motor control system.

Example: If all of the following events occur...

a) the vehicle is being driven down a slope b) the vehicle attempts to exceed the specified top speed with the accelerator pedal depressed or released the regenerative braking will limit the speed of the vehicle to the specified top speed (the warning beeper will not sound). When the regenerative braking system is activated by this sequence of events, the motor generates power which is returned to the batteries.

If the operator attempts to override the regenerative braking feature by moving the direction selector or key switch to another position, the warning beeper will sound and the vehicle will brake rapidly until it reaches the speed of approximately 2 mph (3 kph).

Pedal-Up Braking

Pedal-up braking is regenerative braking that occurs when the accelerator pedal is released while the vehicle is moving between 8 mph (13 kph) and the vehicle’s top speed.


a) the vehicle is being driven down a slope b) the accelerator pedal is released for more than one second the pedal-up braking will slow the vehicle (the warning beeper will not

sound) until either the vehicle speed is reduced to 8 mph (13 kph), at which it freely coasts between 8 and 3 mph (5 kph), or the accelerator pedal is applied. When pedal-up braking system is activated by this sequence of events, the motor generates power which is returned to the batteries.

Page 6 Owner’s Manual and Service Guide



Walk-Away Feature

Walk-Away limits vehicle movement without driver input, slowing the vehicle to 2 mph (3 kph) and sounding an audible alarm (reverse beeper).


a) the vehicle has been stopped for more than 1.5

seconds b) the accelerator pedal has been released for more than one second c) the vehicle begins to roll above 2 mph (3 kph) the electronic braking will limit speed to approximately 2 mph (3 kph) and the warning beeper will sound. When the accelerator pedal is depressed, the electronic braking and warning beeper will be overridden and normal vehicle operation resumes. Any unusual situation sensed by the PDS system will cause a similar response. The system functions in all key switch positions.

Anti-Roll Back Feature

Anti-Roll Back, like Walk-Away, limits backward motion of the vehicle down an incline to less than 2 mph (3 kph).

See ‘Walk-Away Feature’ above.

Anti-Stall Feature

Anti-Stall protection prevents motor damage from stalling the vehicle against an object or on a hill.


a) the system senses that the accelerator pedal is depressed (power applied to motor) b) the motor is stalled long enough that any more time may cause motor damage the PDS system will momentarily interrupt power to the motor. This brief interruption will permit the vehicle to roll backwards slightly before again stopping in the stalled condition. This process will repeat itself periodically until the vehicle is moved from the stalled condition.


a) the system senses that the accelerator pedal is depressed (power applied to motor) b) the brake is engaged so as to prevent vehicle motion the PDS system will sense a stalled motor condition and remove power from the motor. When the brake pedal is released, the vehicle will roll backwards slightly before power is returned to the motor.

High Pedal Disable Feature

High pedal disable prevents undesired acceleration if the direction selector lever is changed, or the key is turned on while the accelerator is depressed.

Default Mode Feature

In the unlikely event of certain electrical system failures, the PDS controller will default to a mode that will permit the vehicle to operate, but at a very reduced speed.

This feature allows the vehicle to be driven back to its storage facility where the problem can be diagnosed.

The controller can be put in diagnostic mode by the technician and the controller will report the failure mode.

STARTING AND DRIVING

To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release the service brake until motor has started.

Remove charger plug from vehicle receptacle and properly store cable prior to moving vehicle.

To operate vehicle:

• Apply the service brake, place the key in the key switch and turn it to the ‘ON’ position.

• Move the direction selector to the direction desired.

• Release the park brake by depressing the service brake pedal until the park brake releases.

• Slowly depress the accelerator pedal to start the motor. Release service brake when motor starts.

• When the accelerator pedal is released, the motor stops. To stop the vehicle more quickly, depress the service brake pedal

.

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




STARTING VEHICLE ON A HILL

To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release the service brake until motor has started.

speeds should be limited to no more than the maximum speed on level ground (see vehicle specification). Limit speed by releasing the accelerator and applying service brake. Severe damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of control, is costly, is considered abuse and will not be covered under warranty.

LABELS AND PICTOGRAMS

Vehicles may be labeled with pictograms as a method of conveying information or warnings. Appendix A illustrates and explains pictograms that may appear on the vehicle. Not all pictograms shown in Appendix A will be found on your vehicle.

Do not hold vehicle on hill by using accelerator and motor. Leaving motor in a stalled condition for more than

3 - 4 seconds will cause permanent damage to motor.

To reduce the possibility of permanent damage to the drive system, it is important to prevent excessive rollback when starting the vehicle on a hill.

If a non PDS vehicle is held on a hill using the accelerator pedal for more than 3 - 4 seconds (depending on the grade of hill), the commutator bars within the motor will become distorted and the motor will become unacceptably noisy.

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.

COASTING

SUN TOP AND WINDSHIELD

The sun top does not provide protection from roll over or falling objects.

The windshield does not provide protection from tree limbs or flying objects.

The sun top and windshield provide some protection from the elements; however, they will not keep the operator and passenger dry in a downpour. This vehicle is not equipped with seat belts and the sun top has not been designed to provide roll over protection. In addition, the sun top does not protect against falling objects nor does the windshield protect against flying objects and tree limbs. Keep arms and legs inside of vehicle while it is moving.

To reduce the possibility of severe injury or death from coasting at above recommended speeds, limit speed with service brake.

Uncontrolled coasting does not occur with PDS model vehicles because the PDS controls the top speed of the vehicle while moving down hill. However, the PDS is not a substitute for the service brake which should be used to control the speed of the vehicle.

Some PDS models are equipped with a feature (pedal-up braking) which slows the vehicle’s speed when the accelerator pedal is released.

On steep hills, it is possible for non-PDS vehicles to coast at faster than normal speeds that may be encountered on a flat surface. To prevent loss of vehicle control,

TOWING A TRAILER

The vehicle may be equipped with a receiver that can be fitted with a standard 1 7/8" ball. The trailer and its load must not exceed 500 lbs (227 kg) and no more than 50 lbs (23 kg) tongue weight may be attached to the hitch.

Remember that the overall capacity of the vehicle, operator, passenger, contents of loadbed and accessories must be reduced to compensate for the trailer and load.

The range of motion of the trailer is limited by the ball and hitch. The trailer should not be used on rough trails or over objects such as logs, large rocks, holes, etc.

