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OWNER`S GUIDE - Bad Boy Buggies

1. 42 Battery Replacement 2 2 edu ge rex d nu 43 Prolonged Storage 44 Battery Charging mE 44 Voltage T Seb SUI Te DES 45 DIAGNOSIS wad 45 FAVOROIMCTCR ete E 45 Usmo A Flydromleter einn heroe 46 Battery Charger Maintenance sse nennen nnne 46 PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE rope ric tepida 49 Owner s Guide TABLE CONTENTS SEE vi Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SAFETY GENERAL For any questions about material in this manual contact an authorized representative Read and understand all labels on the vehicle Always replace any damaged or missing labels Steep hills allow the vehicle to move at faster speeds than on a flat surface To prevent the loss of vehicle control and possible injury speeds must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICA TIONS section Apply the brake to control the speed If you operate the vehicle above the maximum specified speed you can damage the drivetrain components Damaged drivetrain components can c
2. 33 FUSE REPLAGEMEN JT cerent rtr detenta cete n ende S Re ERR eda eR naa 33 TRANSPORTING 34 TOWING 34 state 34 SERVICE AND MAINTENANCE sss enne nennen 34 ROUTINE 214 420 000 000006000000000000000000092 35 nisse 35 BRAKES m 36 Periodic 22 36 PREPARA MB EE 37 Checking the Lubricant Level 37 LUBRICATION breton E 37 CAPACITIES AND REPLACEMENT 37 HARDWARE e but 38 BATTERY CHARGING AND 2 2 00 1 0000 39 DG OLY H 39 Battery DISPOSAL 39 BUSY occi ener diis ite 40 Battery Maintenance 2 1 12 hein I S e bd EE Roca es 40 At Each Charging Cy Cle acts i cepa ee rct Eb etu ede a d dnd 40 decem 40 Electrolyte Level and Water 40
3. H a 13 CLIE 13 FIP EET EET RT 13 Steering Wheel x d E el 13 Brake QUI Ji treten ue ace aute duae ee uera Prud 13 13 TOCK 13 Truck Bed Handle EatQli irte Wiech 13 Electric Truck Bed Litt SWItG h 14 12 Volt Outlet nent 14 DC to P 14 Fuse c 14 OPERATING PROCEDURES SERIAL NUMBER LOCATION cet cet ettet v tac ttg 17 Owner s Guide BEFORE INETIAE US E vers 17 CHARGER P EI E 18 On Board Charger essaie noniine ese 18 HOW TO OPERATE THE VEHICLE 19 Key and Light Switch 20 Direction Selector Operation 21 Accelerator Pedal Operation ssssssssssssseee eene 21 Brake and Parking Brake Operation 21 Tr ck zii corde reete teer dedere re etc de 22 Truck Bed Handle Latch Operation 2 2 400 0 23 Electric Lift Operation enn nnns nnn 23 Tailgate Operation
4. pedal with regard to the safety of all personnel NOTICE a Distance Line or Marker Line or Marker Normal Range of Stopping Distance A subtle loss of performance can occur over time therefore it is important to establish the standard with a new vehicle 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 Periodic Brake Test qualified mechanic This test compares the brake performance of the vehicle to the brake performance of new or known to be good vehicles or to an established acceptable stopping distance Actual stop ping distances are 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 park brake to eliminate different pedal pressures and to include the affects of linkage mis adjustment The Periodic Brake Performance Test should be performed regu larly as an evaluation of braking system performance It is useful as a method of identifying subtle loss of performance over time EN A ie Establish the acceptable stopping distance by testing a new or known to be good vehicle and recording the stopping location or stopping distance Several vehicles should be tested when new and the range of stopping lo
5. BAD BOY OWNER S GUIDE HD ELECTRIC 644582 ISSUED MAY 2015 REVISED AUGUST 2015 Thank you for purchasing this vehicle Before you drive the vehicle read this Owner s Guide This guide contains mainte nance and operation information The illustrations can show items that are optional for your vehicle You can do most of the service procedures in this guide with common automotive hand tools If necessary contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule Repair or replacement parts are available from your E Z GO dealer or E Z GO Service Parts Department When you contact E Z GO about service or parts for your vehicle the information below is needed Vehicle Model PIN VIN or Serial Number OWNER S GUIDE 72V ELECTRIC POWERED VEHICLE HD ELECTRIC STARTING MODEL YEAR 2016 CALIFORNIA Proposition 65 Warning WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm In addition certain fluids con tained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease its stability or increase t
6. Be careful when you drive on loose terrain Be careful when you operate the vehicle around people MAINTENANCE ALWAYS Replace damaged or missing warning caution or information labels Service the vehicle according to the periodic service schedule in this manual Make sure that approved and qualified personnel do all repairs Follow the manufacturers maintenance procedures Use insulated tools within the battery area to prevent sparks or battery explosion Use specified replacement parts DO NOT use replacement parts of less quality Use recommended tools Make sure that tools and procedures not specified by the manufacturer will not be a safety risk to personnel or oper ation of the vehicle Support the vehicle with wheel chocks and jack stands NEVER get below a vehicle that is supported by a jack Lift the vehicle according to the manufacturers instructions Make sure you service the vehicle in an area away from open flame or sparks Know that a vehicle in need of repair does not operate correctly and can be dangerous to operate After you do the repairs or maintenance test the vehicle in a safe area that is without vehicle and person traffic Make sure you record and keep all of the maintenance history of the vehicle Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers LABELS AND PICTOGRAMS TO OPERATE VEHICLE TURN
7. Make sure you understand how to safely operate the vehicle and its equipment Reckless use of this vehicle can cause severe injury or death This vehicle is a light duty vehicle NOT an All Terrain Vehicle ATV Do not engage in rough or reckless operation of this vehicle If you do not know the terrain make sure you prepare for unexpected occurrences If the vehicle gets stuck or the batteries discharge a one hour drive can take many hours on foot Explosive hydrogen gas is created during the charge cycle of batteries Do not charge bat teries without enough ventilation A 4 concentration of hydrogen gas is explosive To prevent battery explosion keep all flammable materials open flame or sparks away from the batteries Owner s Guide uy Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Explosive hydrogen gas is created during the charge cycle of the batteries Good ventilation is necessary to remove gas from closed spaces The air must change every 12 minutes Never charge a vehicle near flammable materials open flame or sparks Never charge a vehicle near gas water heaters and furnaces Before a new vehicle is put into operation complete the items shown in the INITIAL SERVICE CHART INITIAL SERVICE CHART Parane Charge Seal Calculate the distance necessary to stop the vehicle for the brake performance test Tires Check air p
8. PERIODIC SERVICE SCHEDULE CHECK C amp A CHECK amp ADJUST CL CLEAN REPLACE Before each use QUARTERLY SEMI ANNUAL 250 300 hrs Tires Check pressure and inspect condition of tires amp rims Hardware Check for loose or missing Reverse Warning Indicator 5 _ Overall Vehicle Condition Battery Pack Check state of charge condition loose terminals corrosion CL CL CL hold down amp hardware Batteries Check electrolyte level fill if required Brake Pedal Check for smooth operation Parking Brake Check for correct hold capability Accelerator Check for smooth operation Charger Receptacle Inspect charger connector and receptacle Brakes Conduct brake performance test adjust if required Parking Brake Conduct brake performance test adjust if required Controller Check controller braking force for correct operation Wiring Inspect for loose connections broken or missing insulation Direction Selector Inspect attachment and mechanism Steering Assembly Check for excess play loose or missing hardware Tie Rods Check for excess play bent rods loose or missing hardware Front Axle Check for damage to axle loose or missing hardware Rear Axle Check fluid level oil leakage noise loose or missing hardware Parking Brake Inspect linkage rods latch arm and catch bracket Parking Brake Lubricate with light oi
9. KEY TO ON OBEY LOCAL DO NOT OPERATE REMAIN SEATED MOVE DIRECTION SELECTOR TO RULES AND NO PUBLIC UNDER DRUG ALCOHOL OPERATOR MUST KEEP ARMS LEGS FORWARD OR REVERSE REGULATIONS ROAD USE INFLUENCE BE MIN 150 CM WITHIN VEHICLE PRESS ACCELERATOR 634229 OWN ip p AN 2 lt 14 25 lt 14 25 FOR INFORMATION USE CAUTION IN LEAVE VEHICLE _ MAXSIDE READ MANUAL OPERATE FROM TO PARK VEHICLE REFERTO OWNERS INCLEMENT IN THREATOF 14 FOR MAX LOAD DRIVERS SIDE TURN KEY TO OFF MANUAL OR WEATHER LIGHTNING BED CAPACITY ONLY MOVE DIRECTION SELECTOR WEBSITE MAX INCLINE 14 TON ELECTRIC OR F GAS ENGAGE PARKING BRAKE WARNING SECURE LOAD NO HIGH CENTER READ THE BED WEIGHT PASSENGERS GRAVITY MAY MANUAL 500 LBS or 225KG INLOADBED CAUSE TIP OVER A WARNING 14821606 74821G06 DONOTFILLGAS MAX TAILGATE MAX SIDE Keep entire body CAN IN LOAD BED GRAVITY HEIGHT LOAD 100 LBS SLOPE 14 inside car 5 OR 12 CM OR 45 KG ABOVE FLOOR 27653G01 Windshields do not provide protection from golf balls or other flying objects EGWHL14 SAFETY RECYCLE ELECTRIC GLASSES BATTERIES SHOCK HOT ENGINE 75696G01 WARNING NO OPEN DANGER EXPLOSIVE 640561 READ THE FLAMES ELECTROCUTION MANUAL 740499G01 Owner s Guide 5 SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular atte
10. a discharged battery will read in the 1 140 range NOTICE Do not perform a hydrometer test on a battery that has just been watered The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte Weight The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80 F 27 C High Owner s Guide 45 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers quality hydrometers are equipped with an internal thermometer that will measure the temperature of the electrolyte and will include a conversion scale to correct the float reading It is important to recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been operated Using A Hydrometer ELECTROLYTE 1 Draw electrolyte into the hydrometer and release it sev TEMPERATURE eral 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 160 71 032 indicates a problem with the battery and is a sign that the 030 EXAMPLE 1 battery is nearing the end of its life 150 65 028 ELECTROLYTE TEMPERATURE 2 Draw the minimum quantity of electrolyte into the a n Wenn Above 80 F 27 hydrometer to permit the float
