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Industrial 875 Personnel Carrier 05

1. r Fig 23 36V 4 Passenger Battery Connections If the batteries have been cleaned and any acid in the battery rack area neutralized as recommended no corro sion to the battery racks or surrounding area should be present Any corrosion found should be immediately removed with a putty knife and a wire brush The area should be washed with a solution of sodium bicarbonate baking soda and water and thoroughly dried before priming and painting with a corrosion resistant paint The batteries should be placed into the battery racks and the battery hold downs tightened to 45 55 lbs 5 6 Nm torque to prevent movement but not tight enough to cause distortion of the battery cases Inspect all wires and terminals Clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate baking soda and brush clean if required To prevent battery explosion that could result in severe personal injury or death extreme care must be used with aerosol containers of battery terminal protectant Insulate the metal contain er to prevent the metal can from contacting bat tery terminals which could result in an explosion Page 21 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Use care to connect the battery wires as show
2. a Dual rear wheel hydraulic drum brakes Hand operated parking brake with manual adjustment Front hydraulic brakes optional FRONT 5 Independent leaf spring with hydraulic shock absorbers REAR SUSPENSION u u an anan aa Leaf springs with hydraulic shock absorbers SEATING ie o are nin a ie Ros Formed fabric backed vinyl covers over cushion foam Seating for operator and three passengers SPEED oe aee ede ee ede npe Up to 13 5 mph 21 7 km h TRANSAXEE ice ection ee ie eec tee etes Direct drive 14 76 1 ratio CLASSIFICATION te serere verior a UL Underwriters Laboratory Approved type E classification ELECTRICAL 5 5 36 volt DC six 6 volt heavy duty deep cycle storage batteries 115 minute 225 amp hour 9 20 hour discharge rate SPEED GONTROL 15 netter NRBEM Solid state controller 400 amp rated MOTOR Sum 36 volt DC high efficiency series wound brazed armature solid copper windings vented 8 hp 6kw at 1600 rom CHARGE R Sea smsung eo eee eee PowerWise on board 21 amp DC output at 36 volts input 110 120 volts 9 5 amps 60 cycle AC Underwriters Laboratory UL Listed CSA Certified anti drive away charger vehicle interlock Page 32 Owner s Manual and Service Guide GENERAL SPECIFICATIONS INDUSTRIAL 875 36V PC 4 Passenger From Mid 2007 WEIGHT without batteries
3. 6 2 Operation Experience has shown that carriers which comply with the provisions stated in paragraph 9 3 9 are stable when properly operated and when operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions However improper operation faulty maintenance or poor housekeeping may contrib ute to a condition of instability and defeat the purpose of the standard Some of the conditions which may affect stability are failure of the user to follow safety practices also ground and floor conditions grade speed loading the operation of the carrier with improper loads battery weight dynamic and static forces and the judgment exercised by the carrier operator a The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard b The user shall survey specific operating conditions and environment and establish and train carrier operators to comply with additional specific safety practices 6 3 Nameplates Markings Capacity and Modifications 6 3 1 The user shall maintain in a legible condition all nameplates warnings and instructions which are supplied by the manufacturer 6 3 2 Except as provided in 6 3 4 no modifications or alterations to a carrier which may affect the capacity stability or safe operation of the carrier shall be made without the prior written approval of the original carrier manufacturer or a
4. 4427 1 Textron OWNER S MANUAL and SERVICE GUIDE INDUSTRIAL 875 REVISED DATE January 2007 SAFETY For any questions on material contained in this manual contact an authorized representative for clarification Read and understand all labels located on the vehicle Always replace any damaged or missing labels On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface To pre vent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS Limit speed by applying the service brake Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessive speed may cause a loss of vehicle control is costly is considered abuse and will not be covered under warranty For towing transporting vehicle refer to TRANSPORTING VEHICLE Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition BATTERIES ND RELATED PART CONTAIN LEAD BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm WASH HANDS AFTER HANDLING WARNING Battery posts terminals and related accessories contain lead and lead co
5. SIEERING nie he wee See Automotive with steering wheel BRAKES Dual rear wheel hydraulic drum brakes operated parking brake with manual adjustment Front hydraulic brakes optional FRONT SUSPENSION a Independent leaf spring with hydraulic shock absorbers REAR SUSPENSION ettet Leaf springs with hydraulic shock absorbers SEATING iet Ert ER rot CERTE Formed fabric backed vinyl covers over cushion foam Seating for operator and one passenger TRANSAXLE cH E ERES Direct drive 14 76 1 ratio CLASSIFICATION estie eet UL Underwriters Laboratory Approved type E classification ELECTRICAL SYSTEM 48 volt DC eight 6 volt 225 amp hr batteries Precision Drive System PDS electronic speed controller Regenerative braking Batteries contained in swing out battery trays 1 per side DIRECTION SELECTOR Electronic Three position switch SPEED CONTROL Solid State continuously variable speed controller GHAR GER d tee EUER Lestronic fully automatic 48 volt output 25 amp On board MOTOR teet ite High efficiency DC shunt wound brazed armature solid copper windings SPEED it eot o Ma ete d nette det Up to 13 5 mph 22 kph Melle Sound pressure continuous A weighted 7
6. USE CARE LIFTING USE INSULATED TOOLS NO 23 E TAMPERING Ml KEEP HANDS WEAR EYE OUT PROTECTION 24 WARNING CORROSIVE 34 NO SMOKING WARNING 25 EXPLOSIVE 35 HOT SURFACE WARNING 26 LETHAL VOLTAGE Ref Pic 1 2 Owner s Manual and Service Guide Appendix A 5 LABELS AND PICTOGRAMS OPERATE KEEP CLEAR FROM 42 HAND OR DRIVERS SIDE FINGERS CAN ONLY BE TRAPPED 43 I ON ON POSITION KEEP ARMS OFF sees 44 WITHIN VEHICLE OFF POSITION 45 EEE lt gt TO OPERATE VEHICLE IN FORWARD TURN KEY TO ON MOVE DIRECTION SELECTOR 46 FORWARD i DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY UNLOCKED LOCKED TO OPERATE VEHICLE IN REVERSE TURN KEY TO ON MOVE DIRECTION SELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY DIFFERENTIAL LOCKED TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO WARNING FORWARD KEEP ENTIRE BODY INSIDE CAR TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO NEUTRAL POSSIBILE ELECTRIC ARC OR BATTERY EXPLOSION WEAR EYE PROTECTION Bs m Ref Pic 1 3 Appendix A 6 Owner s Manual and Service Guide LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD DEPRESS PEDAL RELEASE amp DEPRESS PEDAL SIMULTANEOUSLY R
7. s imi Fig 15 Lubrication Points Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Hardware Periodically the vehicle should be inspected for loose fasteners Fasteners should be tightened in accordance with the Torque Specifications table Ref Fig 17 on page 17 Use care when tightening fasteners and refer to the Technician s Repair and Service Manual for specific torque values Generally three grades of hardware are used in the vehi cle Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head Unmarked hardware is Grade 2 Ref Fig 17 on page 17 Owner s Manual and Service Guide Page 15 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings PERIODIC SERVICE SCHEDULE Check Clean Adjust etc A Replace To perform service that is listed in this schedule but not described in this manual contact a local Service Representa tive or see the Repair and Service Manual for this vehicle NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions BEFORE USE V Check foot brake general operation Che
8. 22 Fig 26 48V 2 Passenger Battery Connections u 22 PROLONGED STORAGE rnit Ee e Ca RR degen 22 Fig 27 Freezing Point of Electrolyte eese eene eene nnne nnno 23 BATTERY CHARGING e e a ere EC ode oa eee PAR REESE ER passe 23 AG VOLTAGE emet eiii iim Hee e ien a a RE ERR 23 TROUBLESHOOTING taret te en t tte rene tite lc c e o ee tee pec da Nee eq ted n e d 23 HYDROMETER iniit hn eT eR teen een ne Se 24 Pig 28 HydrOme l r u ides So s uksa cl EE BL E AME Ed puteis ue E 24 HYDROMETER REA etia idi tes ER rens 24 Fig 29 Hydrometer Temperature Correction u 25 GENERAL SPECIFICATIONS 5 ce ee cate ee 27 INDUSTRIAL 875 36V 2 Passenger Model Year 2005 Mid 2007 28 INDUSTRIAL 875 36V 2 Passenger From Mid 2007 29 Page iv Owner s Manual and Service Guide TABLE OF CONTENTS INDUSTRIAL 875 48V 2 Passenger Model Year 2005 Mid 2007 30 INDUSTRIAL 875 48V 2 Passenger From Mid 2007 31 INDUSTRIAL 875 36V PC 4 Passenger Model Year 2005 Mid 2007 32 INDUSTRIAL 875 36V PC 4 Passenger
9. 3 000 Ibs 1360 kg CHASSIS BODY amp FINISH eee 1 place with welded high yield strength tubular steel with powder coat pain Heavy duty four way diamond pattern body Safety yellow modified acrylic topcoat over polyester primer NE Removable dash mounted key switch reverse warning indicator deadman accelerator control operator presence seat switch integral handgrip on hip restraints forward reverse selector with neutral and electric horn LIGHTING PACKAGE a Dual taillights brake lights optional headlights STEERING 2222 Automotive with steering wheel DM Dual rear wheel hydraulic drum brakes Hand operated parking brake with manual adjustment Front hydraulic brakes optional FRONT SUSPENSION Independent leaf spring with hydraulic shock absorbers REAR SUSPENSION iienaa cede cea Leaf springs with hydraulic shock absorbers SEATING mti ts c oe ett coros ot as Formed fabric backed vinyl covers over cushion foam Seating for operator and one passenger SPEED deeded eee Up to 13 5 mph 21 7 km h TRANSAXLE niana anun t n ph ua ub q N Direct drive 14 76 1 ratio CLASSIFICATION u int tete ce h ien UL Underwriters Laboratory Approved type E classification ELECTRICAL SYSTEM Rete eer rers 36 volt DC six 6 volt heavy duty deep cycle storage batteries 115 minute 225 amp hour 9
10. 7 3 1 7 Maintain a safe distance from potential hazards such as edges of ramps and platforms 7 3 1 8 Use only approved carriers in hazardous locations as defined in the appropriate safety standards 7 3 1 9 Report all accidents to the user 7 3 1 10 Do not add to or modify the carrier 7 3 1 11 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles access to stair ways or fire equipment 7 3 1 12 Only operate carrier while within operator s station 7 3 2 Traveling 7 3 2 1 Observe all traffic regulations including authorized speed limits Under normal traffic conditions keep to the right Maintain a safe distance based on speed of travel from a carrier or vehicle ahead and keep the carrier under control at all times 7 3 2 2 Yield the right of way to pedestrians ambulances fire trucks or other carriers or vehicles in emergency sit uations 7 3 2 3 Do not pass another carrier or vehicle traveling in the same direction at intersections blind spots or at other dangerous locations 7 3 2 4 Keep a clear view of the path of travel observe other traffic and personnel and maintain a safe clearance 7 3 2 5 Slow down or stop as conditions dictate and activate the sound producing warning device at cross aisles and when visibility is obstructed at other locations 7 3 2 6 Ascend or descend grades slowly 7 3 2 7 Avoid turning if possible and use caution on grades ramps or incline
11. eene 1124 Ibs 510 kg GROUND CLEARANCE at differential 5 in 12 7 cm TIRES btt etait tee eee eL ets Sure Trail Industrial 5 70 x 8 LRC TIRE PRESSURE eni ie eite niece tete e 70 psi 483 kPa LOAD CAPACITY including operator passenger cargo and accessories 3 000 Ibs 1360 kg CHASSIS BODY amp FINISH esse 1 with welded high yield strength tubular steel with powder coat pain Heavy duty four way diamond pattern body Safety yellow modified acrylic topcoat over polyester primer SAFETY ttt meth ett hte te fs Removable dash mounted key switch reverse warning indicator deadman accelerator control operator presence seat switch integral handgrip on hip restraints forward reverse selector with neutral and electric horn LIGHTING PACKAGE uu u ne etenim Dual taillights brake lights optional headlights STEERING ahi aia ie aie a as Automotive wheel type 5 Enden Dual rear wheel hydraulic drum brakes Hand operated parking brake with manual adjustment Front hydraulic brakes optional FRONT SUSPENSION a Independent leaf spring with hydraulic shock absorbers REAR SUSPENSION oo 5 2 2 count idee tief ette cac t Leaf springs with hydraulic shock absorbers SEATING iet rre et ee Fo
12. 20 hour discharge rate SPEED GONTROL e c eae Solid state controller 400 amp rated MOTOR 5 ite o I ERE BEER 36 volt DC high efficiency series wound brazed armature solid copper windings vented 8 hp 6kw at 1600 rpm CHARGER siehe eeu ae PowerWise on board 21 amp DC output at 36 volts input 110 120 volts 9 5 amps 60 cycle AC Underwriters Laboratory UL Listed CSA Certified anti drive away charger vehicle interlock NOISE 3 tte re date hat tutu Sound pressure continuous A weighted lt 70 dB A VIBRATION WBV unus q ood Su ee The weighted RMS acceleration is 0 7 m s2 VIBRATION HAV 2 u a Qu Suma s The weighted RMS acceleration is less than 2 5 m s Owner s Manual and Service Guide Page 29 GENERAL SPECIFICATIONS INDUSTRIAL 875 48V 2 Passenger Model Year 2005 Mid 2007 WEIGHT without batteries 1740 Ibs 790 kg GROUND CLEARANCE at differential 5 in 12 7 cm MRES uie Sure Trail Industrial 5 70 x 8 LRC TIRE PRESSURE rec 70 psi 483 kPa LOAD CAPACITY including operator passenger cargo and accessories 3 000 Ibs 1360 kg CHASSIS BODY amp 1 with welded high yield strength tubular steel with powder coat pain Heavy duty four way diamond pattern body Safety y