Never install baskets or extensions using a hitch receiver. Such items will change the performance characteristics of vehicle and result in unsafe handling, possible roll over or vehicle damage.




VEHICLE CLEANING AND CARE

VEHICLE CLEANING

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

REPAIR

LIFTING THE VEHICLE

Tool List Qty. Required

Floor jack..................................................................... 1

Jack stands ................................................................. 4

Chocks ........................................................................ 4

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

When pressure washing exterior of vehicle, do not use pressure in excess of 700 psi (4825 Kpa). To reduce the possibility of cosmetic damage, do not use any abrasive or reactive solvents to clean plastic parts.

It is important that proper techniques and cleaning materials be used. Using excessive water pressure may cause severe injury to operator or bystander, damage to seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi (4825

Kpa) 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.

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

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

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

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

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

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

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

To raise the entire vehicle, install chocks in front and behind each front wheel (Ref Fig. 9 on page 10). Center the jack under the rear frame crossmember. Raise the vehicle enough to place a jack stand under the outer ends of the rear axle.

Lower the jack and test the stability of the vehicle on the two jack stands.

Place the jack at the center of the front axle. Raise the vehicle enough to place jack stands under the frame crossmember as indicated.

Lower the jack and test the stability of the vehicle on all four jack stands.

If only the front or rear of the vehicle is to be raised, place the chocks in front and behind each wheel not being raised to stabilize the vehicle.

Lower the vehicle by reversing the lifting sequence.


.



Center of

Front Axle

Flat Portion of Frame

Ref Liv 2 View from Underside of Vehicle

Fig. 9 Lifting the Vehicle

Outside End of Rear Axle

WHEELS AND TIRES

Tire Repair


Lug wrench, 3/4" ......................................................... 1

Impact socket, 3/4", 1/2" drive..................................... 1

Impact wrench, 1/2" drive............................................ 1

Torque wrench, 1/2" drive............................................ 1 caused by a broken socket when removing wheels, use only sockets designed for impact wrench use.

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

Do not use low inflation pressure tires on any

E-Z-GO vehicle. Do not use any tire which has a recommended inflation pressure less than the inflation pressure recommended in Owner’s

Manual.

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

Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section for recommended tire inflation pressure. For outdoor applications with major use on grassy areas, the following should be considered. On hard turf, it is desirable to have a slightly

higher inflation pressure. On very soft turf, a lower pressure reduces the possibility of tires cutting into the turf. For vehicles being used on paved or hard surfaces, tire inflation pressure should be in the higher allowable range, but under no condition should inflation pressure be higher than recommended on tire sidewall.

All four tires

should have the same pressure for optimum handling characteristics. Be sure to install the valve dust cap after checking or inflating.

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

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

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

To reduce the possibility of severe injury

Page 10

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

If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire.

Immerse the tire in water to locate the leak and mark with chalk. Insert tire plug in accordance with manufacturer’s instructions.

To reduce the possibility of severe injury, be s u r e m o u n t i n g / d e m o u n t i n g m a c h i n e i s



Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings anchored to floor. Wear OSHA approved safety equipment when mounting/demounting tires.

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

Wheel Installation

For vehicles with headlights mounted in cowl, locate the two screws on backside of cowl that secure headlight

(Ref Fig. 11 on page 11). Remove screws, pull headlight out and disconnect wires. Connect wires to new headlight, install in cowl and secure with screws previously removed.

Turn Signal Lens Inside of Cowl

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

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 lug nuts in a ‘cross sequence’ pattern (Ref Fig. 10 on page 11). Tighten lug nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in 20 ft. lbs.

(30 Nm) increments following the ‘cross sequence’ pattern.

Headlight

Bulb

Turn Signal

Housing

Ref Hdr 2

Fig. 11 Headlight and Turn Signal Bulb Replacement

To replace the turn signal light bulb, support turn signal housing from backside of cowl while removing two screws securing lens. Install new bulb and replace lens.

To replace the tail and brake light bulb, roll the rubber bezel from around the edge of the taillight and remove lens. Install replacement bulb and replace lens.

Tire/wheel style

may vary

Roll Rubber

Bezel Away

From Body

Tail/Brake

Light

'Cross Sequence'

1 3

3

'Cross Sequence'

1

4

Rear

Fender

Ref Whi 2

4 2

5

Fig. 10 Wheel Installation

LIGHT BULB REPLACEMENT

2

Ref Tlr 2

Fig. 12 Tail and Brake Light Bulb Replacement

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

FUSE REPLACEMENT

To replace fuses, locate the fuse block under the driver side seat. Pull out old fuse and replace with a new automotive type fuse. Headlight and taillight bulbs and fuses



Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings are available from a local Distributor, an authorized

Branch or the Service Parts Department.

TRANSPORTING VEHICLE

TOWING

This vehicle is not designed to be towed.

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

HAULING

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

Secure the vehicle and contents.

Never ride on vehicle being transported.

Always remove windshield before transporting.

Maximum speed with sun top installed is 50 mph (80 kph).

If the vehicle is to be transported at highway speeds, the sun top must be removed and the seat bottom secured.

When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points. Always remove windshield when transporting.

Always check that the vehicle and contents are adequately secured before transporting. The rated capacity of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load plus 1000 lbs. (454 kg). Lock the park brake and secure the vehicle using ratchet tie downs.

SERVICE AND MAINTENANCE

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

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

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

To reduce the possibility of motor damage, never operate vehicle at full throttle for more than 4 - 5 seconds while vehicle is in a ‘no load’ condition.

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

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

bility of a dropped wrench

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

Wrap wrenches with vinyl tape to reduce the possi-

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

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

Aerosol containers of battery terminal protectant must be used with extreme care.

Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion.

It is in the best interest of both vehicle owner and service technician, to carefully follow the procedures recommended in this manual. Preventative maintenance,



Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings applied at recommended intervals, is the best guarantee for keeping the vehicle both dependable and economical.

Lift Flap on Access Panel

Before any electrical service is performed on PDS model vehicles, the ‘Run-Tow/Maintenance’ switch must be placed in the ‘Tow/Maintenance’ position.

If a power wire (battery, motor or controller) is disconnected for any reason on the PDS model vehicle, the ‘Run-Tow/Maintenance’ switch must be left in the

‘Tow/Maintenance’ position for at least 30 seconds after the circuit is restored.