11. before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers LIGHT BULB REPLACEMENT To decrease the risk of premature bulb failure do not allow your fingers to contact new bulbs Use clean dry paper or paper towels to touch the glass part of the bulb Headlight Rotate the bulb socket a quarter turn to the left to unlock Remove the bulb and socket Install new bulb and rotate the socket a quarter turn to the right to secure Replacement bulbs are available from a local Distribu tor an authorized Branch or the Service Parts Depart ment Inside of Cowl Headlight Housing Screw Headlight Bulb Taillight Roll rubber bezel away To replace the taillight and brake light bulb lift the rubber bezel from from body around the edge of the taillight and remove the lens Install the replacement bulb and replace the lens Replacement bulbs are available from a local Distributor an authorized Branch or the Service Parts Department FUSE REPLACEMENT The fuse block is below the driver seat Lift the seat bottom to access the fuses Inside of Cowl Remove the old fuse and replace with a new fuse of the same type and size Fuses are available from a local Distributor an authorized Branch or the Ser vice Parts Department Owner s Guide 33 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings an
12. changes were made The information in this manual can change without notice E Z GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL E Z GO IS NOT LIABLE FOR INCIDENTAL OR CONSE QUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL This vehicle meets the current applicable standard for safety and performance requirements These vehicles are for off road use They DO NOT meet the federal Motor Vehicle Safety Standards of the United States of America USA and are not for operation on the public streets Some areas allow the operation of the vehicles on their streets according to local codes Refer to GENERAL SPECIFICATIONS for capacity of the vehicle Do not change the vehicle in any manner that changes the weight distribution decreases stability increases speed or extends the necessary distance to stop more than the factory specification Such changes can cause personal injury or death Do not change the vehicle in any manner that changes the weight distribution decreases stability increases speed or extends the necessary distance to stop more than the factory specification E Z GO is not responsible for changes that cause the vehicle to be dangerous Do not let anyone below the height of 59 inches 150 cm operate the vehicle 2 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers GENERAL OPERATION Read the following war
13. components will eventually fail to perform prop erly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible component failures or the manner in which they may fail A vehicle requiring repair indicates that it is no longer function ing as designed and therefore should be considered poten tially hazardous Use extreme care when working on vehicle When diagnosing removing or replacing any components that are not operating properly take time to consider the safety of yourself and others around you should the component move unexpectedly Some components are heavy spring loaded highly corrosive explosive may produce high amperage or reach high tem peratures Battery acid and hydrogen gas could result in seri ous bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unexpected situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment Before working on vehicle remove all jew elry rings watches necklaces etc Be sure no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise rear of vehicle and support on jack stands before running or adjusting power train Wear eye protection when working on or around the vehicle In particular use care
14. only Unlock the seat lock with a 4 hex bit Turn the two screws 1 4 turn to the left to unlock or 1 4 turn to the right to lock 10 Seat The seat is for two people one person on each side of the seat 11 Hip Restraint The hip restraints help people stay in position if the vehi cle changes position suddenly 12 Steering Wheel The steering wheel controls the direction of vehicle travel 13 Brake Light The brake lights are found on the rear fenders 14 Cup Holder The vehicle has a cup holder for the benefit of the driver and passenger 15 Truck Bed The truck bed provides space to transport cargo 16 Truck Bed Handle Latch A truck bed handle latch is found at the front of the man ual lift truck bed 13 Owner s Guide Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 17 Electric Truck Bed Lift Switch The switch for the electric lift is on the driver s side of the seat panel The switch actu ates the electric lift to raise and lower the truck bed 18 12 Volt Outlet if equipped The 12 volt outlet is on the instrument panel to the right of the cup holder The outlet has a protective cover The 12 volt outlet supplies power to personal electronic devices 19 DC to DC Converter The DC to DC converter supplies power to the power accessories 20 Fuse Block The fuse block supplies protec
15. parts to keep the warranty effective If you do not correctly do maintenance on the batteries you will cancel the warranty Refer to the MAINTENANCE section for instructions on the correct maintenance of the batteries BATTERY PROLONGED STORAGE The batteries discharge over time The rate of discharge changes according to the ambient temperature the age and condition of the batteries Completely charged batteries will not freeze in winter temperatures unless the temperature is less than 75 F 60 For winter storage the batteries must be clean completely charged and disconnected from any electrical drain The battery charger can stay connected to the vehicle to keep a full charge on the batteries while the charger is connected to an active electrical supply If the power to the electrical supply is disconnected or interrupted the battery charger will continuously check the charge on the battery pack A continuous check of the battery pack will pull power from the battery pack and drain the batteries The batteries must be checked and charged again as required or at a minimum of 30 day intervals Check and keep correct fluid level in all battery cells during the storage period Correct fluid level is necessary for maximum battery performance BATTERY DISPOSAL Lead acid batteries are recyclable Return discarded batteries to distributor manufacturer or lead smelter for recycling For neutralized spills put residue in acid
16. to float freely without con 5022 AMBIENT TEMPERATURE tacting the top or bottom of the cylinder 130 54 HEH 020 Above 80 F 27 C 3 Hold the hydrometer in a vertical position at eye level H H 4 018 and note the reading where the electrolyte meets the 120 49 016 2 scale on fhe teat uo 43 2 HYDROMETER READING 1 250 4 Add or subtract four points 004 to the reading for every H H 4949 1250 004 1 254 10 F 6 C the electrolyte temperature is above or 100 P amp H CORRECTED SPECIFIC GRAVITY below 80 F 27 C Adjust the reading to conform with H H READING the electrolyte temperature e g if the reading indicates o0 32 H a specific gravity of 1 250 and the electrolyte tempera H H 002 ture is 90 F 32 C add four points 004 to the 1 250 80 26 0 which gives a corrected reading of 1 254 Similarly if the H H 002 temperature was 70 F 21 C subtract four points 70 21 004 004 from the 1 250 to give corrected reading of H H 006 EXAMPLE 2 1 246 60 15 H 008 ELECTROLYTE TEMPERATURE 5 Test each cell and note the readin 8 Above 80 F 27 C gs corrected to 80 F 50 10 012 or 27 A variation of fifty points between any two cell H 014 ieee tna ee readings example 1 250 1 200 indicates a problem 40 4 016 op Md een so B 922 ELECTROLYTE TEMPERATURE As batte
17. to the front of the load bed Truck Bed Operation Do not allow passengers to ride in the truck bed A sudden move or stop can cause severe injury or death to passengers in the truck bed Before operating make sure no one is behind the vehicle A load bed warning label is attached to the inside front of the truck bed Understand and obey the warnings on this label for safe operation of the vehicle See the load bed warning label for maximum load Position the load in the truck bed as far forward as possible Make sure the center of gravity of the load is within the height limit shown on label e Secure the load to the truck bed aware of the load when you operate the vehicle Do not let passengers to ride in the truck bed Do not drive the vehicle with the truck bed lifted or with the tailgate unsupported Never fill a gas container in the truck bed Static discharge can ignite gasoline vapor and cause an explosion Always put the gas container on the ground before you fill with gas Never fill a gas container in the truck bed Static elec tricity is built up during the fueling process and can discharge and cause the gasoline vapor to ignite 22 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Truck Bed Handle Latch Operation Trick Bea Use caution when you operate the truck bed latch to make
18. vehi cle to move suddenly When the vehicle is parked make sure the key is in the OFF position so that the electrical system is disabled When the key switch is in the ON position press the accelerator pedal start the motor and move the vehicle Release the pedal to stop the motor Press the brake pedal to stop the vehicle quickly If the key switch is in the ON position and the parking brake is Parking engaged the brake releases when you press the accelerator Brake Pedal Accelerator Pedal pedal and can cause the vehicle to move suddenly This is a fea ture to make sure the vehicle is not driven with the parking brake engaged Pressing the accelerator pedal is not the recom mended method to release the parking brake Brake and Parking Brake Operation The function of the lower part of the brake pedal is to control speed Press the lower part of the pedal to decrease speed or stop the vehicle To engage the parking brake press the upper section of the pedal until it locks into position Press the lower part of the pedal to release the parking brake Owner s Guide 2l Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Failure to follow these instructions can cause personal injury damage the vehicle or cause the vehicle to tip over Be aware of the load when you operate the vehicle Read understand and follow the warning label attached
19. Back like Walk Away limits reverse motion of the vehicle down a slope to less than 2 mph 3 kph See Walk Away Feature for more information Anti Stall Feature Anti Stall protection prevents motor damage if the vehicle is stalled against an object or on a hill Example If all of the following events occur e system senses that the accelerator pedal is pressed power applied to motor e motor is stopped long enough that additional time can cause damage to the motor the Anti Stall feature will interrupt power to the motor This short interruption allows the vehicle to move backward slightly before it stops again The procedure will repeat at intervals until the vehicle is moved from the stopped condition Example If all of the following events occur the system senses that the accelerator pedal is pressed power applied to motor e the brake is engaged to prevent vehicle motion the Anti Stall feature senses a stalled motor condition and removes power from the motor When the brake pedal is released the vehicle will move backward slightly before power is returned to the motor High Pedal Disable Feature High pedal disable prevents acceleration of the vehicle if the direction selector is changed or the key is turned on while the accelerator is pressed Diagnostic Mode Feature Diagnostic mode helps with fault diagnosis With some electrical system failures the Diagnostic Mode feature defaults to a mode that allows the veh