13. Owner s Manual and Service Guide VEHICLE WARRANTIES NOT AVAILABLE AT THE TIME OF PUBLICATION Owner s Manual and Service Guide Page 41 VEHICLE WARRANTIES Notes Page 42 Owner s Manual and Service Guide LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner s Manual and Service Guide Appendix A 1 LABELS AND PICTOGRAMS 827664 oe 29165G01 600945 4115473 819936 830926 832080 BETWEEN SEATS COMMON ALL MODELS 86V ONLY 4 PASSENGER ONLY 48V MODEL ONLY See Following Pages for Explanation of SWING OUT BATTERY TRAY MODELS Pictograms 1 2 7 8 10 11 12 Appendix A 2 Owner s Manual and Service Guide LABELS AND PICTOGRAMS 825394 600945 E l O j 832080 29165601 827664 4115473 73398G01 BETWEEN SEATS 606003 ws COMMDON ALL MODELS 86V ONLY 4 PASSENGER ONLY See Following Pages for Explanation of MODEL ONLY Pictograms 1 2 7 8 10 11 12 SWING OUT BATTERY TRAY MODELS Owner s Manual and Service Guide Appendix A 3 LABELS AND PICTOGRAMS NOTE Not all labels and pictograms illustrated are pertinent to the vehicle model See A 2 A 3 for specific labels and pictograms WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY M
14. Safety Interlocks The user shall make periodic inspections of the carrier to be certain that the safety interlock system if so equipped is operating properly 7 OPERATING SAFETY RULES AND PRACTICES 7 1 Personnel and Burden Carrier Operator Qualifications Only persons whoa are trained in the proper operation of the carrier shall be authorized to operate the carrier Oper ators shall be qualified as to visual auditory physical and mental ability to safely operate the equipment according to Section 7 all other applicable parts of this Standard and the operators manual 7 2 Personnel and Burden Carrier Operators Training 7 2 1 The user shall conduct an operators training program 7 2 2 Successful completion of the operators training program by the operator shall be required before operation of the carrier The program shall be presented in its entirely to all new operators and not condensed for those claiming previous experience 7 2 3 The user shall include as a minimum in the operators training program the following a Instructional material provided by the manufacturer including the operators manual b Emphasis on safety of passengers material loads carrier operator and other person s c General safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were formulated d Introduction of equipment control locations of the environme
15. V Check for unusual tire wear align if required Fig 16 Periodic Service Schedule Page 16 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Check for smooth operation of lever Check for damage to ratchet PARK BRAKE Check that park brake holds vehicle at click Lubricate as required use light oil DO NOT LUBRICATE CABLES OR BRAKE LATCH REAR SHOCK ABSORBERS V Check for oil leakage loose mounting hardware V Check for loose or missing hardware and components Tighten or replace missing hardware HARDWARE AND FASTENERS DIRECTION SELECTOR y Check for wear and smooth movement lubricate shaft with light oil if required KING PINS V Check for excessive play and tightness of retaining nuts STEERING ASSEMBLY Check bellows and pinion seal for damage or grease leakage GREASE FITTINGS Lubricate use wheel bearing grease REAR AXLE Check for unusual noise and loose or missing mounting hardware FRONT WHEEL BEARINGS Check and adjust as required see Technician s Repair and Service Manual REAR AXLE v Check lubricant add lubricant SAE 30 oil as required Clean and adjust see Technician s Repair and Service Manual foot brakeS Check brake shoe linings see Technician s Repair and Service Manual V Check brake fluid Fig
16. adequately secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehicle see GENERAL SPECIFICATIONS for vehicle weight and load plus 1000 Ibs 450 kg Lock the park brake and secure the vehicle using ratchet tie downs SERVICE AND MAINTENANCE To reduce the possibility of severe injury or death from improper servicing techniques Do not attempt any type of servicing opera tion before reading and understanding all notes cautions and warnings in this manual Any servicing requiring adjustments to be made to the powertrain while the motor is Page 11 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings running must be made with both drive wheels raised and vehicle properly support ed on jack stands To reduce the possibility of motor damage never operate vehicle at full throttle for more than 4 5 seconds while vehicle is in a no load condition Wear eye protection when work ing on vehicle Use extra care when working around batteries using solvents or compressed air To reduce the possibility of causing an elec trical arc which could result in a battery explosion turn off all electrical loads from the battery before removing battery wires Wrap wrenches with vinyl a tape to reduce the possi bility of a dropped wrench shorting out a ba
17. components and the storage facility floor Sulfuric acid loss will weaken the concentration of acid within the elec trolyte and reduce the life of the battery Over the life of the battery a considerable amount of water is consumed It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction The Owner s Manual and Service Guide Page 19 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings water must be distilled or purified by an efficient filtration system Water that is not distilled should be analyzed and if required filtration installed to permit the water to meet the requirements of the water purity table Ref Fig 20 on page 20 Impurity Parts Per Million hs i Clear SUspelded co uu Su oen sni Trace Total SolidS eee u tr e nd Calcium amp Magnesium Oxides lt R R ee s Organic amp Volatile 5 Nitrates oom eee ce I 10 Chloride uuu 5 Wpt 1S Fig 20 Water Purity Table Even if the water is colorless odorless tasteless and fit for drinking the water should be analyzed to see that it does no
18. in good condition and the ground pin is in place AC Voltage Battery charger output is directly related to the input volt age If multiple vehicles are receiving an incomplete charge in a normally adequate time period low AC volt age could be the cause and the power company should be consulted Troubleshooting In general troubleshooting will be done for two distinct reasons First a battery that performs poorly and is out side of the manufacturers specification should be identi fied in order to replace it under the terms of the manufacturer s warranty Different manufacturers have different requirements Consult the battery manufacturer or a manufacturer representative for specific require ments The second reason is to determine why a particular vehi cle does not perform adequately Performance problems may result in a vehicle that runs slowly or in a vehicle that is unable to operate for the time required A new battery must mature before it will develop its max imum capacity Maturing may take up to 100 charge dis charge cycles After the maturing phase the older a battery gets the lower the capacity The only way to determine the capacity of a battery is to perform a load test using a discharge machine following manufacturer s recommendations A cost effective way to identify a poorly performing bat tery is to use a hydrometer to identify a battery in a set with a lower than normal specific gravity Once the parti
19. posts terminals and related accesso ries contain lead and lead compounds Wash hands after handling This spark ignition system meets all requirements of the Cana dian Interference Causing NOTES CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER OWNER S MANUAL AND SERVICE GUIDE ELECTRIC UTILITY VEHICLES INDUSTRIAL 875 36V INDUSTRIAL 875 48V INDUSTRIAL 875 PERSONNEL CARRIER STARTING MODEL YEAR 2005 E Z GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the infor mation contained in this manual is subject to change without notice E Z GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual TO CONTACT US 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 E Z GO DIVISION OF TEXTRON INC 1451 MARVIN GRIFFIN ROAD AUGUSTA GEORGIA USA 30906 3852 Owner s Manual and Service Guide Page i GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America USA as a World Vehicle The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated Th
20. removed and replaced with a good battery of the same brand type and approximate age Electrolyte Temperature s a N 160 71 1 z 032 H H 030 150 65 6 028 H H 026 140 60 0 024 EXAMPLE 1 022 Electrolyte Temperature 020 op 27 020 Above 80 F 27 C 016 014 Electrolyte temperature 90 F 32 C ed Hydrometer reading 1 250 4 008 1 250 004 1 254 006 Corrected specific gravity 90 322 H H 004 130 544 120 48 9 110 43 3 100 37 8 002 80 26 7 0 002 70 211 004 006 EXAMPLE 2 60 15 6 008 Electrolyte Temperature 010 Below 80 F 27 C 50 10 0 012 014 Electrolyte temperature 40 44 016 70 F 21 C 30 44 eos Hydrometer reading 1 250 022 1 250 004 1 246 20 67 024 corrected specific gravity 026 10 12 1 028 Ref Htc 1 Fig 29 Hydrometer Temperature Correction Owner s Manual and Service Guide Page 25 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Notes Page 26 Owner s Manual and Service Guide GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner s Manual and Service Guide Page 27 GENERAL SPECIFICATIONS INDUSTRIAL 875 36V 2 Passenger Model Year 2005 Mid 2007
21. 0 dB A VIBRATION WBV nennen nennen nnns The weighted RMS acceleration is 0 7 m s VIBRATION HAV oet ec cte hte eis ete eec Re The weighted RMS acceleration is less than 2 5 m s Owner s Manual and Service Guide Page 31 GENERAL SPECIFICATIONS INDUSTRIAL 875 36V PC 4 Passenger Model Year 2005 Mid 2007 WEIGHT without batteries 1475 lbs 640 kg GROUND CLEARANCE at differential 5 in 12 7 cm WIRES uie Sure Trail Industrial 5 70 x 8 LRC TIRE PRESSURE uu deret Rete den 70 psi 483 kPa LOAD CAPACITY including operator passenger cargo and accessories 3 000 Ibs 1360 kg CHASSIS BODY amp 1 with welded high yield strength tubular steel with powder coat pain Heavy duty four way diamond pattern body Safety yellow modified acrylic topcoat over polyester primer i Removable dash mounted key switch reverse warning indicator deadman accelerator control operator presence seat switch integral handgrip on hip restraints forward reverse selector with neutral and electric horn LIGHTING Dual taillights brake lights optional headlights STEERING tts utet e ei Na Automotive wheel type dash
22. 0mph When E Z GO manufactured vehicle is modified an any way by the Distributor Dealer or customer to operate at or in excess of 20mph UNDER FERERAL LAW the modified product will be a Low Speed Vehicle LSV subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the Distributor or Dealer MUST equip the product with headlights rear lights turn signals seat belts top horn and all other modifications for LSV s mandated in FMVSS 571 500 and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571 565 Pursuant to FMVSS 571 500 and in accordance with the State laws applicable in the places of sale and use of the product the Distributor Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV and required to title or register the vehicle as mandated by State law E Z GO will NOT approve Distributor Dealer or customer modifications converting E Z GO products into LSV s The Company in addition recommends that all E Z GO products sold as personal transportation vehicles BE OPER ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the product On behalf of E Z GO am directing that E Z GO Branch personnel Distributors and Dealers advise all customers to adhere to thi
23. 1 000 The concentration of sulfuric acid to water in a new golf car battery is 1 280 which means that the electrolyte weighs 1 280 times the weight of the same volume of water A fully charged battery will test at 1 275 1 280 while a discharged battery will read in the 1 140 range Do not perform a hydrometer test on a battery that has just been watered The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80 27 High quality hydrometers are equipped with an internal thermometer that will measure the temperature of the electrolyte and will include a conversion scale to correct the float reading It is important to recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been operated Using A Hydrometer 1 Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading Examine the color of the electrolyte A brown or gray coloration indicates a problem with the battery and is a sign that the bat tery is nearing the end of its life 2 Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder 3 Hold the hydrometer in a v
24. 16 Periodic Service Schedule 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 8096 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 7 8 1 Grade 2 4 8 15 24 35 55 75 130 125 190 5 11 20 33 47 75 102 176 169 258 Grade 5 ED 6 13 23 35 55 80 110 200 320 480 8 18 31 47 75 108 149 271 434 651 Grade 8 65 6 18 35 55 80 110 170 280 460 680 8 24 47 75 108 149 230 380 624 922 BOLT SIZE M4 M5 M6 M8 M10 M12 M14 Class 5 8 1 2 4 10 20 35 55 Grade 2 s 2 6 90 6 64 Class 8 8 aa 2 4 7 18 35 61 97 Grade 5 N8 8 3 6 10 24 47 83 131 Class 10 9 Gos 3 6 10 25 49 86 136 Grade 8 0 9 4 8 14 34 66 117 184 Ref Tsp 1 Fig 17 Torque Specifications and Bolt Grades Owner s Manual and Service Guide Page 17 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings BATTERIES AND CHARGING Safety Always observe the following warnings when working on or near batteries To prevent battery explosion that could result in severe personal i
25. 5 in 12 cm 114 in 290 cm at Differential o 29 in 74 cm Y 66 in 168 cm 4 75 in 12 cm 114 in 290 cm at Differential Fig 30 Vehicle Dimensions Page 34 Owner s Manual and Service Guide GENERAL SPECIFICATIONS 44 5 in 113 cm RECOMMENDED MAX SDE TIT 36 75 in 93 cm Front 25 or 14 MAX 38 25 in 98 cm Rear RECOMMENDED MAX RAMP GRADE 25 or 14 MAX Fig 31 Vehicle Dimensions and Incline Specifications Owner s Manual and Service Guide Page 35 GENERAL SPECIFICATIONS Outside Turning Clearance Diameter 22 ft 6 7 m Inside Turning Clearance Diameter 102 259 cm Fig 32 Vehicle Turning Clearance Diameter Page 36 Owner s Manual and Service Guide VEHICLE WARRANTIES LIMITED WARRANTIES Owner s Manual and Service Guide Page 37 VEHICLE WARRANTIES DOMESTIC WARRANTY U S AND CANADA To obtain a copy of the limited warranty applicable to the vehicle call or write a local distributor authorized Branch or the Warranty Department with vehicle serial number and manufacturer date code Page 38 Owner s Manual and Service Guide VEHICLE WARRANTIES DECLARATION OF CONFORMITY EUROPE ONLY Owner s Manual and Service Guide Page 39 VEHICLE WARRANTIES Notes Page 40