This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic

Service Schedule for appropriate service intervals (Ref

Fig. 14 on page 14). Refer to Lubrication Points for appropriate lubrication locations (Ref Fig. 17 on page

17).

Part A and B

Serial Number

Labels

Ref Spl 3

Part C/D

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

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

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

SERIAL NUMBER PLATE AND LOCATION

The serial number and manufacture date code label are on the vehicle. One is placed on the body below the front, driver side of the seat. The other is located on the chassis under the seat.

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

Label No.

V

Fig. 13 Serial Number Plate and Location




PERIODIC SERVICE SCHEDULE

3 Check Clean, Adjust, etc. S Replace

To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle.

NOTE

:

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

DAILY

BEFORE USE:

3 Check service brake general operation

3 Check park brake function

3 Check warning device function in reverse

3 Check tire condition

3 Check overall vehicle condition

Recharge batteries to full state of charge after each day’s use

3 Inspect charger connector and receptacle at each charge

TIRES

WHEELS

WEEKLY

3 Examine for cuts, excessive wear and pressure (See GENERAL SPECIFICA-

TIONS)

3 Check for bent rims, missing or loose lug nuts

BATTERIES

PDS SYSTEM

REAR AXLE

MONTHLY - 20 HOURS

(includes items listed in previous table & the following)

Clean batteries & terminals. See BATTERY CLEANING.

3 Check charge condition and all connections

3 Check battery water

WIRING

CHARGER / RECEPTACLE

ACCELERATOR

SERVICE BRAKE

(MECHANICAL BRAKES)

PARK BRAKE

DIRECTION SELECTOR

STEERING ASSEMBLY

TIE ROD/LINKAGES

3

3

3

3

3

3

3

Check all wiring for loose connections and broken/missing insulation

Clean connections, keep receptacles free of dirt and foreign matter

Check for smooth movement

Conduct brake performance test

Check brake performance and adjust if required

Check attachment, tighten if required

Check for abnormal play, tightness of all hardware

Check for excessive play, bent components or loose connections

3 Check for PDS Controller braking force (see PDS MODEL VEHICLES in text) proper operation of system

3 Check for leakage, add SAE 30 oil as required

FRONT AXLE

FRONT SHOCK ABSORBERS

FRONT SPRINGS

FRONT WHEEL ALIGNMENT

PARK BRAKE

QUARTERLY - 50 HOURS

(includes items listed in previous tables & the following)

REAR SHOCK ABSORBERS

3 Check for damage to axle and loose or missing hardware

3 Check for oil leakage and loose fasteners

3 Check for loose hardware, cracks at attachments

3 Check for unusual tire wear, align if required

3 Check for bent/binding linkage rod

3 Check for damage or wear to latch arm or catch bracket

Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE

LATCH

3 Check for oil leakage, loose mounting hardware

Fig. 14 Periodic Service Schedule




HARDWARE AND FASTENERS

3 Check for loose or missing hardware and components

Tighten or replace missing hardware

SEMI-ANNUAL - 125 HOURS


DIRECTION SELECTOR

KING PINS

STEERING ASSEMBLY

RACK END BALL JOINT

REAR AXLE

3 Check for wear and smooth movement (lubricate shaft with light oil if required)

3 Check for excessive play and tightness of retaining nuts

3 Check bellows and pinion seal for damage or grease leakage

Lubricate, use wheel bearing grease

3 Check for unusual noise and loose or missing mounting hardware

ANNUAL - 250-300 HOURS


FRONT WHEEL BEARINGS

REAR AXLE

SERVICE BRAKES

3 Check and adjust as required, see Technician’s Repair and Service Manual

3 Check lubricant, add lubricant (SAE 30 oil) as required

Clean and adjust, see Technician’s Repair and Service Manual

3 Check brake shoe linings, see Technician’s Repair and Service Manual

Fig. 14 Periodic Service Schedule

TIRE INSPECTION

Tire condition should be inspected per the Periodic Service Schedule (Ref. Fig. 14 on page 14). Inflation pressures should be checked when the tires are cool. Be sure to install the valve dust cap after checking or inflating.

BRAKES will be influenced by weather conditions, terrain, road surface condition, actual vehicle weight (accessories installed) and vehicle speed. No specific braking distance can be reliably specified. The test is conducted by latching the parking brake to eliminate different pedal pressures and to include the affects of linkage misadjustment.

Establish the acceptable stopping distance by testing a new or ‘known to be good’ vehicle and recording the stopping location or stopping distance. For fleets of vehicles, several vehicles should be tested when new and the range of stopping locations or distances recorded.

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

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

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

The Periodic Brake Performance Test should be performed regularly (Ref. Fig. 15 on page 16) as an evaluation of braking system performance. It is useful as a method of identifying subtle loss of performance over time.

Periodic Brake Test for Mechanical Brakes

The purpose of this test is to compare the braking performance of the vehicle to the braking performance of new or ‘known to be good’ vehicles or to an established acceptable stopping distance. Actual stopping distances




Dry, Level, Clean, Paved Surface vehicle should stop aggressively. The wheel brakes may or may not lock. Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched. The vehicle should stop within the ‘normal’ range of stopping distances. If the vehicle stops more than 4 ft. (1.2 m) beyond the acceptable stopping distance or pulls to one side, the vehicle has failed the test and should be tested again.

If the vehicle fails the second test, it should immediately be removed from service. The vehicle must

be inspected by a qualified mechanic who should refer to the TROU-

BLESHOOTING section in the Technician’s Repair and

Service Manual.

Accelerate To

Maximum Speed

Latch

Parking Brake and Take Foot

Off Pedal

Line or Marker

REAR AXLE

The rear axle is provided with a lubricant level check/fill plug located on the bottom of the differential. Unless leakage is evident, the lubricant need only be replaced after five years.

Checking the Lubricant Level

Clean the area around the check/fill plug and remove plug. The correct lubricant level is just below the bottom of the threaded hole. If lubricant is low, add lubricant as required. Add lubricant slowly until lubricant starts to seep from the hole. Install the check/fill plug. In the event that the lubricant is to be replaced, vehicle must be elevated and the oil pan removed or the oil siphoned through the check/fill hole (Ref Fig. 16 on page 17).

LUBRICATION

Acceptable

Stopping

Distance

4 ft. (1.2 m)

Line or Marker

Normal Range of

Stopping Distance

Any vehicles that stop more than 4 ft. (1.2 m) beyond the Acceptable

Stopping Distance or pulls to one side should be removed from service and inspected by a qualified mechanic

Fig. 15 Typical Brake Performance Test

Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components.