20. CARE Read and understand all instructions supplied by the manufacturer of the pressure washer before use When you clean the outside of the vehicle with a pressure washer do not use more than 700 psi pressure Keep a minimum distance of 12 inches from the spray nozzle to the painted surface Do not clean the plastic parts with abrasive solvents Make sure you use correct methods and cleaning materials to prevent risk of damage to the outside of the vehicle The use of more than 700 psi water pressure can cause injury to anyone in the area or damage to vehicle Clean the windshield with water and a clean cloth Remove small scratches with a plastic polish or Plexus plastic cleaner available from the service parts department Apply a soap and water solution with a sponge or soft brush to clean the vinyl seats and plastic or rubber trim Dry with a cloth Use a commercially available vinyl and rubber cleaner to remove oil tar asphalt shoe polish etc Wash the vehicle frequently with cool water and mild detergent to protect the painted surfaces Apply wax that is for clear coat automotive finishes to improve the appearance and protection of the painted surfaces Do not apply wax to matte finish surfaces Materials used as fertilizers or for dust control can collect on the bottom of the vehicle These materials will cause corro sion of components unless cleaned with water Clean areas where mud or dirt can collect Loosen the sediment tha
21. IEEE t 23 ER 23 o eet ret tic te imc et cue 24 EL 24 einen interne 24 Antsholl Back Feature eed te eee tec rte uad 25 Anti Stall Feature nitens nnns enne 25 High Pedal Disable Feature 25 Diagnostic Mode Feature eoe eret heec eo sa le 25 STARTING AND DRIVING etu E uadit ern Eit rettet s perde t e x Ern kt dp dees 25 Starting Vehicle On 2 4 200 2 1 1000 nnns 26 COASTING dieu deceis a 26 SUN TOP AND WINDSHIELD IF EQUIPPED 26 MAINTENANCE VEHICLE CLEANING AND CARE icem tee cd cone ait aee redd ec 29 ENVIRONMENTAL CONCERNS ent rec pace keen here 29 Battery DISDOSal ela Voz 30 LIFTING ssh oec 30 WHEELS AND TIRES iinet eee ae 31 Recommended Tire Pressures 31 PAG sec E 31 Whieel Installation 32 LIGHTBULB REPLACEMEN DW aene 33 33 iv Owner s Guide
22. The foot operated parking brake is the top part of the brake pedal To engage the parking brake press on the upper section of the pedal until it locks in position Press the lower part of the brake pedal to release the parking brake A parking brake that is engaged releases when you press the accelerator pedal This is a feature to make sure the vehicle is not driven with the parking brake engaged Pressing the accelerator pedal is not the recommended method to release the parking brake 6 Charger Receptacle if equipped The polarized charger receptacle is found on the panel below the driver seat Connect the off board charger to the receptacle to charge the batteries 7 CE Charger Receptacle if equipped The CE charger receptacle is found on the panel below the driver seat Connect the CE charger to the receptacle to charge the batteries 12 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 8 AC Outlet if equipped The AC outlet is found on the panel below the driver seat The AC outlet supplies power to the onboard charger Connect the grounded AC cord to the outlet to charge the batteries 9 CE Seat Lock CE certified vehicles have a seat lock at the rear of the seat bottom The seat lock is to prevent user access and exposure to the battery compartment The seat lock should be unlocked by maintenance personnel
23. accelerates downhill the speed sensor causes the motor to electrically control the speed of the vehicle through regenerative braking The speed control system is not a alternative for the brake Use the brake to control speed and decrease the risk of injury This vehicle has a speed control system and a regenerative motor control system Example If all of the following events occur a the vehicle being driven down a slope b the vehicle speed is more than the specified top speed with the accelerator pedal pressed or released the regenerative brake will limit the speed of the vehicle to the specified top speed but the warning beeper will not acti vate When the regenerative braking system is activated by this sequence of occurrences the motor generates power which is returned to the batteries If the operator tries to override the electronic brake feature by moving the direction selector or key switch to another posi tion the warning beeper activates and the vehicle brakes quickly until it reaches approximately 2 mph 3 kph Pedal Up Braking Pedal up braking is regenerative braking that occurs when the accelerator pedal is released and the vehicle in motion between 8 mph 13 kph and the vehicle top speed Example If all of the following events occur a the vehicle being driven down a slope b the accelerator pedal is released for more than one second the pedal up braking decreases speed to 8 mph 13 kph then the vehicle freely mov
24. ause loss of vehicle control Damage to the drivetrain caused by excessive speed is abusive and will not be covered under the warranty Use caution when you tow the vehicle Towing the vehicle at above the recommended speed can cause personal injury or damage to the vehicle and other property If the vehicle is used in a commercial environment signs must be in position to inform of possible conditions that can be dangerous Examples shown below BATTERY WARNING BATTERIES cR mem ma WARNING WARNING WARNING WARNING Battery posts terminals and related PY accessories contain i lead and lead compounds z vw 4 chemicals known 147 25 to cause cancer and lt reproductive harm SHARP TURN SHARP TURN STEEP HILL ad Rm WASH HANDS AFTER HANDLING APPLY BRAKE APPLY BRAKE APPLY BRAKE SLOPES IN AFTER HANDLING TO LIMIT SPEED J TO LIMIT SPEED J TO LIMIT SPEED EXCESS OF 14 cenae cancer ind NOTICES CAUTIONS WARNINGS AND DANGERS Read the NOTICES CAUTIONS WARNINGS and DANGERS The person who services a vehicle needs the mechani cal skill and experience to see possible hazardous conditions Incorrect service or repairs can cause damage to the vehi cle or make the vehicle dangerous to operate NOTICE A NOTICE indicates and describes information not related to personal injury A CAUTION indicates a dangerous condition that can cause injury that is not life threatenin
25. 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 SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT The batteries must be tested or charged again at 30 day minimum intervals Battery Charging The battery charger is designed to completely charge the battery set If the batteries are severely deep cycled some automatic battery chargers contain an electronic module that will not activate and the battery charger will not operate Automatic chargers determine the correct length of charge to the battery set and turns off when the batteries are charged Always refer to the instructions of the charger used Do not overfill batteries The charge cycle will expel electrolyte and cause component damage Before charging the following must be observed electrolyte level all cells must be at the recommended level and above the plates charging must occur in an area with good ventilation to remove hydrogen gas that is made during the charge cycle A minimum of five air replacements for each hour is recommended charger connector components must be in good condition and free from dirt and particles e charger connector must be completely installed in the vehicle receptacle 44 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular atten
26. cations or dis tances recorded NOTICE Over time a subtle loss of performance may occur therefore it is important to establish the standard with a new vehi cle Drive the vehicle at maximum speed on a flat dry clean paved surface Quickly press the brake pedal to lock the parking brake at the line or marker in the test area and remove foot from pedal The vehicle must stop fast 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 locked The vehicle must 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 must be tested again If the vehicle fails the second test it must immediately be removed from service The vehicle must be inspected by a qualified mechanic who should refer to the TROUBLESHOOTING or FAULT DIAGNOSIS section in the Technician s Repair and Service Manual 36 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers REAR AXLE The only maintenance necessary for the first five years is the inspection of the rear axle for lubricant leakage Unless leakage is visible the lubricant needs to be replaced after five years Refer to the Service and Repair Manual for the fluid replac
27. control do not move the direction selector while the vehicle is in motion If you move the selector the speed will immediately decrease and a warning device activates Decrease speed before and during turns Do not drive the vehicle up down or across a slope that is more than 14 25 grade See GENERAL SPECIFICATIONS for the vehicle load and seat capacity When the accelerator pedal is pressed the foot operated parking brake releases and can cause accidental or sudden vehicle movement When the vehicle is parked make sure the key is in the OFF position When you leave the vehicle turn the key to the OFF position and remove from the switch to pre vent accidental operation Make sure the direction selector is in correct position before you press the accelerator pedal Make sure you completely stop the vehicle before you move the direction selector to a different position Do not take vehicle out of gear while in motion Before you drive in the reverse direction make sure the area behind the vehicle is clear Owner s Guide 19 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Driver and passengers must stay in their seats while the vehicle is in motion Always keep feet legs hands and arms inside vehicle while in motion Incorrect and irresponsible operation of this vehicle can cause dangerous conditions for the operator passengers and o