26. AL USE uu nou Eas ise Re ee 1 Fig 1 Initial Service Chart ON BOARD CHARGER nerit nennen nnne Fig 2 On board Charger CONTROLS AND INDICATORS u u u KEY LIGH SWITCH ya u cct torta mancum ee aet nan Fig 3 Key Light Switch State of Charge Meter Horn and Hour Meter DIRECTION SELECTOR 2 42 000006000060 Fig 4 Direction Selector Types STATE OF CHARGE METER tite ee perdent tede HOUR METER irit ene Ee Een ACCELERATOR PEDAL tiri h pre eee c Fig 5 Accelerator and Brake Controls BRAKE PEDAL e eine PARK BRAKE ete e ei UH Ern agence RUN TOW MAINTENANCE SWITCH PDS VEHICLES ONLY 4 PASSENGERIMODEL 36V aus ei en edes 3 2 PASSENGER MODEL 48 ENEN RNEER 3 Fig 6 Run Tow Maintenance 5 3 STARTING VEHICLE ON A HILL uuu 5 PDS VEHICLE 48V aaa eem ome 5 36V VEHICLE M ANTI STALL FEATURE PDS VEHICLE 1 1 1 2 21 2 2 0 5 COASTING Lu VEHICLE WITH PDS u
27. AXIMUM RAMP HILL READ MANUAL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED 12 DANGER OF EXPLOSION 140 289 DO FILL GAS IN LOAD BED WARNING MAXIMUM CROSS HILL RAMP ANGLE WARNING AS SPECIFIED MAXIMUM LOAD amp CENTER OF GRAVITY KEEP LOAD LOAD WITH AS FAR HIGH CENTER FORWARD AS 7 OF GRAVITY POSSIBLE COULD RESULT DO NOT RIDE IN TIP OVER IN LOAD BED LOAD KEEP HANDS amp CENTER FINGERS AWAY 8 OF GRAVITY 1 4 FROM DUMP BED MAXIMUM DO NOT STAND HEIGHT BEHIND DUMP BED Ref Pic 1 1 Appendix A 4 Owner s Manual and Service Guide LABELS AND PICTOGRAMS 3 CLEAN UP GASOLINE ne DO NOT SPILLS WITH WATER 27 TT EXPOSE e BEFORE STARTING FLAME on ENGINE 16 UNLEADED GASOLINE DO NOT DISPOSE OF BATTERIES DO NOT 17 o SPILL FUEL IN LANDFILL amp XM CON A ENGINE ee 18 GROUND DRIVE ON FUEL PUMP HIGHWAY LOW OIL PRESSURE NEGATIVE GROUND BATTERY NO An DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND y SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION E E n Z Sa s WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY
28. ERR Bn AER Ar ounces EAE RE NR EISE ea ERSTE be 14 Fig 15 L brication POIS tio eea EO E ER Cg HER XR AVR HER FE FEY ya TR 14 HARDWARE REGEL RE EHE TO PH ER NIRE RI HERR 15 PERIODIC SERVICE SCHEDULE Q TANE ER NIE CIENT 16 Fig 16 Periodic Service Schedule sesenta 17 Fig 17 Torque Specifications and Bolt Grades 17 BATTERIES AND CHARGING SAFETY uie edicere BATTERY SWING OUT BATTERY TRAY Fig 18 Swing Out Battery Tray BATTERY MAINTENANGE iie terere rete ree ina eue 19 AT EAGH GHARGING CY CLE tr eet Yep derent e db va rH Eod d ore Heec eed E OUR 19 MONTHLY ELECTROLYTE LEVEL AND WATE R oa iaieiiea aapea ipae ranae rear ana ai ramae rA Era Aa knapo daira Eiaa oana paa naa ahann 19 Fig 19 Correct Electrolyte 2222020000 00201 niaii aaiae 19 Fig 20 Water Purity Table Fig 23 Automatic Watering E aetna au aa asa BATTERY CLEANING Fa ian iene Gin edet REP ee ER ER UE ee Fig 22 Preparing Acid Neutralizing Solution BATTERY WATERING CLEANING AND REPLACEMENT Fig 23 36V 4 Passenger Battery Connections 2 21 Fig 24 36V 2 Passenger Battery 2 u 22 Fig 25 36V 2 Passenger Battery Connections beginning mid model year 2007
29. From Mid 2007 33 Fig 30 Vehicle Dimensions o utt en dre p EE Rt Ra guste 34 Fig 31 Vehicle Dimensions and Incline Specifications sss 35 Fig 32 Vehicle Turning Clearance Diameter u 36 LIMITED WARRANTIES o1 ree erac Dente 37 DOMESTIC WARRANTY inii eerie egt e to vient a eei eere eta 38 DECLARATION OF CONFORMITY EUROPE ONLY 39 LABELS AND PICTOGRAM S ciii cel retain qua pde acera aane DL ae eg Appendix A Owner s Manual and Service Guide Page v TABLE OF CONTENTS Notes Page vi Owner s Manual and Service Guide SAFETY INFORMATION This manual has been designed to assist the owner operator in maintaining the vehicle in accordance with procedures developed by the manufacturer Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product To reduce the chance of personal injury and or property damage the following instructions must be carefully observed Certain replacement parts can be used independently and or in combination with other accessories to modify an E Z GO manufactured vehicle to permit the vehicle to operate at or in excess of 2
30. WEIGHT without batteries 1410 Ibs 640 kg GROUND CLEARANCE at differential 5 in 12 7 cm TIRES x tette tet tert eae i Kuchuna Sure Trail Industrial 5 70 x 8 LRC TIRE PRESSURE itis secs e s de tese e died 70 psi 483 kPa LOAD CAPACITY including operator passenger cargo and accessories 3 000 Ibs 1360 kg CHASSIS BODY amp 0 1 with welded high yield strength tubular steel with powder coat pain Heavy duty four way diamond pattern body Safety yellow modified acrylic topcoat over polyester primer meet det eet ndi eiiim Removable dash mounted key switch reverse warning indicator deadman accelerator control operator presence seat switch integral handgrip on hip restraints forward reverse selector with neutral and electric horn LIGHTING PACKAGE a Dual taillights brake lights optional headlights STEERING bs a Aches Automotive with steering wheel BRAKES cnx kh ete et ea Re ee Dual rear wheel hydraulic drum brakes Hand operated parking brake with manual adjustment Front hydraulic brakes optional FRONT 5 Independent leaf spring with hydraulic shock absorbers REAR SUSPENSION eet eee u ukla Leaf springs with hydraulic sho
31. age 1 It is wired directly to the batteries only requiring it be plugged into a dedicated 15 amp AC outlet to be operational Front of Vehicle Battery Charger Fig 2 On board Charger When charging cycle is complete replace AC cord in area provided Owner s Manual and Service Guide Page 1 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings CONTROLS AND INDICATORS Vehicle controls and indicators consist of key light switch lights optional direction selector state of charge meter hour meter accelerator pedal foot brake pedal Hand operated park brake Direction selector lever 36V models only Direction selector switch 48V PDS models only Run tow maintenance switch 48V PDS models only Horn Key Light Switch Located on the dash panel this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key To prevent inadvertent operation of the vehicle when left unattended the key should be turned to the OFF position and removed Ref Fig 3 on page 2 DASH PANEL 36V Blank Switch Hour Meter State of Charger Meter i DASH PANEL 48V PDS Horn FNR Switch lt L Hour Meter State of Charger Meter Key Switch Key Switch Fig 3 Key Light Switch State of Charge Meter Horn and Hour Mete
32. ance 6 5 2 The user shall periodically inspect facilities and review procedures to be certain that ANSI NFPA 505 or as required by local ordinance are strictly complied with and shall familiarize carrier operators with it 6 5 3 Maintenance and storage areas for carriers shall be properly ventilated to avoid fire hazards in accordance with applicable fire codes and ordinances Ventilation for internal combustion engine powered carriers shall be provided to remove flammable vapors gases fumes and other flammable materials Consult applicable fire codes for specific levels of ventilation Ventilation for electric powered carriers shall be provided to remove the accumulation of flammable hydrogen gas emitted during the battery charging process The amount of hydrogen gas emitted depends upon a number of factors such as the condition of the batteries the output rate of the battery charger and the amount of time the batteries are on charge Because of the highly volatile nature of hydrogen gas and its propensity to accumulate in pockets a minimum number of air changes per hour is required during charging Consult applicable fire and safety codes for the specific ventilation levels required as well as the use of explosion proof electrical apparatus SAE J1718 can be followed to check for hydrogen gas levels 6 6 Hazardous Locations 6 6 1 The user shall determine the hazard classification of the particular atmosphere or location in which the carr
33. ar attention to all Notes Cautions and Warnings Accelerator Pedal With the key switch ON depressing the accelerator pedal starts the motor When the pedal is released the motor will stop Ref Fig 5 on page 3 To stop the vehicle more quickly depress the foot brake Accelerator Pedal Brake Pedal Fig 5 Accelerator and Brake Controls Brake Pedal Depressing the foot operated brake pedal activates the brakes Ref Fig 5 on page 3 Park Brake The hand operated park brake is located between the front seats The brake is engaged when the handle is raised and is disengaged when the handle is parallel to the panel When leaving the vehicle unattended engage the park brake by raising the handle until it is locked in place To release the park brake depress the release button in the end of the handle while slightly raising the handle then lower the park brake handle Run Tow Maintenance Switch 48V PDS VEHICLES ONLY To reduce the possibility of severe injury or death resulting from loss of vehicle control consider the grade of the terrain the vehicle is on and set vehicle s park brake accordingly before switching the Run Tow Maintenance switch to the Tow Maintenance position When in the Tow Maintenance position the Anti Roll Back and Walk Away safety features of the PDS system no longer function 4 PASSENGER MODEL 36V The 4 passenger model features a fold down cargo bed which when rais
34. ates in each cell Ref Fig 19 on page 19 Expansion Vent Cap Space r 1 4 to 3 8 ur Gas Vent 6 to 10 mm n Vent m ri E LA 1 2 13 mm Electrolyte level should be at least 1 2 13 mm above the plates and 1 4 to 3 8 Plates 6 to 10 mm below bottom of vent Ref Cel 1 Fig 19 Correct Electrolyte Level This level will leave approximately 1 4 3 8 6 10 mm of space between the electrolyte and the vent tube The electrolyte level is important since any portion of the plates exposed to air will be ruined beyond repair Of equal importance is too much water which will result in electrolyte being forced out of the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle Do not overfill batteries The charging cycle will expel electrolyte and result in component damage A battery being charged will gas with the majority of the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas however this loss is minimal If the battery electrolyte level is too high the electrolyte will block the vent tube and the gas will force it out of the vent tube and battery cap The water will evaporate but the sulfuric acid will remain where it can damage vehicle
35. battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc Hydrogen gas is generated in the charging cycle of bat teries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement Never charge a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or pro pane water heaters and furnaces Before a new vehicle is put into operation the items shown in the INITIAL SERVICE CHART must be per formed Ref Fig 1 on page 1 Vehicle batteries must be fully charged before initial use Check for correct tire inflation See GENERAL SPECIFI CATIONS Remove the protective clear plastic that protect the seat bottom and back rest during shipping before placing the vehicle in service ITEM SERVICE OPERATION Batteries Charge batteries Seats Remove protective plastic covering Brakes Check operation and adjust if necessary Check hydraulic brake fluid level Tires Check air pressure see SPECIFICATIONS Ref Isc 8 Fig 1 Initial Service Chart On board Charger The on board charger is located under the cargo deck at the rear of the vehicle Ref Fig 2 on p
36. below the bottom of the threaded hole If lubricant is low add lubricant as required Add lubricant slowly until lubricant starts to seep from the hole Install the check fill plug In the event that the lubricant is to be replaced vehicle must be ele Owner s Manual and Service Guide Page 13 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings vated and the oil pan removed or the oil siphoned through the check fill hole Ref Fig 14 on page 14 Check Fill Plug Fig 14 Add Check and Drain Axle LubricantLubrica tion Page 14 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 components Putting more than three pumps of grease in a grease fit ting could damage grease seals and cause premature bearing failure Ref Fig 15 on page 14 f Brake Pedal N j 2 Lower Control Arms 2 King Pins 4 Wheel Bearing PACK 4 Ball Joints
37. by the manufacturer 7 3 3 4 Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manu facturer 7 3 4 Operator Care of Personnel and Burden Carriers 7 3 4 1 Read and follow operators manual 7 3 4 2 At the beginning of each shift during which the carrier will be used the operator shall check the carrier con dition and inspect the tires warning devices lights battery s speed and directional controllers brakes safety interlocks and steer ing mechanism If the carrier is found to be in need of repair or in any way unsafe the matter shall be reported immediately to the user and the carrier shall not be operated until it has been restored to safe operating condition 7 3 4 3 If during operation the carrier becomes unsafe in any way the matter shall be reported immediately to the user and the carrier shall not be operated until it has been restored to safe operating condition 7 3 4 4 not make repairs or adjustments unless specifically trained and authorized to do so 7 3 4 5 Before refueling the engine shall be stopped and allowed to cool The operator and passengers shall leave the carrier before refueling 7 3 4 6 Spillage of hazardous materials shall be contained immediately and addressed via appropriate hazardous materials regulations 7 3 4 7 Do not operate a carrier with a leak in the fuel system or battery s Battery s shall be charged and serviced per manufacturer s ins