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

Drive the vehicle at maximum speed on a flat, dry, clean, paved surface (Ref. Fig. 15 on page 16). Quickly depress the brake pedal to latch the parking brake at the line or marker in the test area and remove foot from pedal. The




Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head. Unmarked hardware is

Grade 2 (Ref Fig. 19 on page 18).

CAPACITIES AND REPLACEMENT PARTS

Ref Raf 1 Check/Fill Plug

Fig. 16 Add, Check and Drain Axle Lubricant

Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure (Ref Fig. 17 on page 17).

Rear Axle Oil

Fuse

Headlight Bulb

Marker Bulb

Turn Signal Bulb

Tail Light Bulb

Ref Cap 1

40 oz (1.2 liters)

15 amp (P/N 18392-G1)

#894 (P/N 74004-G01)

#912 (P/N 74005-G01)

#921 (P/N 74006-G01)

#1157 (P/N 21759-G1)

Fig. 18 Capacities and Replacement Parts

BATTERIES AND CHARGING

SAFETY

Rack Ball Joint

Ref Lub 1 View From Underside Of Vehicle

Fig. 17 Lubrication Points

PDS SYSTEM TEST

At monthly intervals, test the PDS system by allowing the vehicle to roll down an incline with the accelerator pedal released. Braking force should be felt at approximately 2 mph (3 kph) indicating that the PDS system is functioning. If vehicle speed continues to rise, apply the service brake and have vehicle inspected by a trained mechanic.

HARDWARE

Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref Fig. 19 on page

18).

Use care when tightening fasteners and refer to the

Technician’s Repair and Service Manual for specific torque values.

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 flame or sparks away from the batteries.

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

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

Never disconnect a circuit under load at a battery terminal.




BOLT SIZE

Grade 2

Grade 5

Grade 8

BOLT SIZE

Class 5.8

(Grade 2) 5.8

Class 8.8

(Grade 5) 8.8

Class 10.9

(Grade 8)

Ref Tsp 1

10.9

M4

1

(2)

2

(3)

3

(4)

1/4"

4

(5)

6

(8)

6

(8)

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.

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)

M5

2

(3)

4

(6)

6

(8)

M6

4

(6)

7

(10)

10

(14)

M8

10

(14)

18

(24)

25

(34)

M10

20

(27)

35

(47)

49

(66)

M12

35

(47)

61

(83)

86

(117)

M14

55

(76.4)

97

(131)

136

(184)

Fig. 19 Torque Specifications and Bolt Grades

Batteries are heavy. Use p r o p e r l i f t in g t e c h n iq u e s when moving them. Always lift the battery with a commercially available battery lifting device. Do not tip batt e r i e s w h e n r e m o v i n g o r 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 expelled 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 pos sibility of a dropped wrench from

‘shorting out’ a battery, which could result in an explosion and severe personal injury or death.

BATTERY

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




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

As a battery ages, it still performs adequately except that its capacity

is diminished. Capacity describes the time that a battery can continue to provide its design amperes from a full charge.

A battery has a maximum life, therefore good maintenance is designed to maximize the available

life and reduce the factors that can reduce the life of the battery.

BATTERY MAINTENANCE


Insulated wrench, 9/16"............................................... 1

Battery carrier ............................................................. 1

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

Battery maintenance kit P/N 25587-G01 .................... 1

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

Electrolyte Level and Water

The correct level of the electrolyte is 1/2" (13 mm) above the plates in each cell (Ref Fig. 20 on page 19).

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. Of equal importance is too much water which will result in electrolyte being forced out of the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle.

Expansion

Space

1/4" to 3/8"

(6 to 10 mm)

Vent Cap

Gas Vent

Vent

1/2" (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

Ref Cel 1

Plates

Fig. 20 Correct Electrolyte Level

At Each Charging Cycle

To reduce the possibility of fire, never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle.

Overcharging could cause damage to the vehicle batteries and result in extreme overheating.

The charger should be checked after 24 hours and unplugged after the charge cycle is complete.

Before charging the batteries, inspect the plug of the battery charger and vehicle receptacle housing for dirt or debris.

Charge the batteries after each days use.

Monthly

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

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

• Clean the batteries and wire terminations.

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

A battery being charged will ‘gas’ with the majority of the gassing taking place at the end of the charging cycle.

This gas is hydrogen which is lighter than air. Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas; however, this loss is minimal.

If the battery electrolyte level is too high, the electrolyte will block the vent tube and the gas will force

it out of the vent tube and battery cap. The water will evaporate but the 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.

Over the life of the battery, a considerable amount of water is consumed. It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction. The water must be distilled or purified by an efficient filtration system. Water that is not distilled should be analyzed and if required, filtration installed to permit the water to



Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings meet the requirements of the water purity table (Ref Fig.

21 on page 20).

Battery Cleaning

Wpt 1S

Fig. 21 Water Purity Table

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

Automatic watering devices such as the one included in the Battery Maintenance Kit (P/N 25587-G01) can be used with an approved water source (Ref Fig. 22 on page 20). These watering devices are fast and accurate to use and maintain the correct electrolyte level within the battery cells.

Watering gun similar to the type included in the

Battery Maintenance Kit

Valve consistently fills to a predetermined level

Electrolyte

Level

Pure Water

Ref Awg 1

Single Battery Cell

Fig. 22 Automatic Watering Gun

The watering device should only be used if the electrolyte level is less than 1/2" (13 mm) above top of plates.

Page 20

To prevent battery damage, be sure that all battery caps

(if equipped) are tightly installed.

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

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

Cleaning should take place per the Periodic Service

Schedule (Ref. Fig. 14 on page 14).

When cleaning the outside of batteries and terminals, first spray with a solution of sodium bicarbonate (baking soda) and water to neutralize any acid deposits before rinsing with clear water.

Use of a water hose without first neutralizing any acid will move acid from the top of batteries to another area of the vehicle or storage facility where it will attack the metal structure or the concrete/asphalt floor. Additionally, conductive residue will remain on the batteries and contribute to their self discharge.

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

The correct cleaning technique is to spray the top and sides of the batteries with a solution of sodium bicarbonate (baking soda) and water. This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or plastic spray bottle

. The solution should consist of the ingredients shown in the illustration

(Ref Fig. 23 on page 21). In addition, special attention should be paid to metal components adjacent to the batteries which should also be sprayed with the solution.