28. d Dangers TRANSPORTING VEHICLE Do not ride or allow other people on the vehicle being towed Towing Do not try to tow the vehicle with ropes chains or any device different from a tow bar approved by the factory Do not tow the vehicle on highways Do not tow the vehicle at speeds more than 12 mph 19 kph Make sure you secure the vehicle and all items before you move a vehicle on a trailer Hauling Do not allow any people on a vehicle being moved on a trailer Remove the windshield before you move a vehicle on a trailer Maximum speed with sun top installed is 50 mph 80 kph If you move the vehicle on a trailer at highway speeds the sun top must be removed and the seat bottom secured When you move the vehicle on a trailer below highway speeds check for tight hardware and cracks in sun top at the mounting points The rated capacity of the trailer or truck must be more than the weight of the vehicle and load plus 1000 Ibs 454 kg See GENERAL SPECIFICATIONS for the weight of the vehicle Secure the vehicle to the trailer with ratchet tie downs SERVICE AND MAINTENANCE Read all notices cautions and warnings in this manual before you do any type of service opera tions The drive wheels must be lifted and supported on jack stands before you do any service to the powertrain when the motor is in operation To decrease the risk of motor damage do not operate the vehicle at full throttle for more than 5 seconds wi
29. e or automatic watering devices like the one included in the E Z GO Battery Maintenance Kit P N 25587 G01 can be used with an approved water supply These watering devices are accurate easy to use and allow for fast fill They also keep the correct electrolyte level within the battery cells NOTICE The watering device must only be used if the electrolyte level is less than 1 2 13 mm above top of plates Gas Vent Expansion Space IE 1 4 to 3 8 T 6 mm to 10mm Plates Electrolyte level should be at least 1 2 13mm above the plates and 1 4 to 3 8 6 to 10 mm below vent Correct Electrolyte Level Impurity Parts Per Million COO RE MO E Clear Suspended 222 cecus ER Trace Total 4444 2 100 Calcium amp Magnesium Oxides _____________ 40 MOMs ME PEN FREE ERES 5 Ammonia 220362 bene 8 Organic amp Volatile Matter _________________ 50 ________________________ 5 Nitrate Si ees bt ERREUR LE Ha 10 Chloride 5 Water Purity Table Watering gun similar to the type included in the E Z GO Battery Maintenance Kit __ Valve consistently fills to a predetermined level Electrolyte Level Pure Water Single Battery Cell 41 Owner s Guide Read all of SAFETY this section before attempting any procedure Pay particular attentio
30. e that the charger plug is not damaged and is correctly connected to a grounded outlet The power AC cord has a plug with a ground post Do not remove cut or bend the ground post 18 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers The on board charger is below the driver side of the truck bed The on board charger is wired to the batteries Before you charge the batteries make sure you e park the vehicle in an area with good ventilation engage the parking brake turn the key to the OFF position and remove the key Connect the charger cord to a dedicated 15 amp AC outlet to activate the charger When the charge cycle is complete disconnect the charger cord HOW TO OPERATE THE VEHICLE Incorrect use of the vehicle or lack of maintenance can cause damage or decreased performance Read the following warnings before you operate the vehicle Make sure you know the terrain and traffic conditions Make sure you know environmental condi tions that change the terrain and your ability to control the vehicle Drive the vehicle only as fast as terrain and conditions allow When possible stay in approved areas and do not drive on steep slopes Do not arive fast downhill Sudden stops or change of direction can cause a loss of control Use the brake to control the speed of the vehicle when you drive down a slope To prevent loss of
31. ement procedure Checking the Lubricant Level Clean the area around the check fill plug and remove the plug The correct lubri cant level is just below the bottom of the threaded hole If lubricant is low add lubri cant as required Add lubricant 80 WT engine oil slowly until lubricant starts to seep from the hole Install the check fill plug In the event that the lubricant is to be replaced the oil pan must be removed or the oil siphoned through the check fill hole Check Fill Plug LUBRICATION 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 compo nents Lubrication Points Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure 2 Rack Ball Joint View from Underside of Vehicle CAPACITIES AND REPLACEMENT PARTS Rear Axle Oil 12 oz 1 2 liters 30 WT Engine Oil Fuse 15 amp P N 18392 G1 Headlight Bulb P N 619100 Turn Signal Bulb P N 619102 Tail Light Bulb P N 21759 1 Owner s Guide 37 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers HARDWARE Normally three classes of standard hardware and three classes of metric hardware are used in the vehicle Grade 5 hardware is id
32. en you leave the vehicle turn the key to the OFF position and remove the key from the switch NOTICE 4 and Light Switch If the vehicle has accessories that were installed at the factory some acces sories continue to operate with the key switch in the OFF position 20 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Direction Selector Operation To prevent loss of control do not move the direction selector to a different position while the vehi cle is in motion If you move the selector the speed will immediately decrease and a warning device activates Move the direction selector to F to move in the forward direction Move the direction selector to R to move in the reverse direction A reverse warning buzzer activates when the direction selector is moved to the R position Direction Selector When you leave the vehicle put the direction selector in the neutral posi tion engage the parking brake and remove the key from the switch When you leave the vehicle put the direction selector in the neutral posi tion engage the parking brake and remove the key from the switch Accelerator Pedal Operation Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause severe injury or death An engaged parking brake will release when the accelerator pedal is pressed and cause the
33. entified by the three marks on the hexagonal head grade 8 hardware is identified by six marks on the head grade 2 hardware is not marked The class specification is marked on metric hardware Inspect the vehicle for loose fasteners periodically The fasteners must be tightened carefully and according to the Torque Specifications table or as specified in the Repair and Service Manual ALL TORQUE FIGURES ARE IN FT LBS Nm Unless otherwise noted in text tighten all hardware in accordance with this chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners BOLT SIZE 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 4 8 15 24 35 5 11 20 33 47 55 75 75 102 130 176 13 23 35 55 18 31 47 75 80 110 108 149 200 271 BOLT SIZE M10 M12 Class 5 8 20 Grade 2 aa 27 35 47 Class 8 8 35 Grade 5 8 8 47 61 83 Class 10 9 Gog 49 Grade 8 10 9 66 86 117 Torque Specifications and Bolt Grades 38 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BATTERY CHARGING AND MAINTENANCE Safety Always obey the following warnings when working on or near batteries To prevent the risk of battery
34. eries need attention to keep them maintained and prevent discharge In high temperatures the OF C chemical reaction is faster while low temperatures cause the chemical reaction to slow A vehicle that is stored at 90 F 32 C will lose 002 of specific gravity each day If a com pletely charged battery has a specific gravity of 1 275 and the battery is not used it will become partially discharged When it reaches 1 240 which it will do in less than 20 days it must be charged again If a battery stays in a discharged state sul fating occurs on and within the plates This condition is not reversible and will cause permanent damage to the battery To prevent damage the battery must be charged again Use a hydrometer to find the specific gravity and the state of charge of a battery 15 9 In winter conditions the battery must be completely charged to prevent the risk of freezing A completely charged battery will not freeze in temperatures above 75 F 60 C Although the chemical reaction is decreased in cold tempera tures the battery must be stored completely charged and dis connected from circuits that can discharge the battery The controller must be disconnected from the batteries macaYramVema m r O2 7 1omr m 1 JI For portable chargers disconnect the charger plug from the vehicle receptacle 1 120 1160 1 200 1 240 1 280 For on
35. ery terminals Use a container with insu lation to prevent an explosion Use wrenches with insulation to decrease the risk of a short circuit if a wrench falls across the bat tery terminals A battery short circuit can cause an explosion Battery Disposal Lead acid batteries are recyclable Return used batteries to distributor manufacturer or lead smelter for recycling For neutralized spills put residue in acid resistant containers with absorbent material sand or earth and discard according to state and federal regulations for acid and lead compounds Contact state environmental officials for disposal information Owner s Guide 39 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Battery A battery is described as two dissimilar metals immersed in an acid If the acid is absent or if the metals are not dissimi lar a battery has not been created The batteries in this vehicle are lead acid A battery does not store electricity but it can produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy The chemical reaction occurs faster in warm conditions and slower in cold conditions Temperature is important when conducting tests on a battery and test results must be corrected to adjust for temperature differences An older battery can perform adequately except that its capacity i
36. es without the accelerator pressed between 8 and 3 mph 5 kph or the accelerator pedal is applied The warning beeper will not activate When pedal up braking is activated by this sequence of occurrences the motor generates power which is returned to the batteries Terrain The vehicle is for use on improved roads do not use on public highways You can operate the vehicle on dirt roads or open terrain that is free from fallen trees branches large rocks or holes Do not drive the vehicle through water Walk Away Feature Walk Away limits vehicle movement without driver input decreases vehicle speed to 2 mph 3 kph and activates an alarm reverse beeper Example If all of the following events occur e vehicle is stopped for more than 1 5 seconds the accelerator pedal is released for more than one second e the vehicle starts to move at more than 2 mph 3 kph the Walk Away feature limits speed to approximately 2 mph 3 kph and the warning beeper activates When the acceler ator pedal is pressed the Walk Away feature and warning beeper stops and normal vehicle operation continues When the speed control system senses any condition that is not normal it responds in a similar manner The system functions in all key switch positions 24 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Anti Roll Back Feature Anti Roll