38. c ular cell or cells that are the problem are identified the suspect battery can be removed and replaced At this point there is nothing that can be done to salvage the battery however the individual battery should be Owner s Manual and Service Guide Page 23 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings replaced with a good battery of the same brand type and approximate age Cylinder 32 Add to Float Reading 16 A 12 8 Y LO A 4 8 Subtract 24 ubtraci from Float Reading Weight Thermometer Fig 28 Hydrometer Hydrometer A hydrometer P N 50900 G1 is used to test the state of charge of a battery cell Ref Fig 28 on page 24 This is performed by measuring the density of the electrolyte which is accomplished by measuring the specific gravity of the electrolyte The greater the concentration of sulfu ric acid the more dense the electrolyte bocomes The highter the desity the higher the sate of charge To prevent battery explosion that could result in severe personal injury or death never insert a metal thermometer into a battery Use a hydrometer with a built in thermometer that is designed for testing batteries Specific gravity is the measurement of a liquid that is compared to a baseline The baseline is water which is assigned a base number of
39. ck absorbers SEATING iret Adora ho a eld Formed fabric backed vinyl covers over cushion foam Seating for operator and one passenger SPEED de cm ceret qe eene rrt Up to 13 5 mph 21 7 km h TRANSAXLE eee uu Direct drive 14 76 1 ratio UL Underwriters Laboratory Approved type E classification ELECTRICAL 5 5 36 volt DC six 6 volt heavy duty deep cycle storage batteries 115 minute 225 amp hour 20 hour discharge rate SPEED CONTROL Solid state controller 400 amp rated MOTOR uu qu sunum ees 36 volt DC high efficiency series wound brazed armature solid copper windings vented 8 hp 6kw at 1600 rpm GHARGE Riss L Sa a PowerWise on board 21 amp DC output at 36 volts input 110 120 volts 9 5 amps 60 cycle AC Underwriters Laboratory UL Listed CSA Certified anti drive away charger vehicle interlock Page 28 Owner s Manual and Service Guide GENERAL SPECIFICATIONS INDUSTRIAL 875 36V 2 Passenger From Mid 2007 WEIGHT without batteries 1148 lbs 521 kg GROUND CLEARANCE at differential 5 in 12 7 cm TMBES tete ido teak bec ecc e ds Sure Trail Industrial 5 70 x 8 LRC TIRE PRESSURE utres re ce hs 70 psi 483 kPa LOAD CAPACITY including operator passenger cargo and accessories
40. ck park brake function Check warning device function in reverse V Check tire condition Check overall vehicle condition Recharge batteries to full state of charge after each day s use Inspect charger AC plug and cord for damage Be sure ground pin is in place TIRES v Examine for cuts excessive wear and pressure See GENERAL SPECIFICATIONS WHEELS V Check for bent rims missing or loose lug nuts Clean batteries amp terminals See BATTERY CLEANING BATTERIE Check charge condition and all connections WIRING Check all wiring for loose connections and broken missing insulation ACCELERATOR Check for smooth movement foot brake HYDRAULIC BRAKES PARK BRAKE Check brake performance and adjust if required DIRECTION SELECTOR 36V models Check attachment tighten if required STEERING ASSEMBLY Check for abnormal play tightness of all hardware TIE ROD LINKAGES V Check for excessive play bent components or loose connections Check for PDS Controller braking force see PDS MODEL VEHICLES in text proper operation of system REAR AXLE Check for leakage add SAE 30 oil as required Z Conduct brake performance test PDS SYSTEM FRONT AXLE Check for damage to axle and loose or missing hardware FRONT SHOCK ABSORBERS Check for oil leakage and loose fasteners FRONT SPRINGS V Check for loose hardware cracks at attachments FRONT WHEEL ALIGNMENT
41. ctor For vehicles with headlights Ref Fig 10 on page 10 Remove the two screws on rear of the headlight Remove screws pull headlight out and disconnect wires Connect wires to new headlight Installation is the reverse of dissasesembly To replace the turn signal light bulb remove connector from rear of bulb and lens Unsnap bulb and lens from housing Install new bulb and lens by snapping into hous ing Install connector Page 10 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Roll Rubber Bezel Away From Lense Using Small Screwdriver Rear Body Tail Brake Light Fig 11 Tail and Brake Light Bulb Replacement To replace the tail and brake light bulb insert a small screwdriver between the rubber bezel and the taillight lense Roll the rubber bezel from around the edge of the lense and remove Install replacement bulb and replace lens Headlight and taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department Fuse Replacement To replace fuses remove the load bed and remove the controller cover Locate the fuse block in the electrical box adjacent to the controller Pull out old fuse and replace with a new automotive type fuse TRANSPORTING VEHICLE Towing This vehicle is not designed to be towe
42. d It is recommended that the vehicle be moved by placing the entire vehicle on a trailer flatbed truck or other suit able transport For non PDS vehicles place direction selector in neutral position prior to moving to prevent possible damage to electric motor For PDS vehicles place Run Tow Maintenance switch in Tow Mainteneance position prior to moving to prevent Owner s Manual and Service Guide damage to electric motor and controller PDS model vehicles are equipped with a Run Tow Main tenance switch located below the rear of the load bed on the rear of the controller enclosure The Tow Mainte nance position allows the vehicle to roll freely without activating the warning beeper and eliminating potential damage to controller or motor Ref Fig 6 on page 3 Check to see that vehicles to be moved are switched to the Tow Maintenance position To prevent possible serious personal injury or death never use ropes or chains to tow vehi cle s Hauling To reduce the possibility of severe injury or death while transporting vehicle Secure the vehicle and contents Never ride on vehicle being transported If the vehicle is to be transported at highway speeds the sun top if equipped must be removed When transport ing vehicle below highway speeds check for tightness of hardware and cracks in sun top at mounting points Always remove windshield when transporting Always check that the vehicle and contents are
43. d Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings facture date code serial number and vehicle model must be provided when ordering service parts Augusta Georgia USA 1 800 241 5855 Lb kg W Batt Nom Power Hp kw Label No Rated Capacity W 0perator Ib kg Lb kg W O Batt 1 System voltage v Max Batt Ib kg Max Draw bar Ib kg SERIAL No Bar Code Fig 12 Serial Number Plate amp location Tire Inspection Tire condition should be inspected per the Periodic Ser vice Schedule Ref Fig 16 on page 16 Inflation pres sures should be checked when the tires are cool Be sure to install the valve dust cap after checking or inflating Brakes To reduce the possibility of severe injury or death always evaluate pedal travel before operating a vehicle to verify some braking func tion is present All driving brake tests must be done in a safe location with regard for the safety of all person nel Periodic Brake Test for Hydraulic Brakes Depress the brake pedal The pedal should have some free travel and then become hard A brake pedal that has no free travel excessive free travel or a spongy feel indi cates that a brake inspection is required A brake pedal that falls after it is applied indicates a leak in the master or wheel cy
44. e Solid State continuously variable speed controller CHARGER 3 indien e Eun Lestronic fully automatic 48 volt output 25 amp On board MOTOR High efficiency DC shunt wound brazed armature solid copper windings SPEED ches bito rS tma celi erroe MS LM Lees Up to 13 5 mph 22 kph Page 30 Owner s Manual and Service Guide GENERAL SPECIFICATIONS INDUSTRIAL 875 48V 2 Passenger From Mid 2007 WEIGHT without batteries sene 1164 Ibs 528 kg GROUND CLEARANCE at differential 5 in 12 7 cm TIRES btt etait eee eee eee eL ets Sure Trail Industrial 5 70 x 8 LRC TIRE PRESSURE eni ie eite niece tete e 70 psi 483 kPa LOAD CAPACITY including operator passenger cargo and accessories 3 000 Ibs 1360 kg CHASSIS BODY amp FINISH esse 1 piece body with welded high yield strength tubular steel with powder coat paint Heavy duty four way diamond pattern body Safety yellow modified acrylic topcoat over polyester primer SAFETY Hotel at At A meth ett hte kayu ayk Removable dash mounted key switch reverse warning indicator deadman accelerator control operator presence seat switch integral handgrip on hip restraints forward reverse selector with neutral and electric horn LIGHTING Dual taillights brake lights optional headlights
45. e information contained in this manual is subject to change without notice The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual Owner s Manual and Service Guide Page vii SAFETY INFORMATION This vehicle conforms to the current applicable standard for safety and performance requirements These vehicles are designed and manufactured for off road use They do not conform to Federal Motor Vehicle Safety Standards and are not equipped for operation on public streets Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances With electric powered vehicles be sure that all electrical accessories are grounded directly to the battery post Never use the chassis or body as a ground connection Refer to GENERAL SPECIFICATIONS for vehicle seating capacity Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease its stability or increase the speed beyond the factory specification Such modifications can cause serious personal injury or death Modifications that increase the speed and or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle Do not make any such modifications or changes The manufacturer prohibits and disclaims responsibility for any such modifications or any other a
46. e use of non Original Equipment Manufacturer OEM approved parts may void the warranty Overfilling battery may void the warranty Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of electrical drain The battery charger and the controller are both sources of electrical drain Disconnect the battery charger from the vehicle receptacle As with all electric vehicles the batteries must be checked and recharged as required or ata minimum of 30 day intervals Page ii Owner s Manual and Service Guide TABLE OF CONTENTS Inside covers MODELS Vics EIC EP E i GENERAL INFORMATION 2 2 4 40 ii SAFETY INFORMATION a lea eel vi BEFORE INITI
47. ed converts to a second row seating for two additional passengers Be sure to fasten the seat back restraining strap when lowering the seat Remember to deduct the weight of the driver and all passen gers from the overall vehicle weight capacity 2 PASSENGER MODEL 48V PDS Before attempting to move vehicle move the Run Tow Maintenance switch to the Tow Maintenance position Failure to do so could damage the controller or motor Before disconnecting or connecting a battery or any oth er wiring move the Run Tow Maintenance switch to the Tow Maintenance position After connecting a battery or any other wiring wait a minimum of 30 seconds before moving the Run Tow Maintenance switch to the Run position The 48V PDS vehicle is equipped with a two position switch located under the passenger cargo deck Ref Fig 6 on page 3 Fig 6 Run Tow Maintenance Switch With the switch in TOW MAINTENANCE position the controller is deactivated the electronic braking system is deactivated which allows the vehicle to be moved or roll freely the warning beeper is deactivated With the switch in RUN position the controller is activated the electronic braking system and warning beeper features are activated Owner s Manual and Service Guide Page 3 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention t
48. ef Pic 1 4 Owner s Manual and Service Guide Appendix A 7 LABELS AND PICTOGRAMS Notes Appendix A 8 Owner s Manual and Service Guide Read and understand the following warnings before attempting to operate the vehicle To prevent personal injury or death observe the following When vehicle is to be left unattended engage parking PARK brake move direction selector to neutral turn key to OFF position and remove key Drive vehicle only as fast as terrain and safety considerations allow Consider the terrain and traffic conditions Consider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of direction may result in a loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet pavement gravel etc All travel should be directly up or down hills Use extra care when driving the vehicle across an incline Stay in designated areas and avoid steep slopes Use the parking brake whenever the vehicle is parked Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Make sure the direction selector is in correct positi
49. ellow modified acrylic topcoat over polyester primer sanan aed Removable dash mounted key switch reverse warning indicator deadman accelerator control operator presence seat switch integral handgrip on hip restraints forward reverse selector with neutral and electric horn LIGHTING Dual taillights brake lights optional headlights lee ieu e iuis Automotive with steering wheel BRAKES aus Ademas min Dual rear wheel hydraulic drum brakes Hand operated parking brake with manual adjustment Front hydraulic brakes optional FRONT SUSPENSION eene Independent leaf spring with hydraulic shock absorbers REAR SUSPENSION essere Leaf springs with hydraulic shock absorbers SEATING u inci ect eere Pete ip ie a Formed fabric backed vinyl covers over cushion foam Seating for operator and one passenger WRANSAXL E228 tities tene Dem Direct drive 14 76 1 ratio UL Underwriters Laboratory Approved type classification ELECTRICAL SYSTEM eese 48 volt DC eight 6 volt 225 amp hr batteries Precision Drive System PDS electronic speed controller Regenerative braking Batteries contained in swing out battery trays 1 per side DIRECTION SELECTOR aieeaa eia eaea eo araa haaa Electronic Three position switch SPEED CONTRO a e