Allow the solution to sit for at least three minutes. Use a soft bristle brush or cloth to wipe the tops of the batteries to remove any conductive residue. Rinse the entire area with low pressure clear water. Do not use a pressure washer. All of the items required for complete battery cleaning and watering (electric vehicles only) are contained in the Battery Maintenance Kit (P/N 25587-G01).




Battery Replacement of sodium bicarbonate (baking soda) and brush clean if required.

Before any electrical service is performed on PDS model vehicles, the Run-Tow/Maintenance switch must be placed in the ‘Tow/Maintenance’ position.

If a power wire (battery, motor or controller) is disconnected for any reason on the PDS model vehicle, the

Run-Tow/Maintenance switch must be left in the ‘Tow/

Maintenance’ position for at least 30 seconds after the circuit is restored.

1 1/2 gallons

(6 liters)

Clear Water

1 quart

(1 liter)

Clear Water

1/4 Cup (60 ml)

Sodium Bicarbonate

(Baking Soda)

OR

2 Teaspoons

(10 ml)

Sodium

Bicarbonate

(Baking Soda)

Non

Metallic

Wand

2 Gallon

(7.5 liter)

Garden

Sprayer

Ref Pns 1

Plastic

Spray

Bottle

Fig. 23 Preparing Acid Neutralizing Solution

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

If the batteries have been cleaned and any acid in the battery rack area neutralized as recommended, no corrosion to the battery racks or surrounding area should be present. Any corrosion found should be immediately removed with a putty knife and a wire brush. The area should be washed with a solution of sodium bicarbonate

(baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint.

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

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

Inspect all wires and terminals. Clean any corrosion from the battery terminals or the wire terminals with a solution

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 batt e r y t e r m i n a l s w h i c h c o u l d r e s u l t i n a n explosion.

Use care to connect the battery wires as shown (Ref Fig.

24 on page 21). 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.

Front of Vehicle

-

-

+

+

-

-

-

+

+

-

-

+

-

+

Ref Bat 2

Fig. 24 Battery Connections

Prolonged Storage

BL +

BL -

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

During periods of storage, the batteries will need attention to keep them maintained and prevent discharge.

In high temperatures the chemical reaction is faster, while low temperatures cause the chemical reaction to slow down. A vehicle that is stored at 90° F (32° C) will 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



Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings a discharged state, sulfating takes place on and within the plates. This condition is not reversible and will cause permanent damage to the battery. In order to prevent damage, the battery should be recharged. A hydrometer can be used to determine the specific gravity and therefore the state of charge of a battery.

In winter conditions, the battery must be fully charged to prevent the possibility of freezing (Ref Fig. 25 on page

22). A fully charged battery will not freeze in temperatures above -75° F (-60° C). Although the chemical reaction is slowed in cold temperatures, the battery must be stored fully charged, and disconnected from any circuit that could discharge the battery. For PDS vehicles, the controller should be disconnected from the batteries by setting the Run-Tow/Maintenance switch, located under the passenger seat, to the ‘TOW/MAINTENANCE’ position. For portable chargers, disconnect the charging plug from the vehicle receptacle. For on-board chargers, disconnect the charging harness from the batteries. The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge. The batteries should be tested or recharged at thirty day minimum intervals.

E

L

E

C

T

R

O

L

Y

T

E

O F

+15

+5

-5

-15

-25

O C

-9

-15

-21

-26

-32

-35 -37

P

E

R

A

T

E

M

T

U

R

E

-45

-55

-65

-75

-85

-43

-48

-54

-60

-65

-95 -71

1.100

1.140 1.180 1.220 1.260 1.300

1.120 1.160 1.200 1.240 1.280

SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT

Ref Fpe 1

Fig. 25 Freezing Point of Electrolyte

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.

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

Before charging, the following should be observed:

• 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 are in good condition and free from dirt or debris.

• The charger connector is 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.



Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 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.

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

AC Voltage

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

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.

TROUBLESHOOTING

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

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

A new battery must mature

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

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

Hydrometer

A hydrometer (P/N 50900-G1) is used to test the state of charge of a battery cell (Ref Fig. 26 on page 24). This is performed by measuring the density of the electrolyte,

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.




Add to Float

Reading

Subtract from Float

Reading

Cylinder

16

20

24

28

0

4

8

12

32

36

16

12

8

4

32

28

24

20

Thermometer

Ref Hyd 1

Bulb

1100

1125

1150

1200

1225

1250

1275

1300

16

20

28

32

28

24

16

12

4

0

4

8

Fig. 26 Hydrometer

Float

1100

1125

1150

1175

1200

1225

1250

1275

1300

Weight

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

Page 24 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 (Ref Fig.

27 on page 24).

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 71.1

150 65.6

140 60.0

130 54.4

120 48,9

110 43.3

100 37.8

90 32.2

80 26.7

70 21.1

60 15.6

50 10

40 4.4

30 –1.1

20 –6.7

10 –12.12

0

–.002

–.004

–.006

–.008

–.010

–.012

–.014

–.016

–.018

–.020

–.022

–.024

–.026

–.028

+.016

+.014

+.012

+.010

+.008

+.006

+.004

+.002

+.032

+.030

+.028

+.026

+.024

+.022

+.020

+.018

EXAMPLE #1:

Electrolyte Temperature

Above 80 ° F (27 ° C)

Electrolyte temperature

90 ° F (32 ° C)

Hydrometer reading 1.250

1.250 + .004 = 1.254

corrected specific gravity

EXAMPLE #2:

Electrolyte Temperature

Below 80

°

F (27

°

C)

Electrolyte temperature

70 ° F (21 ° C)

Hydrometer reading 1.250

1.250 - .004 = 1.246

corrected specific gravity

Fig. 27 Hydrometer Temperature Correction


GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS



Page 28

MODEL: ST 400 E

TYPE: ELECTRIC POWERED TRUCK

MODEL YEAR: 2009

Part No:. 612134

MODEL: ST 40048V

TYPE: ELECTRIC POWERED TRUCK

MODEL YEAR: 2009

Part No:. 612134

PRODUCT SPECIFICATION

Precision Drive System™ (PDS): Programmable to terrain

CONFIGURATION HIGHLIGHTS

Inductive throttle sensor

Battery Charger:

Dash mounted direction selector switch (Forward-Neutral-Reverse) Inductive throttle sensor

Diagnostic indicator

Input: 110 – 120 Volt, 50/60 Hz, 8 amp Output: 48 Volt at 16 amps DC

Motor:

Regenerative ’Pedal Down’ and/or ‘Pedal Up’ braking

48 Volt DC shunt wound, brazed armature, solid copper windings

Battery Charger: 48 VDC PowerWise™, 120/230 VAC 50/60 Hz. Underwriters Laboratories (U.L.) Listed, (C.S.A. Certified)

Drive Train:

Motor:

Electrical System: 48 Volt DC, eight, 6 volt deep cycle batteries (115 minute minimum, 225 amp-hour @ 20 hr. discharge rate)

Transaxle:

Brakes:

Capacity:

Differential with helical gears

Brakes:

Cargo Bed:

Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with self-compensating system

Seating for 2 persons.