37. explosion keep all flammable materials open flames or sparks away from the batteries Hydrogen gas is made as batteries are charged Do not charge batteries without good ventilation A 4 concentration of hydrogen gas is explosive Make sure that the key switch is in the OFF position and all electrical accessories are off before you start to work on the vehicle Turn off all accessories before disconnecting from the battery terminal Use safe procedures to move the batteries Always lift the battery with a SAFETY FIRST commercially available battery lifting device Do not tilt the batteries during removal or installation An electrolyte spill can cause burns and damage Se The electrolyte in a storage battery is an acid solution which can cause 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 you add water or charge the batteries fec lt J Neutralize electrolyte spills with a solution of 2 teaspoons 10 ml sodium bicarbonate baking soda mixed in 1 quart 1 liter of water Clean with water If you fill the batteries with electrolyte above the maximum level you can cause an electrolyte spill during the charge cycle An electrolyte spill can cause damage to the vehicle and storage facility Be careful when you use aerosol containers near the batt
38. g A WARNING indicates a dangerous condition that can cause death or serious injury DANGER A DANGER indicates a dangerous condition that will cause death or serious injury Owner s Guide Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers This manual contains recommended maintenance procedures from the manufacturer Follow these procedures and fault isolation information to get the best service from the product To decrease the risk of personal injury or property damage read and follow all safety information and operational procedures in this manual Certain replacement parts can be used independenily and or in combination with other accessories to modify E Z GO manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph 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 FEDERAL LAW the modified product will be a Low Speed Vehicle LSV subject to the stric tures 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 Identifi cation Number to the product in accordance with the req
39. he speed beyond the factory specifications Such modifications can cause serious personal injury or death E Z GO Division of Textron Inc prohib its and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle E Z GO Division of Textron Inc reserves the right to incorporate engineering and design changes to products in this manual without obli gation to include these changes on units sold previously The information contained in this manual may be revised periodically by 2 and therefore is subject to change without notice E Z GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE QUENTIAL DAMAGES resulting from the use of the information and materials in this Manual These are the original instructions as defined by 2006 42 EC CONTACT US E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 North America Technical Assistance amp 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 This vehicle was designed and manufactured in the United States of America USA The Standards and Specifications listed in the following text originate in the USA unless other wise indicated Use Original Equipment Manufacturer OEM approved
40. he two jack stands How to lift the front of the vehicle only 1 Put the wheel chocks in front and behind each rear wheel 30 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 2 Put the jack at the center of the front axle 3 Liftthe vehicle enough to put two jack stands below the front frame crossmember as shown 4 Lower the jack and test the stability of the vehicle on the two jack stands E Lower the vehicle n iw d 1 Lift the vehicle enough to remove the jack EN Center of stands Front Axle lt lt Y 2 Carefully lower the vehicle to the ground with the jack Outside End of Rear Axle View from Underside of Vehicle WHEELS AND TIRES To decrease the risk of tire explosion do not exceed the tire inflation pressure rating on the tire sidewall To decrease the risk of tire explosion inflate small amounts of air into the tire at intervals to seat beads Because of the low volume of the small tires over inflation can occur in seconds Never exceed the tire inflation pressure rating on the tire sidewall when seating a bead Protect the face and eyes when you remove a valve core When you remove the wheels use only sockets made for impact wrenches to decrease the risk of injury by a broken socket Do not use tires with lo
41. hicle dependable and decreases costs for repairs Refer to the Periodic Service Schedule for service and intervals Refer to Lubrication Points for correct lubrica tion locations ROUTINE MAINTENANCE To increase the life of a vehicle that is used in rough conditions some maintenance must be done more often than recommended in the Periodic Service Schedule For example high or low temperatures high dust and dirt conditions high use with maximum load To access the powertrain for normal maintenance lift or remove the seat and remove the rear access panel For major repairs refer to the applicable Technician s Repair and Service Manual Some service procedures make it necessary to lift the vehicle Refer to LIFTING THE VEHICLE for correct lift procedure and safety information TIRE INSPECTION Inspect the tire condition according to the Periodic Service Schedule Tire inflation pressures must be checked when the tires are cool Always install the valve dust cap after you check or inflate the tires Owner s Guide 35 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BRAKES Dry Level Clean Paved Surface Accelerate to maximum speed Always inspect the pedal travel before you operate a vehicle to confirm some brake function is found Latch park brake and take Make sure you do all brake tests in a safe 2
42. icle to operate at a decreased speed This feature allows you to return the vehicle to the storage facility and identify the problem The technician can put the controller in diagnostic mode and the controller identifies the failure mode STARTING AND DRIVING Remove the charger plug from the receptacle and correctly store the cable before you move the vehicle To operate the vehicle Apply the brake put the key in the key switch and turn to the ON position e Move the direction selector to the correct direction e Press the brake pedal to release the parking brake e Slowly press the accelerator pedal to start the motor and release the brake pedal When the accelerator pedal is released the motor decreases the speed of the vehicle To stop the vehicle quickly press the brake pedal NOTICE When the direction selector is in the reverse position a warning signal activates to indicate that the vehicle is ready to run in the reverse direction Owner s Guide 25 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Starting Vehicle On A Hill To decrease the risk of roll back do not release the brake until the motor has started Do not use the accelerator and motor to hold the vehicle on a hill Doing so for more than 3 4 seconds will cause permanent damage to motor To decrease the risk of permanent damage to the drive system do not all
43. l Do not lubricate cables or brake latch Rear Axle Drain amp replace fluid Rear Suspension Inspect for shock oil leakage worn bushings loose or missing hardware Front Suspension Inspect for strut oil leakage excessive play in hubs or kingpins worn bushings loose or missing hardware Front Wheel Alignment Inspect for unusual tire wear CBA Steering Assembly Inspect bellows and pinion seal for damage and leakage Rack End Ball Joint Check for noise and loose or missing hardware f d EE d EE go E go gt go 2 go 2 gt go go go gt gt gt gt C amp A go gt go gt IE IE d O Qo gt O gt O Qo gt O Qo gt O Qo gt O Qo gt O Qo gt Use only distilled or purified water that is free from contaminates to fill batteries NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions Owner s Guide 49 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes i 50 Owner s Guide NOTICE Read the following warnings before
44. le before you get below the vehicle Put wheel chocks in front and behind the wheels that remain on the ground Do not allow any person in or on the vehicle being lifted When you lift the vehicle put the jacks and jack stands at the areas indicated only Tool List Quantity List Quantity Floor Jackie 1 etin dus 4 Wheel 40 40 4 Remove payload from vehicle before lifting person s should be in or on the vehicle while lifting How to lift the entire vehicle Install the wheel chocks in front and behind each front wheel Put the jack below the center of the rear frame crossmember Lift the vehicle enough to put jack stands below the outer ends of the rear axle as shown Lower the jack and test the stability of the vehicle on the two jack stands Put the jack at the center of the front axle Lift the vehicle enough to put two jack stands below the front frame crossmember as shown Lower the jack and test the stability of the vehicle on all four jack stands How to lift the rear of the vehicle only NQOaPpown 1 Put the wheel chocks in front and behind each front wheel 2 Put the jack below the center of the rear frame crossmember 3 Lift the vehicle enough to put a jack stand below the outer ends of the rear axle as shown 4 Lower the jack and test the stability of the vehicle on t
45. n to Notices Cautions Warnings and Dangers The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes Clean all electrolyte spills to the body and eyes with clear water Contact a physician immediately To clean an electrolyte spill use a solution of 2 teaspoons 10 sodium bicarbonate baking soda mixed with 1 quart 1 liter of water J Always wear safety shield or approved safety goggles when add water or charge the batteries Battery Cleaning To prevent battery damage make sure you correctly install all battery caps To decrease the risk of damage to vehicle or floor neutralize acid before you spray the battery with water To decrease the risk of damage to the electrical components while cleaning do not use a pressure washer Clean the batteries according to the Periodic Service Schedule When you clean the battery cases and terminals do not use a water hose without neutralizing any acid deposits first The water hose moves the acid from the top of the batteries to another area of the vehicle or storage facility where it can cause damage After spraying the batteries a conductive residue remains on the batteries and contributes to the dis charge of the batteries Preparing Acid Neutralizing Solution C 4 2 teaspoons 10 ml 1 quart 1 liter Sodium Bicabonate Plastic Spray Clear Water Baking Soda Bottle The correct cleaning method is to spray the t