50. eping of a warning device Permitting the vehicle to coast down an incline at speeds in excess of 2 mph 3 kph with the accelerator pedal released after bringing the vehicle to a complete stop will Page 4 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings cause an electronic braking force to be applied and a beeping from the warning device Depressing the accel erator pedal will return control to the operator and deacti vate the warning beeper Before attempting to move vehicle move the Run Tow Maintenance switch to the Tow Maintenance position Failure to do so will damage the controller or motor Before disconnecting or connecting a battery or any other wiring move the Run Tow Maintenance switch to the Tow Maintenance position After connecting a battery or any other wiring wait a minimum of 30 seconds before moving the Run Tow Maintenance switch to the Run position STARTING VEHICLE ON A HILL PDS Vehicle 48V To start the PDS vehicle on a hill With the left foot apply the foot brake Turn the key to the ON position Move the direction selector to the direction desired Fully release the hand operated parking brake With the right foot depress the accelerator pedal to start the motor and release the foot brake as the vehicle starts to mo
51. ertical position at eye level and note the reading where the electrolyte meets the scale on the float 4 Add or subtract four points 004 to the reading for every 10 6 C the electrolyte temperature is above or below 80 F 27 Adjust the reading to conform with the electrolyte temperature e g if the Page 24 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings reading indicates a specific gravity of 1 250 and the electrolyte temperature is 90 F 32 add four points 004 to the 1 250 which gives a corrected reading of 1 254 Similarly if the temperature was 70 F 21 subtract four points 004 from the 1 250 to give a corrected reading of 1 246 Ref Fig 29 on page 25 5 Test each cell and note the readings corrected to 80 For27 C A variation of fifty points between any two cell readings example 1 250 1 200 indi cates a problem with the low reading cell s As a battery ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the battery providing all cells are within fifty points of each other Since the hydrometer test is in response to a vehicle exhibiting a performance problem the vehicle should be recharged and the test repeated If the results indicate a weak cell the battery or batteries should be
52. guide covers the operation of several vehicles therefore some picto rial views may not represent your vehicle Physical differ ences in controls will be illustrated This vehicle has been designed and manufactured as a World Vehicle Some countries have individual require ments to comply with their specifications therefore some sections may not apply in your country Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in accordance with the Periodic Service Sched ule Service Parts Manuals and Technician s Repair and Ser vice Manuals are available from a local Distributor an authorized Branch or the Service Parts Department When ordering parts or requesting information for your vehicle provide vehicle model serial number and manu facture date code BEFORE INITIAL USE Read understand and follow all of the safety labels affixed to the vehicle Be sure you understand how to operate the vehicle its equipment and how to use it safely Maintaining good performance depends to a large extent on the operator Hydrogen gas is generated as a natural part of the lead acid battery charging process A 4 concentration of hydrogen gas is explosive and could cause severe injury or death Charging must take place in an area that is adequately ventilated minimum of 5 air exchanges per hour To reduce the chance of
53. icle remove all jewelry rings watch necklaces etc Be sure no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise rear of vehicle and support on jack stands before attempting to run or adjust powertrain Wear eye protection when working on or around the vehicle In particular use care when working around batteries using solvents or compressed air Hydrogen gas is formed when charging batteries Do not charge batteries without adequate ventilation Do not permit open flame or anyone to smoke in an area that is being used for charging batteries A concentration of 4 hydrogen gas or more is explosive Certified ISO 9001 ISO 14001 by A Textron Company E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US 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 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
54. icle is in motion Moving the selector will result in a sudden slowing of the vehicle and the beeping of a warning device Slow down before and during turns All turns should be executed at reduced speed All travel should be directly up or down hills Use extra care when driving the vehicle across any incline Stay in designated areas and avoid steep slopes To reduce the possibility of severe inju ry or death resulting from improper vehicle operation the following warnings must be observed Refer to GENERAL SPECIFICATIONS for seating capacity Make sure that the direction selector is in correct position before attempting to start the vehicle Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operating in reverse Always bring the vehicle to a complete stop before shifting the direction selector Always remain seated and hold on while the vehicle is in motion Keep feet legs hands and arms inside the vehicle at all times To prevent inadvertent movement when the vehicle is to be left unattended engage the parking brake move direction selector to neu tral position turn key to OFF position and remove key Additional Warnings and Cautions applicable to PDS vehicles To prevent loss of control do not move PDS vehicle direction selector while the vehicle is in motion Moving the selector will result in a sud den slowing of the vehicle and the be
55. ier is to be use in the accordance with ANSI NFPA 505 6 6 2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI NFPA 505 Page x Owner s Manual and Service Guide SAFETY INFORMATION 6 7 Lighting for Operating Area The user in accordance with his responsibility to survey the environment and operating conditions shall determine if the carrier requires lights and if so shall equip the carrier with appropriate lights 6 8 Control of Noxious Gases and Fumes When equipment powered by internal combustion engines is used in enclosed areas the atmosphere shall be main tained within limits specified in the American Conference of Governmental Industrial Hygienists publication Threshold Limit Values for Chemical Substances and Physical Agents in the Workroom Environment This may be accomplished by ventilation maintenance of emission control equipment recommended or provided by the manufacturer of the equip ment 6 9 Warning Device s 6 9 1 The user shall make periodic inspections of the carrier to be certain that the sound producing and or visual device s if so equipped are maintained in good operating condition 6 9 2 The user shall determine if operating conditions require the carrier to be equipped with additional sound pro ducing or visual devices or both and be responsible for providing and maintaining such devices in accordance with the manufacturer s recommendations 6 10
56. iet et e vedo etre bic ao C eee ebbe n d e 10 LIGHT BULB REPLACEMENT e it een deem mE edt 10 Fig 10 Headlight Turn Signal amp Marker Light Bulb Replacement 10 Fig 11 Tail and Brake Light Bulb Replacement sese 11 FUSE REBEAGEMENCL rere en TR ep HY REPAS ERN UR EUH SITO Regio 11 TRANSPORTING VEHICLE aa 11 pelvic 11 BAUEING 5 4 eee em eet NE de 11 SERVICE AND MAINTENANCE 11 SERIAL AND MANUFACTURING NUMBER LABEL LOCATIONS 12 Fig 12 Serial Number Plate amp location TIRE INSPECTION u trente roc oett CER o e Qha CIE e WE RE TOR A XC IE EAE VETE UT BRAKES ceti RO eme n RR ERE CH RR HOP RR PERIODIC BRAKE TEST FOR HYDRAULIC BRAKES PDS SYSTEM TEST u reta dt dee dre e eh cian er ELI Ere e DX I ee ERES DE AE Re RR CAPACITIES AND REPLACEMENT PARTS 2 0 Fig 13 Capacities and Replacement Parts REAR AXLE 5 5 Et rente d ied aaa ape ena CHECKING THE LUBRICANT EEVMEL 2 ec ritiene ere dtr Leere nn erre Irene Ee M eeu eat Fig 14 Add Check and Drain Axle Lubricant sss 14 EUBRIGATIGN S u y D REUTERS
57. in that it is in accor dance with ANSI NFPA 505 and ANSI NFPA 30 or as required by local ordinance 6 4 2 Storage and handing of liquefied petroleum gas fuels shall be in accordance with ANSI NFPA 505 and ANSI NFPA 58 or as required by local ordinance If such storage or handling is not in compliance with these standards the user shall prevent the carrier from being used until such storage and handling is in compliance with these standards 6 43 Prevent fire and explosion caused by static electric discharge Use only non metal portable fuel containers approved by the Underwriter s Laboratory U L or the American Society for Testing amp Materials ASTM If using a fun nel make sure it is plastic and has no screen or filter Static electric discharge can ignite gasoline vapors in an ungrounded fuel container Remove the fuel container from the bed of a carrier or the trunk of a car ban place on the ground away from the carrier before filling Keep nozzle in contact with container opening while filling When practical remove equipment from trailers or truck beds and re fuel them on the ground If this is not possible use a portable plastic fuel container to refuel equipment on a truck bed or trailer 6 5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 6 5 1 The user shall require battery changing and charging facilities and procedures to be in accordance with ANSI NFPA 505 or as required by local ordin
58. linders It is important to periodically check and maintain proper brake fluid levels in the brake master cylinder The fill cap for the cylinder is located under the front floorboard and is accessible by removing the cover panel When check ing the fluid wipe off any dirt from the fill cap before removing it to reduce the possibility of contamination Fluid level should be maintained at 1 8 3 mm below the top of the housing If fluid must be added inspect system for fluid leaks PDS System Test At monthly intervals test the PDS system by allowing the vehicle to roll down an incline with the accelerator pedal released Braking force should be felt at approximately 2 mph 3 kph indicating that the PDS system is function ing If vehicle speed continues to rise apply the foot brake and have vehicle inspected by a trained mechanic Capacities and Replacement Parts Rear Axle Oil 40 oz 1 2 liters SAE 30 Headlight Bulb 894 P N 74004 G01 Marker Bulb 912 P N 74005 G01 Turn Signal Bulb 921 P N 74006 G01 Tail Light Bulb 1157 P N 21759 G1 Ref Cap 2 Fig 13 Capacities and Replacement Parts Rear Axle The rear axle is provided with a lubricant level check fill plug located on the bottom of the differential Unless leakage is evident the lubricant need only be replaced after five years Checking the Lubricant Level Clean the area around the check fill plug and remove plug The correct lubricant level is just
59. lteration which would adversely affect the safety of the vehicle Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment Additionally speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition Always read and observe all warnings and operation instruction labels affixed to the vehicle Always follow all safety rules established in the area where the vehicle is being operated Always reduce speed to compensate for poor terrain or conditions Always apply service brake to control speed on steep grades Always maintain adequate distance between vehicles Always reduce speed in wet areas Always use extreme caution when approaching sharp or blind turns Always use extreme caution when driving over loose terrain Always use extreme caution in areas where pedestrians are present MAINTENANCE Always maintain your vehicle in accordance with the manufacturer s periodic service schedule Always ensure that mechanics performing repairs are trained and qualified to do so Always follow the manufacturer s directions if you do any maintenance on your vehicle Be sure to disable the vehicle before performing any maintenance Disabling includes removing the key from the key switch and removal of a batte
60. mpon 5 chemicals known to cause cancer and reproductive harm WASH HANDS AFTER HANDLING WARNING WARNING WARNING WARNING SHARP TURN SHARP TURN STEEP HILL APPLY BRAKE TO LIMIT SPEED gt wA 4 lt 14 25 DO NOT DRIVE ACROSS SLOPES IN EXCESS OF 14 APPLY BRAKE TO LIMIT SPEED APPLY BRAKE TO LIMIT SPEED Be sure that this manual remains as part of the permanent service record should the vehicle be sold NOTES CAUTIONS AND WARNINGS Throughout this guide NOTE CAUTION and WARNING will be used A NOTE indicates a condition that should be observed A CAUTION indicates a condition that may result in damage to the vehicle A WARNING indicates a hazardous condition that could result in severe injury or death Observe these NOTES CAUTIONS and WARNINGS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe Engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defects or other reproductive harm The exhaust emissions of this vehicles engine complies with regulations set forth by the Environmental Protection Agency EPA of the United States of America USA at time of manu facture Significant fines could result from modifications or tam pering with the engine fuel ignition or air intake systems Battery
61. must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which could result in an explosion Z Wrap wrenches with 2 vinyl tape to prevent the possibility of a dropped wrench from shorting out a battery which could result in oe and severe personal injury or eath Battery A battery is defined as two dissimilar metals immersed in an acid If the acid is absent or if the metals are not dis similar a battery has not been created The batteries most commonly used in these vehicles are lead acid A battery does not store electricity but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy The chemical reaction takes place faster in warm conditions and slower in cold conditions Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences As a battery ages it still performs adequately except that its capacity is diminished Capacity describes the time that a battery can continue to provide its design amperes from a full charge A battery has a maximum life therefore good mainte nance is designed to maximize the available life and reduce the factors that can reduce the life of the battery Page 18 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become