Dimensions

O

O v v e e r r a a l l

l

l L

W e i n d t g h t h

Dimensions

O v e r a ll L e n g t h

Overall Width i n ( 283

4 6 .

5 i n ( 1 1 8

G

R e e a r a r

A x l e

S e l e c

R a it it o

Performance o n

R e a r A x l e R a it o

1 4 .

7 : 1

D

1 a

2 .

s

4 h

4 :

M

1 o u n t e d F o r w a r d N e u t r a -l R e v e r s e

O v e r a ll e i g h t ( W ti h 49.5 in (126 cm) (Top of steering wheel)

O

F r v o e n r

t a

W h e e l l l H e i g h t ( W

F ti h h r o n t e l

C a n s o

W h e e l e p

T y ) r a c k

7 3 .

0

B a s e

W h e e

R e a r T r a c k

6 5 .

5

l T

W h e e l r a c 3 8 .

0

R e a r W h e e l T r a c C k a r g o B o x W i d t h i( n 3 s i 8 d .

5 ) i n ( 185

3 7 .

0 i n ( 1 6

7 7

6

.

c c

0

3 8 .

0 m n

) i n m ) i n i n ( 96.5

c m )

( 1 9 6

( 9 4

( 9 7 c m ) c m ) c m ) i n ( 97.8

.

c m n ) ( 1 1 2 c m )

D r y W e i g h

S

D e r a u r b

B e d y it n

L g

W e

V e h i c l e e

C i g i g o a d a h p t h t

L o a d a c

C a p a c ti ti y y

C a p a c ti y

C u r u b t s i

W e e i

C g l h t a r a n c e C ri c l e

2 P

885 e

1375 r s o n l b ( 401 l b k g ) ( W

( 624 k g)

B I e n d t e r L s o e a it d n C a i p s l a e c C ti l y e a r a n c N / A 5 0 0 l b ( 2 3 0 k g ) ti h o u t B a tt e ir e s )

G

C

C n d C a r g o l e a r

B o x a r g o B o x a n c

W i e d t

L e n g t h a r

D i o ff e o r e n e it n a g l t h i(

5 n

.

s

3 i d i e n

)

( 13.5

3 6 c

.

m i

) n

C a r g o i(

B o x n s i d e )

D e p t h i( n s i d e ) h

Cargo Box Capacity

4 4 .

5 i( n s i d e ) 3 0 .

5 i n ( 1 1 3 c i n (

1 0 .

5 i n m

(

( 9 1

2 7 c m ) c m )

)

9.6 cu ft (0.27 m3)

7 7

Roto-molded polyethylene

C

C a r g o a r g o

B o x

B o x

D e

C a p t p

M o t o r T y p e

Cargo Box Material

Horsepower (kW)

Vehicle Power a

P c o ti w y

E l e c t e r S o u r c e ir c a l S y s t e m

7 .

5 i n ( 1 9 c m )

5 .

9 c u f t ( 0 .

4

1 7

V o m tl

3 )

D C

S h u n t W o u n d

Roto-molded polyethylene

2.5 hp (1.9 kW) @ 2700 rpm

4 8 V o tl

V o tl s D C P o w e r S o u r c e

M o t o r T y p e

Key or Pedal Start

H

E l o r e c s e p o t ir c a w

l e r

S y s

( k W

Battery Charger

)

Speed Controller t e m

S

2 .

h

48

5 u

V n

H P o

t tl

W o u n

I

V

O n e t

T u t h s o n i e c i e

F r o n t

t d l e o w i n g e l

( L o e a v d l c

C a p a c

C ri e s l e a

Front Tires

A r

G i a r ti y p a n s l u a n c d ) ti y c e C

Steering & Suspension e it n g

S p e e d ( L e v

F

R r S u s p e C rl n c e e l G r o u n d ) e n s i o n n

C o

48 VDC PowerWise™ w/10 ft (3 m) DC Cord Frame n it n u o u s

400 Amp Precision Drive System (PDS)

Motor Shaft Direct Drive

S e

P a r v i c e B r a k e

Front Body & Finish ri c l e

1 3

8 p

0 h

0

22.0

17

L e a

± m

f l f b

0 .

(

5

3 6 0 h k

( g )

1 p s

t ( 6.7

h p ir

± n m

0 .

g s

5

) w m ti k p h ± 0 .

8 k p h ) p h ( h h y

2 7 k d r a u p il h c

± s h

0 .

o c

8 k

T o w i a n r g u

C a e p n a s i c o ti n y

L e a f

5 s

0 p

0 ir n l b s

( 2 ti

3 h

0 h k y g r

) a m il a x s h l o c a k d a b s o r b e r s

S e r v i c e B r a k e R e a r w h e e l m e c h a n i c a l s e fl a d j u s it n g d r u m

Steering & Suspension

Parking Brake Self-compensating, single point engagement k a p h ) b s o r b e r s

L e a f s p ir n g s w ti h h y d r a u il c s h o c k a b s o r b e r s

Welded steel. DuraShield™ powder coat

R e a r w h e e l m e c h a n

Injection Molded Geloy XTW

S e fl c o m p e n s a it n g , s i c i a n

l s e g l e fl a d p o i n j

t u s e it n n g g d r u a g e m m e n t

Trail Wolf 20 x 11 - 10 (4 Ply Rated) Uni-directional

K e y o r P e d a l S

Battery Charger t a r t T r a i l W o l f 2 0 x 1 1 1 0 ( 4 P l y R a t e d ) U n -i d ri e c it o n a l