46. ne Refer to the discharge machine manufacturer instructions A hydrometer is used to identify a poorly performing battery in a set with a low specific gravity When the particular cell or cells that are the problem are identified the battery can be removed and replaced The battery can not be restored The individual battery should be replaced with a good battery of the same brand type and approximate age Hydrometer A hydrometer P N 50900 G1 is used to test the state of charge of Thermometer a battery cell This is performed by measuring the density of the Cylinder Bulb Float electrolyte which is accomplished by measuring the specific grav ity of the electrolyte The greater the concentration of sulfuric acid the more dense the electrolyte becomes The higher the density Add to Float the higher the state of charge Reading A AWARNING 7 Subtract To prevent battery explosion never insert a metal thermometer into a battery Use a hydrometer with a built in thermometer that is designed for testing batteries from Float Reading Specific gravity is the measurement of a liquid that is compared to a baseline The baseline is water which is assigned a 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 Hydrometer times the weight of the same volume of water A fully charged bat tery will test at 1 275 1 280 while
47. nings before attempting to operate the vehicle When you leave the vehicle turn the key to the OFF position and remove the key from the vehicle Drive the vehicle only as fast as terrain and conditions allow Consider the terrain and traffic condi tions Consider environmental conditions that change the terrain and your ability to control the vehicle Do not drive fast downhill Sudden stops or change of direction can cause a loss of control Use the brake to control the speed of the vehicle when you drive down a slope When possible stay in approved areas and do not drive on steep slopes Always keep feet legs hands and arms inside vehicle Do not drive on rough terrain Before you drive in the reverse direction make sure the area behind the vehicle is clear Make sure the direction selector is in the correct position before you press the accelerator pedal Decrease speed before and during turns Make sure you completely stop the vehicle before you move the direction selector See GENERAL SPECIFICATIONS for the vehicle load and seat capacity NOTICE Read the following text and warnings before you service the vehicle Normal use age wear or abuse can cause some components on the vehicle to fail The manufacturer can not know all possible component failures or the methods that failures can occur A vehicle in need of repair does not operate correctly and can be dangerous Be careful when you service the vehicle Be aware of your safet
48. ntion to Notices Cautions Warnings and Dangers Notes 6 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS BAD BOY BUGGIES E MODEL HD Electric TYPE ELECTRIC 72V POWERED TRUCK MODEL YEAR 2016 Part No 644586 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Solid State continuously variable AC speed controller e Full torque reduced speed reverse Seat wrap mounted direction selector switch Forward Neutral Reverse 9 Inductive throttle sensor Anti roll back walk away braking and alarm only with key in on position Diagnostic indicator Anti stall motor protection Factory programmable to application Regenerative Pedal Down and or Pedal Up braking Battery Charger 900 W 72 VDC 120 230 VAC 50 60 Hz Underwriters Laboratories U L Listed C S A Certified Motor 72V AC Induction solid copper windings Non vented 22 4 hp 16 7 kW Peak Drive Train Direct motor shaft connected to transaxle pinion shaft Electrical System 72 V DC nine 8 volt deep cycle storage batteries 78 minutes 75 Amps 170 amp hour 20 hour discharge rate Transaxle Differential with helical gears Brakes Dual rear wheel mechanical self adjusting drum brakes Automatic single point park brake release with self compensating system Cargo Bed Roto molded cross linked polyethelene Lifts for access t
49. o powertrain Removable hinged multi position tailgate requires no latch mechanism PRODUCT OVERVIEW Dimensions Performance Overall Length 111 in 281 cm Seating Capacity 2 Person Overall Width 49 8 in 126 cm Dry Weight 1060 Ib 480 kg without Batteries Overall Height No Canopy 52 0 in 132 cm Top of steering wheel Curb Weight 1620 Ib 730 kg Overall Height with Canopy 77 0 in 196 cm Bed Load Capacity 500 Ib 227 kg Wheel Base 78 0 in 198 cm Vehicle Load Capacity 900 Ib 408 kg Front Wheel Track 38 0 in 97 cm Outside Clearance Circle 24 0 ft 7 3 m Rear Wheel Track 38 8 in 99 cm Intersecting Aisle Clearance N A Ground Clearance at Differential 7 0 in 18 cm Speed Level Ground 16 mph 0 5 mph 26 kph 0 8 kph Cargo Box Width inside 44 0 in 112 cm Towing Capacity 930 Ib 4137 max drawbar Cargo Box Length inside 36 0 in 91 cm Cargo Box Depth inside 10 5 in 27 cm Steering Self compensating rack and pinion Cargo Box Capacity 9 6 cu ft 0 27 m3 Front Suspension Leaf springs with hydraulic shock absorbers Cargo Box Material Roto molded polyethylene Rear Suspension Leaf springs with hydraulic shock absorbers Service Brake Rear wheel mechanical self adjusting drum Power Source 72 Volts DC Parking Brake Self compensating single point engagement Motor Type AC Induction Front Tires 23 x 10 5 12 4 Ply Rated Horsepower kW 22 4 hp 16 7 kW Peak Rear Tires 23 x 10 5 12 4 Ply Rated Electrical S
50. on the tire sidewall All four tires must have the same pressure for best control qualities Always install the valve stem cap after you check or inflate the tires The vehicle has low pressure tubeless tires installed on one piece rims Use a tire plug to repair small holes in the tread part of the tire For large holes and cuts replace the tire NOTICE Tire plug tools and plugs are available at automotive outlets The tires do not have to be removed from the wheel to install the tire plugs If the tire is flat remove the wheel and inflate the tire to the recommended maximum pressure for the tire Submerge the tire in water to find the leak and mark with chalk Install the tire plug according to manufacturers instructions Wheel Installation To decrease the risk of component damage do not tighten lug nuts to more than 85 ft Ibs 115 Nm torque NOTICE Always follow the cross sequence pattern when you install the lug nuts to make sure the ee is evenly seated against the ub With the valve stem to the outside of the wheel install the wheel on the hub with lug nuts Tighten the lug nuts 1 with your fingers in the cross sequence pattern shown Tighten the lug nuts to 50 to 85 ft lbs 68 to 115 Nm torque in 20 ft Ibs 27 Nm increments Continue to follow the cross sequence pattern until the correct torque is reached Tire style may vary Cross Sequence 32 Owner s Guide Read all of SAFETY and this section
51. op and sides of the batteries with a solution of baking soda and water Apply this solution with a plastic spray bottle The solution is 2 teaspoons 10 ml sodium bicarbonate baking soda mixed with 1 quart 1 liter of water Spray the solution on all metal components near the batteries also Allow the solution to set a minimum of three minutes Use a soft bristle brush or cloth to clean the top of each battery to remove residue that can cause the discharge of the battery Clean the area with low pressure clear water Be careful when you use aerosol containers near the battery terminals Use a container with insu lation to prevent an explosion Clean one time a month or more often in harsh conditions After the batteries are clean and dry apply a commercially available protectant to the terminals 42 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Battery Replacement Remove the battery hold downs and cables Remove the batteries with a commercially available lifting device If the batteries are cleaned and acid in the battery rack area is neutralized as recommended no corrosion to the battery racks or surrounding area should be found Any corrosion found must be removed with a putty knife and a wire brush The area must be washed with a solution of sodium bicarbonate baking soda and water and dried before primer and corrosion resistan
52. operating vehicle To prevent personal injury or death observe the following When vehicle is to be left unattended engage park brake move direction selector to neutral turn key to OFF position and remove from key switch Drive vehicle only as fast as terrain and safety considerations allow Con sider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of direction may result in loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc All travel should be directly up or down hills use extra care if ever forced to drive across an incline Stay in designated areas and avoid steep slopes Activate the park brake when the vehicle is parked Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Make sure direction selector is in desired position before starting the vehicle Slow down before and during turns All turns should be executed at reduced speed Always bring vehicle to a complete stop before shifting direction selector See GENERAL SPECIFICATIONS for vehicle load and seating capacity NOTICE Read the following information and warnings before operating vehicle In any product
53. ow roll back when you start the vehicle on a hill Put left foot on the brake pedal and release the parking brake Press the accelerator with right foot and release the brake pedal Coasting Do not allow the vehicle to coast at above recommended speeds Control vehicle speed with the brake The vehicle has a braking feature pedal up that decreases the speed when the accelerator pedal is released The fea ture continues to decrease the speed until the vehicle stops Press the brake pedal if you need to decrease speed or stop the vehicle quickly SUN TOP AND WINDSHIELD IF EQUIPPED The sun top does not supply protection from roll over or falling objects The windshield does not supply protection from tree branches or moving objects The sun top and windshield supply some protection from the elements but do not keep the operator and passenger dry in heavy rain 26 Owner s Guide OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide 27 OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Oi 28 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers MAINTENANCE VEHICLE CLEANING AND
54. resistant containers with absorbent material sand or earth and discard according to local state and federal reg ulations for acid and lead compounds Contact local or state environmental authorized peo ple for the disposal information i Owner s Guide SAFETY GENERAL last dual 1 NOTICES CAUTIONS WARNINGS AND DANGERS 1 GENERAL OPERATION iecore RE coc i tetris e dre od cree Hg 3 MAINTENANCE z 4 LABELS PICTOGRAM S Sect nuevas serv ruo tu er ua Pet cda 5 GENERAL SPECIFICATIONS VEHICLE DIMENSIONG ettam tec tne rnt etae o 8 TURNING DIAMETER AND INCLINE INFORMATION eene 9 INTRODUCTION PEA gcc a 11 General Information erc ety y taedis 11 IKey and 11 State of Charge nennen 11 Direction Selector 12 Accelerator Pedal isis der e 12 Brake and eid eens edd ee iocus 12 Charger Receptacle if 12 CE Charger Receptacle 12 AC Outlet IT quippedg coit eir este iecore deir eiie aii 13 GE SCAU LOCK qu