62. n depend ing on vehicle model Ref Fig 23 36V 4 Passenger Bat tery Connections on page 21 Ref Fig 24 36V 2 Passenger Battery Connections on page 22 Ref Fig 25 36V 2 Passenger Battery Connections begining mid model Year 2007 on page 22 Ref Fig 26 48V 2 Pas senger Battery Connections on page 22 Tighten the battery post hardware to 50 70 in Ibs 6 8 Nm torque Protect the battery terminals and battery wire terminals with a commercially available protective coating Fig 26 48 2 Passenger Battery Connections 2 Passenger Battery Connections 2 Fig 24 36V Prolonged Storage ef of MIT 24 2 09 09 09 1 5 1 5 1 5 Y Battery charger controller and other electronic devices need to be disconnected since they will contribute to the premature discharge of batteries During periods of storage the batteries will need atten tion to keep them maintained and prevent discharge In high temperatures the chemical reaction is faster while low temperatures cause the chemical reaction to slow down A vehicle that is stored at 90 F 32 will lose 002 of specific gravity each day If a fully charged battery has a specific gravity of 1 275 and the ba
63. nents needing service Modifications and additions which affect capacity and safe carrier operation shall not be performed without man ufacturer s prior written authorization where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or safety labels are changed accord ingly r Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment S Disconnect batteries negative connection s first When reconnecting connect positive connection first 0 Hydraulic systems if so equipped shall be checked for leaks for condition of parts Keep body and hands away from pin holes or nozzles that eject fluids under high pressure Use paper or cardboard not hands to check for leaks n IL Page xiv Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Thank you for purchasing this vehicle Before driving the vehicle we ask you to spend some time reading this Owner s Manual and Service Guide This guide contains the information that will assist you in maintaining this highly reliable vehicle Some illustrations may show items that are optional for your vehicle This
64. nflating tires Due to the low volume of the small tires overinflation can occur in seconds Over Owner s Manual and Service Guide Page 9 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings inflation could cause the tire to separate from the wheel or cause the tire to explode Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor appli cations with major use on grassy areas the following should be considered On hard turf it is desirable to have a slightly higher inflation pressure On very soft turf a lower pressure reduces the possibility of tires cutting into the turf For vehicles being used on paved or hard sur faces tire inflation pressure should be in the higher allowable range but under no condition should inflation pressure be higher than recommended on tire sidewall All four tires should have the same pressure for opti mum handling characteristics Be sure to install the valve dust cap after checking or inflating The vehicle is fitted with low pressure tubeless tires mounted on one piece rims therefore the most cost effective way to repair a puncture in the tread is to use a commercial tire plug Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of n
65. njury or death keep all smok ing materials open flame or sparks away from the batteries Hydrogen gas is formed when charging bat teries Do not charge batteries without ade quate ventilation A 4 concentration of hydrogen gas is explosive Be sure that the key switch is off and all electrical accessories are turned off before starting work on vehicle Never disconnect a circuit under load at a battery terminal Batteries are heavy Use proper lifting techniques when moving them Always lift the battery with a com mercially available battery lifting device Do not tip bat teries when removing or installing them spilled elec trolyte can cause burns and damage The electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physi cian immediately Always wear a safety shield or approved safety goggles when adding water or charging batter ies E Any electrolyte spills should be neutralized with a solution of 1 4 cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and flushed with water Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aerosol containers of battery terminal pro tectant
66. nt which could affect carrier operation e Operator competency evaluations 7 3 Personnel and Burden Carrier Operator Responsibility 7 3 1 General Operator Responsibility Owner s Manual and Service Guide Page xi SAFETY INFORMATION 7 3 1 1 Read and follow operators manual 7 3 1 2 Do not operate carrier under the influence of drugs and alcohol 7 3 1 3 Safeguard the pedestrians at all times Do not drive carrier in a manner that would endanger other persons 7 3 1 4 Riding on the carrier by persons other than the operator is authorized only on personnel seat s provided by the manufacturer All parts of each person s body shall remain within the plan view outline of the carrier 7 3 1 5 When a carrier is to be left unattended stop the carrier apply the parking brake stop the engine or turn off power turn off the control or ignition circuit and remove the key if provided Additionally for the electric carriers the forward and reverse directional controls should be neutralized if a means is provided Block the wheels if the carrier is on a n incline 7 3 1 6 Acarrier is considered unattended when the operator is 7 6m 25 ft or more from the carrier which remains in his view or whenever the operator leaves the carrier and it is not within his view When the operator is dismounted and within 7 6m 25 ft of the carrier still in his view he still must have controls neutralized and the parking brake s set to prevent movement
67. ntial for injury refer the repair or maintenance to a qualified mechanic Always test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic Always replace damaged or missing warning caution or information labels Always keep complete records of the maintenance history of the vehicle VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement Never charge a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane gas water heaters and furnaces Always use a dedicated circuit for each battery charger Do not permit other appliances to be plugged into the recepta cle when the charger is in operation Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable electrical code whichever is higher Owner s Manual and Service Guide Page ix SAFETY INFORMATION Notes Page x Owner s Manual and Service Guide SAFETY INFORMATION ANSI ITSDF B56 8 2005 The following text is provided as recommended b
68. o all Notes Cautions and Warnings PDS vehicles operate only in the RUN position The PDS is a low power consumption unit but it will drain the vehicle batteries over a period of time If the vehicle is to be stored for a prolonged period of time the PDS should be disconnected from the batteries Refer to Pro longed Storage on page 22 Horn The horn is operated by pushing the horn button located on the left side of the dash panel Ref Fig 3 on page 2 OPERATING THE VEHICLE Improper use of the vehicle or the lack of proper maintenance may result in decreased performance or damage to the vehicle Read and understand the following warnings before attempting to operate the vehicle To reduce the possibility of severe injury or death resulting from loss of vehicle control the following warnings must be observed Drive the vehicle only as fast as terrain and safety considerations allow Consider the terrain traffic conditions and the environ mental factors which effect the terrain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc Avoid extremely rough terrain Avoid driving fast down hill A sudden stop or change of direction may result in loss of control Use foot brake to control speed when traveling down an incline To prevent loss of control do not move the direction selector of a PDS vehicle while the veh
69. on before attempting to start the vehicle Slow down before and during turns All turns should be executed at reduced speed Always bring vehicle to a complete stop before shifting the direction selector See GENERAL SPECIFICATIONS for standard vehicle load and seating capacity Read and understand the following text and warnings before attempting to service vehicle In any product components will eventually fail to perform properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating correctly take time to consider the safety of yourself and others around you should the component move unexpectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach high temperatures Battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with the utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Before working on the veh
70. ot requiring the tire be removed from the wheel If the tire is flat remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in accordance with manufacturer s instructions To reduce the possibility of severe injury be sure mounting demounting machine is anchored to floor Wear OSHA approved safety equipment when mounting demounting tires If the tire is to be removed or mounted the tire changing machine manufacturer s recommendations must be fol lowed in order to reduce possibility of severe injury Wheel Installation To reduce the possibility of component damage do not tighten lug nuts to more than 85 ft lbs 115 Nm torque It is important to follow the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten lug nuts in a cross sequence pattern Ref Fig 9 on page 10 Tighten lug nuts to 50 85 ft Ibs 70 115 Nm torque in 20 ft 165 30 Nm increments following the cross sequence pat tern Tire wheel style may vary Cross Sequence Fig 9 Wheel Installation LIGHT BULB REPLACEMENT Bulb Turn Signal Turn Signal Headlight SN Housing Housing Fig 10 Headlight Turn Signal amp Marker Light Bulb Replacement Conne
71. ple If all of the following events occur a the vehicle is being driven down a slope Page 6 b the vehicle attempts to exceed the specified top speed with the accelerator pedal depressed or released the motor control system will limit the speed of the vehi cle to the specified top speed the warning beeper will not sound When the system is activated by this sequence of events the motor generates power which is returned to the batteries If the operator attempts to override the feature by moving the direction selector or key switch to another position the warning beeper will sound and the vehicle will slow rapidly until it reaches the speed of approximately 2 mph 3 kph Pedal Up Feature The pedal up feature slows the vehicle when the acceler ator pedal is released while the vehicle is moving between 8 mph 13 kph and the vehicle s top speed Example If all of the following events occur a the vehicle is being driven down a slope b the accelerator pedal is released for more than one second the pedal up feature will slow the vehicle the warning beeper will not sound until either the vehicle speed is reduced to 8 mph 13 kph at which it freely coasts between 8 and 3 mph 5 kph or the accelerator pedal is applied When pedal up feature is activated by this sequence of events the motor generates power which is returned to the batteries Walk Away Feature Walk Away limits vehicle movement without dri
72. r If the vehicle is equipped with lights the key switch has a position to operate them indicated by the light icon Direction Selector To prevent loss of control do not move Preci sion Drive System PDS vehicle direction selector while the vehicle is in motion Moving the selector will result in a sudden slowing of the vehicle and the beeping of a warning device To reduce the possibility of component damage the vehicle must be completely stopped before moving the direction selector On PDS models if the direction selector is shifted before the vehicle comes to a complete stop a warning beeper will activate Located on the dash panel or between seats this lever or switch permits the selection of either F forward R reverse or neutral the position between forward and reverse Vehicle should be left in neutral when unat tended Ref Fig 4 on page 2 FWD A Go Forward Neutral as shown REV pn Neutral Reverse Forward C Fig 4 Direction Selector Types State Of Charge Meter Located in the dash the state of charge meter indicates the amount of usable power in the batteries Ref Fig 3 on page 2 Hour Meter Located in the dash the hour meter indicates total hours of operation Ref Fig 3 on page 2 Page 2 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particul
73. r and load The range of motion of the trailer is limited by the hitch The trailer should not be used on rough trails or over objects such as logs large rocks holes etc Owner s Manual and Service Guide Page 7 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings CAB AND WINDSHIELD The optional cab does not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects The cab and windshield provide protection from the ele ments This vehicle is not equipped with seat belts and the cab has not been designed to provide roll over pro tection In addition the cab does not protect against fall ing objects nor does the windshield protect against flying objects and tree limbs Keep arms and legs inside of vehicle while it is moving VEHICLE CLEANING AND CARE Vehicle Cleaning To reduce the possibility of severe injury or vehicle damage read and understand all instructions supplied by manufacturer of pres sure washer When pressure washing exterior of vehicle do not use pressure in excess of 700 psi 4800kPa To reduce the possibility of cosmetic damage do not use any abrasive or reactive solvents to clean plastic parts It is important that proper techniques and cleaning mate rials be used Using excessive water pressure may cause se