Speed Controller

Drive Train

P e d a l S t a r t

48 VDC PowerWise™ QE, 120 VAC, Body & Chassis

UL/CSA

* Field installed accessories may require installationl charges

300 Amp Precision Drive System Front Body & Finish

Motor Shaft Direct Drive Rear Body & Finish

Standard Color

Some items shown may be optional equipment

Welded steel with DuraShield™ powder coat

Injection molded TPO

Steel. Base coat/clear coat

Black

2009 Electric ST 400 E

Released:

Revised:

Specifications are subject to change without notice

* Field installed accessories may require installation charges



73 in

(185 cm)

Rear

38 in (96.5 cm)

Front

38.5 in (97.8 cm)

ST 400 48V

49.5 in

(126 cm)

111.5 in (283 cm)

7.5 in

(19 cm)

65.5 in (166 cm)

30.5 in (77 cm)

44.5 in

(113 cm)

Fig. 28 Vehicle Dimensions



RECOMMENDED MAX SIDE TILT

25% or 14o MAX

RECOMMENDED MAX RAMP GRADE

25% or 14o MAX

TURNING CLEARANCE DIAMETER

ST 400 48V 22 ft (6.7 m)

Page 30

Fig. 29 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter


LIMITED WARRANTIES

WARRANTY


WARRANTY

DOMESTIC WARRANTY

(U.S. AND CANADA)

To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer date code.


LABELS AND PICTOGRAMS

LABELS AND PICTOGRAMS

Owner’s Manual and Service Guide Appendix A - 1


See Following

Pages For

Explanation

Of These

Pictograms:

(2,3,4,6,9,36,37,

38,39,40,29)

!

!

< 14° 25%

See Following

Pages For

Explanation

Of These

Pictograms:

(19,43,44,45)

OFF

ON

71131-G01

71131G01

!

1.

T o Prevent Roll-Back A pply Service

On a Hill From a

Stopped Position

Brake With

Left Foot

See Following

Pages For

Explanation

Of These

Pictograms:

(1,2)

74443G01

See Following Pages

For Explanation Of

These Pictograms:

(1,2)

74443G01

71489G01

On Battery Under Seat

See Following Pages

For Explanation Of

This Pictogram:

(28)

28203G01

Pb

35493-G01

35493G01

See Following Pages

For Explanation Of

These Pictograms:

(20,1,21,22)

3.

F ully

Release

4.

D epress Accelerator While

Releasing Service Brake As

< 14° 25%

!

71771G01

F R

P

F

35962-G01

35962G01

35964G01

See Following Pages For

Explanation Of Pictogram: (49)

WARNING

Keep entire body inside car.

27653G01

See Following Pages For

Explanation Of Pictogram: (30)

WARNING

Windshields do not provide protection from golf balls or other flying objects.

71419G01 (24)

71417G01 (25)

71415G01 (26) EGWHL14

See Following Pages

For Explanation Of These

Pictograms: (23,27,18,20,

22,17,15) PP

PP

1

PP

74093G01

2 3

74093-G01

Appendix A - 2

!

PP

35980G01

35980G02

35980G03

35980G04

MAX

250 lbs.

114 kg

MAX

4 in.

10 cm

See Following

Pages For

Explanation

Of These

Pictograms:

(1,2,12,10,8,

7,5,11)

MAX

14 o / 25%

74821G01

74821G02

74821G03

35980G01

See Following

Pages For

Explanation

Of These

Pictograms

(1,2,12,10,8,

11,51,7,5)

WARNING

DO NOT TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE

GOVERNOR. FAILURE TO COMPLY COULD RESULT IN SERIOUS

PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY.

24880G01

This Label Is Located

On Governor Cover At

Top Of Rear Axle.



1.

2.

3.

4.

5.

6.

7.

8.

Ref Pic 1-1

WARNING

READ MANUAL

9.

!

10.

WARNING

USE CAUTION IN

INCLEMENT WEATHER

WARNING

DO NOT OPERATE

UNDER THE INFLUENCE

OF DRUGS OR ALCOHOL.

11.

MAX

14 O /25 %

MAXIMUM

CROSS HILL/RAMP

ANGLE AS SPECIFIED

12.

!

WARNING

MAXIMUM CROSS

HILL/RAMP

ANGLE AS

SPECIFIED

< 14 O /25 %

LOAD WITH

HIGH CENTER

OF GRAVITY

COULD RESULT

IN TIP OVER

MAX

XX in.

XX cm

LOAD

CENTER

OF GRAVITY,

MAXIMUM

HEIGHT

13.

14.

MAX LOAD

XXX LBS

PP

< 14 O /25 %

!

WARNING

READ MANUAL

FOR MAXIMUM

LOAD BED

CAPACITY.

MAXIMUM RAMP/HILL

MAX

XXX lbs.

XXX kg

SECURE LOAD

AS FAR FORWARD

AS POSSIBLE.

MAXIMUM LOAD BED

CAPACITY

DO NOT RIDE IN

LOAD BED

DANGER OF EXPLOSION

DO NOT FILL GAS CAN

IN LOAD BED

WARNING

MAXIMUM LOAD

& CENTER OF

GRAVITY.

KEEP LOAD

AS FAR

FORWARD AS

POSSIBLE.

DO NOT RIDE

IN LOAD BED

KEEP HANDS &

FINGERS AWAY

FROM DUMP BED.

DO NOT STAND

BEHIND DUMP

BED

NOTE: All Pictograms may not apply to your product.



20.

21.

22.

23.

15.

16.

17.

PP

1

PP

PP

18.

19.

PP

24.

3

UNLEADED

GASOLINE

DO NOT

SPILL FUEL

ON A HOT

ENGINE

GROUND

FUEL PUMP

LOW OIL PRESSURE

NEGATIVE

GROUND

BATTERY

DO NOT CONNECT

POSITIVE BATTERY

TERMINAL TO GROUND

SHORTING BATTERY

TERMINALS MAY

CAUSE EXPLOSION

NO

TAMPERING.

KEEP HANDS

OUT

WARNING

CORROSIVE

CLEAN UP GASOLINE

SPILLS WITH WATER

BEFORE STARTING

ENGINE

27.

28.

29.

30.

31.

32.

33.

34.

25.

WARNING

EXPLOSIVE

35.

26.