55. ressure See Recommended Tire Pressures on page 31 General Check for possible leaks that may have started during shipment CHARGER Both off board and on board chargers must be operated according to the charger manufacturer s instructions An on board charger is standard equipment on this vehicle If the vehicle has the off board charger option make sure you keep and follow the operation instructions supplied with the charger Always remove the off board charger from the vehicle before and during the charge cycle Never charge the batteries in a hazardous environment DANGER Risk of electric shock Connect the charger power cord to an outlet that is correctly installed and connected to an electrical ground according to all codes and regulations A grounded outlet is necessary to decrease the risk of electric shock do not use ground adapters or replace the plug Do not touch parts of output connector or battery terminals that do not have insulation Disconnect the DC plug before you make or break the connections to a battery that is charging Do not open or disassemble the charger Do not operate the charger if the AC cord is damaged Make sure qualified personnel does all repair work to the charger Refer to APPENDIX A for the charger manufacturer User s Guide for operation instructions maintenance instructions and fault diagnosis On Board Charger To decrease the risk of electrical shock or electrocution make sur
56. ry ages the specific gravity of the electrolyte will rH 022 Above 70 F 21 C decrease at full charge This is not a reason to replace the 20 6 024 READING 1 250 battery providing all cells are within fifty points of each other HH 026 1250 004 1 246 Since the hydrometer test is in response to a vehicle exhibit 10 12 028 Ai ing 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 Battery Charger Maintenance Connect the charger plug into the vehicle receptacle and wait for the relay to activate Hydrometer Temperature Correction Move the plug back and forth in the receptacle If the charger turns off check the plug for a broken red wire in the DC cord 46 Owner s Guide MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide 47 MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes at 48 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers PERIODIC SERVICE SCHEDULE
57. s decreased Capacity describes the time that a battery can continue to supply its design amperes from a full charge A battery has a maximum life Good maintenance maximizes the available life and decreases the conditions that can reduce the life of the battery Battery Maintenance Tool List Quantity List Quantity Insulated Wrench 9 16 1 Battery Cannel 1 Hydromil o EE 1 Battery Maintenance Kit P N 25587 G01 1 Battery Protective 1 SOCKeL 9 16 4 undi I et te T 1 Torque Wrench 1 At Each Charging Cycle e Before you charge the batteries inspect the plug of the battery charger and vehicle receptacle housing for dirt or other particles Charge the batteries after each use Monthly Inspect all wires for wear loose connections corrosion or damage of insulation Make sure that the electrolyte level is correct and add clean water as required Clean the batteries and wire connections e Apply battery protectant to the battery terminals Electrolyte Level and Water The correct level of the electrolyte is 1 2 13 mm above the plates in each cell This level will leave approximately 1 4 3 8 6 10 mm of space between the electrolyte and the vent tube The electrolyte level is important because any part of the plates open to air will be damaged Do no
58. sure the truck bed does not accidentally drop during lift or lower procedure If the truck bed drops fingers or other body parts can be trapped To lift the truck bed pull up the latch release handle behind the driver seat Use the latch handle to lift up on the truck bed Use the latch handle to lower the truck bed into the resting position Make sure your hands are not trapped by the truck bed Electric Lift Operation Make sure your clothing can not be caught while you oper ate the electric lift Make sure your fingers and other body parts can not be caught while you operate the electric lift Before you operate the electric lift make sure no one is behind the vehicle Move the switch upward to raise the truck bed Move the switch downward to lower the truck bed Tailgate Operation Open the tailgate Liftthe tailgate upward with a sharp pull e Pivot out for open position Remove the tailgate e Remove the side cables from the truck bed Open the tailgate and allow to swing completely down e Lift the tailgate upward to remove from the pins and the truck bed PERFORMANCE The speed of the motor is sensed and controlled by the controller Owner s Guide 23 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Speed Control Regenerative Braking The motor speed is sensed and controlled by the controller As the vehicle
59. t is packed in closed areas to help with removal Be careful not to damage the paint ENVIRONMENTAL CONCERNS As a responsible user practice respect for all wildlife and their habitat Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles Always be respectful of the environment Make sure you are permitted by property owners to operate the vehicle on their property There is a risk of fire when the vehicle is operated near combustible material Be careful of environmental hazards like steep slopes tree branches etc Owner s Guide 29 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Battery Disposal Return used batteries to the manufacturer or lead smelter for recycling purposes For neutralized spills put residue in acid resistant containers with absorbent material sand or earth and discard according to state and federal regulations for acid and lead compounds Contact authorized environmental people for information about disposal LIFTING THE VEHICLE You must lift the front the rear or the entire vehicle for some service and maintenance operations The vehicle is not stable during the lifting process Make sure the vehicle is on a hard and level surface Never get below a vehicle that is supported by a jack only Make sure a vehicle that is supported on jack stands is stab
60. t overfill with water Too much water pushes the electrolyte from the battery by release of gas and a decrease in volume of the electrolyte DO NOT overfill batteries The charge cycle will expel electrolyte and cause component damage 40 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers A battery being charged will gas with most gassing occurring at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulphuric acid droplets will be car ried out of the battery vents by the hydrogen gas however this loss is minimum If the electrolyte level is high the elec trolyte will block the vent tube and the gas will push it out the vent tube and battery cap The water will dry but the sulphuric acid will stay and damage the vehicle components and the storage facility floor Sulphuric acid loss will weaken the amount of acid within the electrolyte and decrease the life of the battery Over the life of the battery a large amount of water is used The water used must be clean and without contamination Water that is not clean decreases the life of the battery by reducing the chemical reaction Use distilled water or filtered water only Test water that is not distilled water and filter if needed Refer to the water purity table for requirements Hand held watering devices available at an automotive parts stor
61. t paint is applied Put the batteries in the battery racks and tighten the hold downs to 45 55 in lbs 5 6 Nm torque The hold downs must be tight enough to prevent movement of the battery but not tight enough to cause distortion of the battery cases Inspect all wires and terminals Clean corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate baking soda and soft brush if needed Be careful when you use aerosol containers near the battery terminals Use a container with insu lation to prevent an explosion Make sure you connect the battery wires as shown WHT from i z Charger From Battery Tighten the battery post hardware to 90 100 in Ibs 6 8 Temp Sensor Front of Vehicle Nm torque Do not over tighten the terminal stud nut this will cause a mushroom effect on the battery post which will pre vent the terminal nut from being correctly tightened Receptacle Protect the battery terminals and battery wire terminals with a commercially available coating BLU from Receptacle To Charger Owner s Guide 43 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Prolonged Storage Disconnect the battery charger controller and other electronic devices for extended storage All connected electronic components cause the discharge of batteries During storage the batt
62. th the drive wheels lifted off the ground Disconnect the negative battery terminal before you service the vehicle to prevent accidental operation 34 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Wear eye protection when you service the vehicle Be careful when you do work around batteries use solvents or compressed air To decrease the risk of electrical arc which can cause a battery explosion dis able all electrical loads from the battery before you remove the battery wires Use wrenches with insulation to decrease the risk of a short circuit if a wrench falls across the bat tery terminals A battery short circuit can cause an explosion The electrolyte in a battery is an acid solution which can cause burns to the skin and eyes Com pletely clean all electrolyte spills that contact the body and eyes with clear water Contact a physi cian immediately Neutralize electrolyte spills with a solution of 2 teaspoons 10 ml sodium bicarbonate baking soda mixed in 1 quart 1 liter of water Clean with water Be careful when you use the aerosol containers near battery terminals Use a metal container that has insulation to prevent an explosion The vehicle owner and service technician must carefully follow the procedures recommended in this manual The pre ventative maintenance applied at recommended intervals keeps the ve
63. ther people in the area Do not allow children or anyone without a license to operate the vehicle Children may not have the skill and ability to make good decisions or strength to operate the vehicle Drugs and alcohol decrease the ability of the driver to operate the vehicle safely Always check with a medical profes sional before you operate the vehicle When you drive the vehicle at full speed on dirt road loose surface or wet grass the necessary distance to stop the vehicle will increase The necessary distance to stop a loaded vehicle is more than the necessary distance to stop a vehi cle without a load In wet weather conditions apply light pressure to the brakes to supply enough friction to dry the brake unit Wet brakes lose much of their effect If you drive on a steep hill and can not get enough traction do not try to turn around on the hill Slowly drive in the reverse direction and use the brake to control the speed Key and Light Switch Operation When you leave the vehicle turn the key to the OFF position and remove from the switch to pre vent accidental operation To prevent possible damage to the components stop the vehicle before you move the key switch or the direc tion selector to a different position Turn the key to the right to enable the electrical system of the vehicle The first stop is ON and supplies power that allows you to drive the vehicle The second stop has a light icon and activates the lights Wh