74. rmed fabric backed vinyl covers over cushion foam Seating for operator and three passengers SPEED 3 M Up to 13 5 mph 21 7 km h TRAN SAA L E eet bete Direct drive 14 76 1 ratio CLASSIFIGATION iiiter Hr tet ea es UL Underwriters Laboratory Approved type E classification ELECTRICAL SYSTEM sse 36 volt DC six 6 volt heavy duty deep cycle storage batteries 115 minute 225 amp hour 9 20 hour discharge rate gt SS rennen nennen Solid state controller 400 amp rated eto diete tete une Gah ates u N 36 volt DC high efficiency series wound brazed armature solid copper windings vented 8 hp 6kw at 1600 rpm CHARGER Ask BU Ae E PowerWise on board 21 amp DC output at 36 volts input 110 120 volts 9 5 amps 60 cycle AC Underwriters Laboratory UL Listed CSA Certified anti drive away charger vehicle interlock NOISE see o ue ceto ane nt Sound pressure continuous A weighted 70 dB A VIBRATION WBV a a a ia ha aa nnns The weighted RMS acceleration is 0 7 m s2 VIBRATION HAV suu ee ee The weighted RMS acceleration is less than 2 5 m s Specifications subject to change without notice Owner s Manual and Service Guide Page 33 GENERAL SPECIFICATIONS 29 74 Y 66 in 168 cm L 4 7
75. ront and behind your vehicle PDS vehicles incorporate an anti stall feature to protect the motor from damage If the controller senses that the accelerator pedal is depressed power applied to motor and the motor is stalled long enough to cause motor damage it will momentarily interrupt power to the motor This brief interruption will permit the vehicle to roll back wards slightly before again stopping in the stalled condi tion This process will repeat itself periodically until the vehicle is moved from the stalled condition If the brake is engaged while the accelerator is depressed the controller will sense a stalled motor con dition and remove power from the motor When the brake pedal is released the vehicle will roll backwards slightly before power is returned to the motor COASTING Vehicle With PDS The PDS controls the top speed of the vehicle while mov ing down hill Therefore overspeed coasting does not occur with PDS model vehicles The PDS is not a substi tute for the foot brake which should be used to control the speed of the vehicle Some PDS models are equipped with a feature which slows the vehicle s speed when the accelerator pedal is released Owner s Manual and Service Guide Page 5 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Vehicle Without PDS To prevent injury or death re
76. ry wire Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by short ing the battery terminals or associated wiring Remove the batteries or cover exposed terminals with an insulating material Page viii Owner s Manual and Service Guide SAFETY INFORMATION Always check the polarity of each battery terminal and be sure to rewire the batteries correctly Always use specified replacement parts Never use replacement parts of lesser quality Always use recommended tools Always determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Always support the vehicle using wheel chocks and safety stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated The manufacturer cannot anticipate all situations therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the pote
77. s SAFETY RESTRICTION in connection with the use of all products new and used the Distributor or Dealer has rea son to believe may be operated in personal transportation applications Information on FMVSS 571 500 can be obtained at Title 49 of the Code of Federal Regulations section 571 500 or through the Internet at the website for the U S Department of Transportation at Dockets and Regulation then to Title 49 of the Code of Federal Regulations Transportation GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur No warnings can take the place of good common sense and prudent driving practices Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined The manufacturer strongly suggests that the owner operator read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein It is further recommended that employees and other operators be encouraged to do the same If you have any questions contact your closest representative or write to the address on the back cover of this publica tion Attention Product Service Department The manufacturer reserves the right to make design changes without obligation to make these changes on units previ ously sold and th
78. s normally travel straight up and down 7 3 2 8 Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop in a safe manner 7 3 2 9 Make starts stops turns or direction reversals in a smooth manner so as not to shift the load endanger passengers or lose control of the carrier 7 3 2 10 Do not operate carrier in a dangerous manner 7 3 2 11 Slow down when approaching or on wet or slippery surfaces 7 3 2 12 Do not drive carrier onto any elevator unless specifically authorized to do so Approach elevators slowly and then enter squarely after the elevator car is properly leveled Once on the elevator neutralize the controls shut off power and set parking brakes It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 7 3 2 13 Avoid running over loose objects potholes and bumps 7 3 2 14 Reduce carrier speed to negotiate turns 7 3 2 15 Avoid any action verbal or physical by an operator or passenger which could cause the operator to be dis tracted 7 3 3 Loading 7 3 3 1 Refer to operators manual for loading instruction Page xii Owner s Manual and Service Guide SAFETY INFORMATION 7 3 3 2 Handle only stable and safely arranged loads When handling off center loads which cannot be centered operate with extra caution 7 3 3 3 Handle only loads within the capacity of each cargo area of the carrier as specified
79. scharge the battery For PDS vehicles the controller should be disconnected from the batteries by setting the Run Tow Maintenance switch located below the rear of the load bed on the rear of the control ler enclosure to the TOW MAINTENANCE position 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 dis charge The batteries should be tested or recharged at thirty day minimum intervals Battery Charging The battery charger is designed to fully charge the bat tery set If the batteries are severely deep cycled some automatic battery chargers contain an electronic module that may not activate and the battery charger will not function Automatic chargers will determine the correct duration of charge to the battery set and will shut off when the battery set is fully charged Always refer to the instructions of the specific charger used Before charging the following should be observed Do not overfill batteries The charging cycle will expel electrolyte and result in component damage The electrolyte level in all cells must be at the rec ommended level and cover the plates The charging must take place in an area that is well ventilated and capable of removing the hydro gen gas that is generated by the charging pro cess A minimum of five air exchanges per hour is recommended The charging plug and cord are
80. sed to stabilize the vehicle Lower the vehicle by reversing the lifting sequence WHEELS AND TIRES Tire Repair Tool List Qty Required Lug wrench 3 4 000000000 1 Impact socket 3 4 1 2 drive 1 Impact wrench 1 2 1 Torque wrench 1 2 drive 1 A tire explosion can cause severe injury or death Never exceed inflation pressure rating on tire sidewall To reduce the possibility of tire explosion pressurize tire with small amount of air applied intermittently to seat beads Due to the low volume of the small tires overinfla tion can occur in seconds Never exceed the tire manufacturer s recommendation when seating a bead Protect face and eyes from escaping air when removing valve core To reduce the possibility of severe injury caused by a broken socket when removing wheels use only sockets designed for impact wrench use View from Underside of Vehicle Steering Box Skid Plate Y X Y 7 Fig 8 Lifting the Vehicle Use caution when inflating tires Overinfla tion could cause the tire to separate from the wheel or cause the tire to explode either of which could cause severe injury Use caution when i
81. successor thereof When the carrier manufacturer or its successor approves a modification or alteration appropriate changes shall be made to capacity plates decals tags and operation and maintenance manuals 6 3 3 As required under paragraphs 6 3 1 or 6 3 2 the manufacturer shall be contacted to secure new nameplates warnings or instructions which shall then be affixed in their proper place on the carrier 6 3 4 In the event that the carrier manufacturer is no longer in business and there is no successor in interest to the business the user may arrange for a modification or alteration to a carrier provided however the controlling party shall Owner s Manual and Service Guide Page ix SAFETY INFORMATION 1 Arrange for the modification or alteration to be designed tested and implemented by an engineer s expert in carrier s and their safety 2 Maintain a permanent record of the design test s and implementation of the modification or alteration 3 Make appropriate changes to the capacity plate s decals tags and operation and maintenance manuals 4 Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been mod ified or altered together with the date of the modification or alteration and the name of the organization that accomplished the tasks 6 4 Fuel Handling and Storage 6 4 1 The user shall supervise the storage and handling of liquid fuels when used to be certa
82. sulting from coast ing at above recommended speeds limit speed with foot brake On steep hills it is possible for non PDS vehicles to coast at faster than normal speeds that may be encoun tered on a flat surface To prevent loss of vehicle control speeds should be limited to no more than the maximum speed on level ground see GENERAL SPECIFICA TIONS Limit speed by releasing the accelerator and applying foot brake Severe damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessive speed may cause a loss of control is costly is considered abuse and will not be covered under warranty Performance PDS vehicles operate only when the Run Tow Maintenance switch is in the RUN position Refer to Run Tow Mainte nance Switch 48V PDS VEHICLES ONLY on page 3 The options are defined as follows Ref Fig 7 on page 6 PERFORMANCE TOP SPEED SPEED CONTROL No Plugs 13 5 mph 22 kph Mild Fig 7 Performance Characteristics The vehicle s top speed is sensed and regulated directly by the controller and the feature to slow the vehicle when the accelerator pedal is up is mild Speed Control To prevent the possibility of loss of control that could cause severe injury or death use foot brake to control speed The PDS system is not a substitute for the foot brake PDS models are equipped with a motor control system Exam
83. t exceed the impurity levels specified in the table Automatic watering devices such as the one included in the Battery Maintenance Kit P N 25587 G01 can be used with an approved water source Ref Fig 21 on page 20 These watering devices are fast and accurate to use and maintain the correct electrolyte level within the battery cells Watering gun similar to the type included in the Battery Maintenance Kit Valve consistently fills to a predetermined level Electrolyte Level Pure Water Single Battery Cell Ref Awg 1 Fig 21 Automatic Watering Gun The watering device should only be used if the electrolyte level is less than 1 2 13 mm above top of plates Battery Cleaning To prevent battery damage be sure that all battery caps if equipped are tightly installed To reduce the possibility of damage to vehicle or floor neutralize acid before rinsing battery To reduce the possibility of damage to electrical compo nents while cleaning do not use a pressure washer Cleaning should take place per the Periodic Service Schedule Ref Fig 16 on page 16 When cleaning the outside of batteries and terminals first spray with a solution of sodium bicarbonate baking soda and water to neutralize any acid deposits before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from the top of batteries to another area of the vehicle or storage facilit
84. t use an open flame to check level or leakage of fuel battery electrolyte or coolant i Properly ventilate the work area in accordance with applicable regulations or local ordinance j Handle fuel cylinders with care Physical damage such as dents scrapes or gouges may dangerously weaken the tank and make it unsafe for use Owner s Manual and Service Guide Page xiii SAFETY INFORMATION k Brakes steering mechanisms speed and directional control mechanisms warning devices lights governors guards and safety devices shall be inspected regularly and maintained in accordance with manufacturer s rec ommendations l Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved safe operating features m Fuel systems shall be checked for leaks and condition of parts If a leak is found action shall be taken to prevent the use to the carrier until the cause of the leak has been repaired The carrier manufacturer s capacity operation and maintenance instruction plated tags or decals shall be maintained in legible condition Batteries motors speed and directional controllers limit switches protective devices electrical conductors insulators and connections shall be inspected and maintained per carrier manufacturer s recommendation Carriers shall be kept in a clean condition to minimize hazards and facilitate detection of compo