WARNING

LETHAL

VOLTAGE

Ref Pic 1-2

Appendix A - 4



DO NOT

EXPOSE

TO FLAME

DO NOT

DISPOSE OF

BATTERIES

IN LANDFILL

DO NOT

DRIVE ON

HIGHWAY

WINDSHIELDS

DO NOT

PROVIDE

PROTECTION

FROM

FLYING OBJECTS

BATTERIES ARE

HEAVY.

USE CARE LIFTING

USE INSULATED

TOOLS

WEAR EYE

PROTECTION

NO SMOKING

HOT SURFACE


36.

37.

38.

39.

R

F

40.

P

F

41.

P

Ref Pic 1-3

N

OPERATE

FROM

DRIVERS SIDE

ONLY

42.

KEEP ARMS

AND LEGS

WITHIN VEHICLE

43.

44.

45.

TO OPERATE VEHICLE IN FORWARD:

TURN KEY TO ON

MOVE DIRECTION SELECTOR TO

FORWARD

DEPRESS ACCELERATOR PEDAL

AND ACCELERATE SMOOTHLY

46.

ON

OFF

TO OPERATE VEHICLE IN REVERSE:

TURN KEY TO ON


REVERSE

AN AUDIBLE DEVICE WILL SOUND

DEPRESS ACCELERATOR PEDAL

AND ACCELERATE SMOOTHLY

47.

48.

TO LEAVE A GASOLINE POWERED

VEHICLE IN PARK:

APPLY PARKING BRAKE

TURN KEY TO OFF


FORWARD

49.

TO LEAVE AN ELECTRIC POWERED

VEHICLE IN PARK:

APPLY PARKING BRAKE

TURN KEY TO OFF


NEUTRAL

50.

KEEP CLEAR

HAND OR

FINGERS CAN

BE TRAPPED

ON

POSITION

OFF

POSITION

HEADLIGHTS

UNLOCKED

LOCKED

DIFFERENTIAL

LOCKED

WARNING

KEEP ENTIRE BODY

INSIDE CAR

WARNING

POSSIBILE ELECTRIC

ARC OR BATTERY

EXPLOSION. WEAR

EYE PROTECTION.




51.

MAXIMUM

TAILGATE

LOAD


Ref Pic 1-4

Appendix A - 6 Owner’s Manual and Service Guide

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

(EUROPE ONLY)

Owner’s Manual and Service Guide Appendix B - 1

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY NOT AVAILABLE AT

TIME OF PUBLICATION

Appendix B - 2 Owner’s Manual and Service Guide

Read and understand 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, engage parking (PARK) brake, move direction selector to neutral, 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 effect the terrain and the ability to control the vehicle.

Avoid driving fast down hill. Sudden stops or change of direction may result in a 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 when driving the vehicle across an incline.

Stay in designated areas and avoid steep slopes. Use the parking brake whenever 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 the direction selector is in correct position before attempting to start the vehicle.

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

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

See GENERAL SPECIFICATIONS for standard vehicle load and seating capacity.

Read and understand the following text and warnings before attempting to service 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 each component may fail.

Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and therefore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diagnosing, removing or replacing any components that are not operating correctly, take time to consider the safety of yourself and others around you should the component move unexpectedly.

Some components are heavy, spring loaded, highly corrosive, explosive or 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 the utmost caution. Be careful not to place hands, face, feet or body in a location that could expose them to injury should an unforeseen situation occur.

To prevent personal injury or death, observe the following:

Before working on the vehicle, remove all jewelry (rings, watch, 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 attempting to run or adjust 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 is formed when charging batteries. Do not charge batteries without adequate ventilation.

Do not permit open flame or anyone to smoke in an area that is being used for charging batteries. A concentration of 4% hydrogen gas or more is explosive.

E-Z-GO Division Of Textron, Inc.,

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

TO CONTACT US

North America:

Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124

Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175

International:

Phone: 001-706-798-4311, FAX: 001-706-771-4609

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

Ezgo ST 400 48V Owner's Manual & Service Manual

OWNER'S MANUAL

&

SERVICE GUIDE

ELECTRIC POWERED VEHICLE

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

OWNER’S MANUAL

AND SERVICE GUIDE

ELECTRIC POWERED

UTILITY VEHICLES

ST 400 E

Starting Model Year 2009

TABLE OF CONTENTS

TABLE OF CONTENTS

GENERAL

6 GENERAL SAFETY PRACTICES

7 OPERATING SAFETY RULES AND PRACTICES

8 MAINTENANCE PRACTICES

ANSI/ITSDF B56.8 - 2006

BEFORE INITIAL USE

CONTROLS AND INDICATORS

PLASTIC LOADBED

OPERATING THE VEHICLE

VEHICLE CLEANING AND CARE

REPAIR

TRANSPORTING VEHICLE

SERVICE AND MAINTENANCE

BATTERIES AND CHARGING

GENERAL SPECIFICATIONS

LIMITED WARRANTIES

DOMESTIC WARRANTY

(U.S. AND CANADA)

LABELS AND PICTOGRAMS

DECLARATION OF CONFORMITY

(EUROPE ONLY)

DECLARATION OF CONFORMITY NOT AVAILABLE AT

TIME OF PUBLICATION

Related manuals

Table of contents

Ezgo ST 400 48V Owner's Manual & Service Manual

OWNER'S MANUAL

&

SERVICE GUIDE

ELECTRIC POWERED VEHICLE

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

OWNER’S MANUAL

AND SERVICE GUIDE

ELECTRIC POWERED

UTILITY VEHICLES

ST 400 E

Starting Model Year 2009

TABLE OF CONTENTS

TABLE OF CONTENTS

GENERAL

6 GENERAL SAFETY PRACTICES

7 OPERATING SAFETY RULES AND PRACTICES

8 MAINTENANCE PRACTICES

ANSI/ITSDF B56.8 - 2006

BEFORE INITIAL USE

CONTROLS AND INDICATORS

PLASTIC LOADBED

OPERATING THE VEHICLE

VEHICLE CLEANING AND CARE

REPAIR

TRANSPORTING VEHICLE

SERVICE AND MAINTENANCE

BATTERIES AND CHARGING

GENERAL SPECIFICATIONS

LIMITED WARRANTIES

DOMESTIC WARRANTY

(U.S. AND CANADA)

LABELS AND PICTOGRAMS

DECLARATION OF CONFORMITY

(EUROPE ONLY)

DECLARATION OF CONFORMITY NOT AVAILABLE AT

TIME OF PUBLICATION

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Table of contents