64. tion and remove from N the switch NOTICE If the vehicle has accessories that were installed at the factory some accessories continue to operate with the key switch in the OFF position 2 State of Charge Meter The illuminated state of charge meter is found on the instrument panel near the key switch The meter indicates the amount of power within the batteries F indicates a full charge on the battery pack and E indicates the battery pack needs to be charged The yellow light indicates the batteries must be charged immediately Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 3 Direction Selector To prevent loss of control or possible damage to the vehicle do not move the direction selector while the vehicle is in motion The direction selector is found on the seat wrap panel and allows the operator to select F forward or R reverse or N neutral When the direction selector is moved to the R position a reverse warning buzzer activates Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause severe injury or death 4 Accelerator Pedal With the key switch in the ON position press the accelerator pedal to start the motor When the pedal is released the motor will stop To stop the vehicle immediately press the brake pedal 5 Brake and Parking Brake Pedal
65. tion to Notices Cautions Warnings and Dangers charger connector cord set must be protected from damage The charger connector cord set must be used in an area where it is not possible for personnel to run over or trip over the cord set charger automatically turns off during the connect and disconnect cycle so no electrical arc is generated at the DC plug and receptacle contacts AC Voltage The battery charger output is directly related to the input voltage If the vehicle receives an incomplete charge in a nor mally adequate time period low AC voltage can be the cause Consult an electrician if necessary Fault Diagnosis Fault diagnosis is done for two reasons Abattery that performs poorly and is outside of the manufacturers specification must be identified to replace it within the terms of the manufacturer s warranty Different manufacturers have different requirements Refer the battery manufacturer or the manufacturer s representative for specified requirements Find the reason a vehicle does not perform adequately Performance problems can cause a vehicle to run slowly or can not operate for the time needed A new battery must mature before it develops its maximum capacity Maturing can take 100 or more charge and dis charge cycles After the maturing phase the older a battery gets the lower the capacity The only method to find the capacity of a battery is a load test with a discharge machi
66. tion to some electrical components and vehicle accessories The fuse block is found on the driver side fender liner below the truck bed 14 Owner s Guide INTRODUCTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide INTRODUCTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 16 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers OPERATING PROCEDURES SERIAL NUMBER LOCATION The PIN plate is attached to the frame below the seat wrap panel Two serial number and manufacture date code labels are on the vehicle One label is found on the steering column The second label is found on the chassis below the drivers side of the cowl Design changes occur continuously When you order service parts the PIN number manufacture date code or serial number must be provided to ensure correct parts for your vehicle Serial Number PART A PART B EZGO 2 AUS ee 7 DO NOT APPLY SERIAL 5083125 TOVEHICLE 5083125 mew 508 25 31 t of Vehicle BEFORE INITIAL USE Read understand and follow the safety label on the instrument panel
67. tions Warnings and Dangers TURNING DIAMETER AND INCLINE INFORMATION TURNING CLEARANCE DIAMETER 24 ft 7 3 m Owner s Guide GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 10 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers INTRODUCTION FEATURES General Information NOTICE If the vehicle has accessories that were installed at the factory some accessories continue to operate with the key switch in the OFF position ALL accessories that do NOT use the accessory wiring harness MUST be connected to the DC to DC con verter to pull from the full 48 Volt battery pack A DC to DC converter is necessary for the accessories that need voltage different from 48 volts to operate correctly All accessories connected to the vehicle that do not use the accessory harness must be connected to the DC to DC con verter 1 Key and Light Switch To decrease the risk of component damage stop the vehicle before you move the key switch or the direction selector D A The key and light switch is found on the instrument panel The switch controls the LNN basic electrical system of the vehicle and the lights To prevent accidental opera f Q tion of an unattended vehicle turn the key the OFF posi
68. uirements 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 changes that change an E Z GO product into a Low Speed Vehicle LSV Anyone who operates this vehicle must be A LICENSED DRIVER AND OPERATE THE VEHICLE ACCORDING TO APPLICABLE STATE REQUIREMENTS This rule is important to the SAFE USE AND OPERATION of the product All customers must obey this SAFETY RULE Information on FMVSS 571 500 is found at Title 49 of the Code of Federal Regulations section 571 500 For information online go to www ecfr gov Vehicles are used for different purposes so it is not possible to know and inform of every possible occurrence Be careful when you drive to prevent avoidable personal injury or damage to the vehicle All users must read and obey this manual Make sure you give special attention to the CAUTIONS WARNINGS and DANGERS For questions about this vehicle contact your E Z GO CUSHMAN dealer or write to the address on the back cover of this publication Attention Customer Care Department E Z GO has the right to change the design of the vehicle There is no responsibility to make the changes on units pur chased before
69. w rated pressure Do not use tires that have a recommended tire inflation pressure less than the tire inflation pressure recommended in the owner s guide Do not over inflate the tires Excess pressure can cause the tire to separate from the wheel or cause a tire explosion Recommended Tire Pressures PART NUMBER TIRE SIZE RECOMMENDED PSI 12 15 5 83_103 Tire Repair Tool List Quantity Tool List Quantity Lug Wrench 3 47 044 0080 00 1 Impact Socket 3 4 1 Impact Wrench 1 Torque Wrench ft Ips ioca Eze vea 1 Owner s Guide 31 Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Use caution when you inflate the tires Because of the low volume of the small tires over inflation can occur in seconds Over inflation can cause the tire to separate from the wheel or cause a tire explosion See Recommended Tire Pressures on page 31 for recommended inflation pressures but inflation pressure can be adjusted according to the condition of the terrain For outdoor applications with primary use on areas with grass consider the following Slightly higher tire inflation pressure is suitable on hard turf e A lower pressure decreases the risk of tires cutting into a soft turf For hard surfaces or pavement tire inflation pressure must be in the higher allowed range but not more than recom mended
70. when working around batteries using sol vents or compressed air Hydrogen gas forms when charging batteries Do not charge batteries without adequate ventilation Do no permit open flame or smokers in an area being used for charging batteries A concentration of 4 hydrogen gas or more is explosive CONTACT US Bad Boy Buggies 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA FAX 855 256 9900 E mail info badboybuggies com E BAD BOY For parts and repair contact local dealer Dealers can be located at www BADBOYBUGGIES com Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
71. y and the safety of other people in the area Some components are heavy spring loaded corrosive explosive can cause high amperage or get hot Battery acid and hydrogen gas can cause injury Do not put your hands face feet or body in a location that can expose them to injury if an unexpected situation occurs Always use the correct tools shown in the tool list and wear safety equipment Owner s Guide Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Remove all jewelry before you service the vehicle Do not allow loose clothing or hair to contact the moving parts Do not touch hot objects When you service the vehicle always wear eye protection Be careful when you do work around batteries or you use solvents or compressed air ALWAYS Use the vehicle with responsibility and keep the vehicle in safe condition for operation Read and obey all warnings and operation instruction labels on the vehicle Follow all safety rules in the area where the vehicle is operated When there is a risk of lightning leave the vehicle and look for a safe location to wait until the lightning has stopped Drive the vehicle only as fast as terrain and conditions allow Apply brake to control the speed on steep grades Keep enough distance between vehicles Decrease speed in wet areas Be careful when you make sharp turns or turns you are not familiar with
72. ystem 72 Vot Batteries Qty Type Nine 8 Volt Deep Cycle Frame Welded steel DuraShield powder coat Key or Pedal Start Pedal Start Front Body amp Finish Injection molded TPO Battery Charger 900 Watt 72VDC Standard Color Matte black Speed Controller 350 Amp AC Noise amp Vibration Drive Train Motor shaft direct drive Noise Sound pressure continued A weighted lt 70 db A Transaxle Differential with helical gears Vibration WBV Highest RMS value of weighted acceleration less than 2 5 m s Gear Selection Seat wrap mounted F N R Vibration HAV Highest RMS value of weighted acceleration less than 2 5 m s The uncertainty of measurement is 0 12 m s Rear Axle Ratio 174 Measurement methods were applied per the ISO 2631 and ISO 5349 N Owner s Guide Read all of SAFETY this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers VEHICLE DIMENSIONS 78 in 198 cm 37 in 94 cm 111 in 281 cm 38 in 97 cm m 36 91 cm RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP GRADE 25 or 149 MAX 25 or 149 MAX 8 Owner s Guide Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cau

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