85. ted All vehicles are equipped with an interlock system that disables the controller and prevents the vehicle from being operated while the charger is connected to an AC supply Remove charger plug from the AC receptacle and properly store cable prior to moving vehicle To operate vehicle Apply the foot brake place the key in the key switch and turn it to the ON position Move the direction selector to the direction desired Release the park brake Slowly depress the accelerator pedal to start the motor Release foot brake when motor starts When the accelerator pedal is released the motor stops To stop the vehicle more quickly depress the foot brake pedal When the direction selector is in the reverse position a warning signal will sound to indicate that the vehicle is ready to run in reverse LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings Appendix A illus trates and explains pictograms that may appear on the vehicle Not all pictograms shown in Appendix A will be found on your vehicle TOWING A TRAILER The vehicle may be equipped with a pintle hitch The trailer and its load must not exceed 500 Ibs 227 kg and no more than 50 Ibs 23 kg tongue weight may be attached to the hitch Remember that the overall capacity of the vehicle operator passenger contents of loadbed and accessories must be reduced to compensate for the traile
86. tenance Refer to the Periodic Service Schedule for appropriate service intervals Ref Fig 16 on page 16 Refer to Lubrication Points lllustra tion for appropriate lubrication locations Ref on page 16 To prolong vehicle life some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures extreme dust debris conditions frequent use with maxi mum load To access powertrain for routine maintenance lift or remove load bed For major repair refer to appropriate Technician s Repair and Service Manual Some service procedures may require the vehicle to be lifted Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information Serial and Manufacturing Number Label Locations Supplemental Information Label Location The supplemental Information label is located on the inside of the cowl driver side Serial and Manufacturing No Label Location The serial and manufacturing number label is located on the inside of the cowl driver side Serial and Manufacturing No Stamped For EE Vehicle only The serial number and manufacturing number are stamped on the frame below the load bed Serial No Sticker Location The serial number is located on steering column Ref Fig 12 on page 13 Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manu Page 12 Owner s Manual an
87. the rear wheels or the entire vehicle be raised To reduce the possibility of severe injury or death from a vehicle falling from a jack Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is sup ported by a jack Use jack stands and test the stability of the vehicle on the stands Always place chocks in front and behind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process Page 8 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings When lifting vehicle position jacks and jack stands at the areas indicated only To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 8 on page 9 Center the jack under the rear frame crossmember Raise the vehicle enough to place a jack stand under the outer ends of the rear frame crossmember Lower the jack and test the stability of the vehicle on the two jack stands Place the jack at the flat section of steering box skid plate Raise the vehicle enough to place jack stands under the frame members as indicated Lower the jack and test the stability of the vehicle on all four jack stands If only the front or rear of the vehicle is to be raised place the chocks in front and behind each wheel not being rai
88. thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Swing Out Battery Tray Bumper should be always in contact with battery door when closed Ref Fig 18 on page 19 Adjust rubber bumper as needed to remove slack between the latch and latch lock Rubber Bumper Latch Lock Fig 18 Swing Out Battery Tray Battery Maintenance Tool List Qty Required Insulated Wrench 9 16 1 Battery een 1 1 Battery maintenance kit P N 25587 06001 1 At Each Charging Cycle To reduce the possibility of fire never attach a battery charger to a vehicle that is to be unat tended beyond the normal charging cycle Overcharging could cause damage to the vehi cle batteries and result in extreme overheating The charger should be checked after 24 hours and unplugged after the charge cycle is com plete Before charging the batteries inspect the AC plug of the battery charger for damage Charge the batteries after each days use Monthly Inspect all wiring for fraying loose terminations corrosion or deterioration of insulation Check that the electrolyte level is correct and add suitable water as required Clean the batteries and wire terminations Electrolyte Level and Water The correct level of the electrolyte is 1 2 13 mm above the pl
89. tructions 7 3 4 8 not use open flames for checking electrolyte level in storage battery s or liquid level in fuel tanks 8 MAINTENANCE PRACTICES 8 1 Introduction Carriers may become hazardous if maintenance is neglected Maintenance facilities trained personnel and proce dures shall be provided Such facilities may be on or off the premises 8 2 Maintenance Procedures Maintenance and inspection of all carriers shall be performed in conformance with the following practices and should follow the manufacturer s recommendations a A scheduled preventive maintenance lubrication and inspection system shall be followed b Only trained and authorized personnel shall be permitted to maintain repair adjust and inspect carriers c Before undertaking maintenance or repair follow the manufacturer s recommendations for immobilizing the car rier d Chock wheels and support carrier before working underneath it e Before disconnecting any part of the engine fuel system be sure the shutoff valve if so equipped is closed and follow carrier manufacturer s recommended practice f Operation to check performance of the carrier shall be conducted in an authorized area where suitable condi tions exist free of vehicular and pedestrian traffic g Before returning carrier to service follow the manufacturer s instructions and recommended procedure h Avoid fire hazards and have fire protection equipment present in the work area Do no
90. ttery which could result in an explosion The electrolyte in a battery is an acid solu tion which can cause severe burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician imme diately Any electrolyte spills should be neutralized with a solution of 2 teaspoons 10 ml sodi um bicarbonate baking soda dissolved in 1 quart 1 liters of water and flushed with water Aerosol containers of battery terminal pro tectant must be used with extreme care Insulate metal container to reduce the pos sibility of can contacting battery terminals which could result in an explosion It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recom mended in this manual Preventative maintenance applied at recommended intervals is the best guarantee for keeping the vehicle both dependable and economical Before any electrical service is performed on PDS model vehicles the Run Tow Maintenance switch must be placed in the Tow Maintenance position amp fa If a power wire battery motor or controller is discon nected for any reason on the PDS model vehicle the Run Tow Maintenance switch must be left in the Tow Maintenance position for at least 30 seconds after the circuit is restored This vehicle will give years of satisfactory service provid ing it receives regular main
91. ttery is allowed to sit unused it will become partially discharged When it reaches 1 240 which it will do in less than twenty days it should be recharged If a battery is left in a discharged state sulfating takes place on and within the plates This condition is not reversible and will cause permanent damage to the battery In order to prevent damage the battery should be recharged hydrometer Fig 25 36 2 Passenger Battery Connections can be used to determine the specific gravity and there begining mid model Year 2007 fore the state of charge of a battery Page 22 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings OF 15 9 5 15 macaAramvema lt 1 100 1 140 1 180 1 220 1 260 1 300 1 120 1 160 1 200 1 240 1 280 SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT Fig 27 Freezing Point of Electrolyte In winter conditions the battery must be fully charged to prevent the possibility of freezing Ref Fig 27 on page 23 A fully charged battery will not freeze in tempera tures above 75 60 Although the chemical reaction is slowed in cold temperatures the battery must be stored fully charged and disconnected from any cir cuit that could di
92. upt power to the motor This brief interruption will permit the vehicle to roll backwards slightly before again stopping in the stalled condition This process will repeat itself periodically until the vehicles is moved from the stalled condition Example If all of the following events occur a the system senses that the accelerator pedal is depressed power applied to motor b the brake is engaged so as to prevent vehicle motion the PDS system will sense a stalled motor condition and remove power from the motor When the brake pedal is released the vehicle will roll backwards slightly before power is returned to the motor High Pedal Disable Feature High pedal disable prevents undesired acceleration if the direction selector lever is changed or the key is turned on while the accelerator is depressed Diagnostic Mode Feature Diagnostic mode eases troubleshooting In the unlikely event of certain electrical system failures the PDS controller will default to a mode that will permit the vehicle to operate but at a very reduced speed This feature allows the vehicle to be driven back to its storage facility where the problem can be diagnosed The controller can be put in diagnostic mode by the tech nician and the controller will report the failure mode STARTING AND DRIVING To reduce the possibility of roll back which could result in severe injury or vehicle damage do not release the foot brake until motor has star
93. uu e recen ec e Pere dete t ec tet e etr C ete aaa VEHICLE WITHOUT 5 2 2 27 2 410 004 4020 010100000000000000000 Fig 7 Performance Characteristics SPEED CONTROL aki 2 Sess L S L re WERE ET eet PEDAL UP FEATURE uu nn ceti cet cte tte De e Ce dena WALK AWAY ANIT ROLL BACK FEATURE ANTESTALI FEATURE uuu u aaa er nee nasua as HIGH PEDAL DISABLE a Em neinei endete bte ter dete o aa Pe Y X RES STARTING AND DRIVING U U U 7 LABELS AND 5 11 7 TOWING A TRAILER 2 neret eter etre cree xe sene xeu ume Leo Ea cuo CHE RIO onc cO iss EENAA ENEE une 7 CAB AND WINDSHIELD u U eren puente tie Hera nore Seo a 8 VEHICLE CLEANING AND CARE u u nnn 8 VEHICLE GLEEANI G A I IL P 8 REPAIR gt EET EIETINGSTTIE MEHIGEE EHE RERO Ue isnt desee Fig 8 Lifting the Vehicle WHEELS AND TIRES Fig 9 Wheel Installation Owner s Manual and Service Guide Page iii TABLE OF CONTENTS WHEEL INSTAELDATION ce ttt pec
94. ve When the direction selector is in the reverse position a warning signal will sound This is a device to indicate the vehicle is ready to run in reverse The motor stops when the accelerator pedal is released To stop the vehicle more quickly depress the foot brake pedal 36V Vehicle Non PDS Vehicle 36V Do not hold vehicle on hill by using accelerator and motor Leaving motor in a stalled condition for more than 3 4 seconds will cause perma nent damage to motor When starting the electric vehicle on a hill it is important to follow the procedure below to prevent excessive roll back or permanent damage to the motor Do not hold vehicle on hill by using accelerator and motor Leaving motor in a stalled condition for more than 3 4 seconds will raise the commutator bars resulting in unacceptable noise and accelerated brush wear and cause permanent damage to motor To start the electric vehicle on a hill Place left foot on the foot brake Place the key in the key switch and turn the key to the ON position Move the direction selector to the direction desired Place right foot on accelerator Fully release park brake Depress the accelerator pedal to start the motor and release the foot brake as the vehi cle starts to move Anti Stall Feature 48V PDS Vehicle To prevent possible injury or vehicle damage never walk or stand behind a vehicle stopped on hill Always maintain adequate clearance between cars in f
95. ver input slowing the vehicle to 2 mph 3 kph and sounding an audible alarm reverse beeper Example If all of the following events occur a the vehicle has been stopped for more than 1 5 seconds b the accelerator pedal has been released for more than one second c the vehicle begins to roll above 2 mph 3 kph the walk away feature will limit soeed to approximately 2 mph 3 kph and the warning beeper will sound When the accelerator pedal is depressed the walk away fea ture and warning beeper will be overridden and normal vehicle operation resumes Any unusual situation sensed by the PDS system will cause a similar response The system functions in all key switch positions Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Anti Roll Back Feature Anti Roll Back like Walk Away limits backward motion of the vehicle down an incline to less than 2 mph 3 kph See Walk Away Feature above Anti Stall Feature Anti Stall protection prevents motor damage from stalling the vehicle against an object or on a hill Example If all of the following events occur a the system senses that the accelerator pedal is depressed power applied to motor b the motor is stalled long enough that any more time may cause motor damage the PDS system will momentarily interr
96. vere injury to operator or bystander damage to seals plastics seat material body finish or electrical sys tem Do not use pressure in excess of 700 psi 4800 kPa to wash exterior of vehicle Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use of a commercially available vinyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces Occasional cleaning and waxing with non abrasive prod ucts designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle These mate rials will cause corrosion of underbody parts unless flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sedi ment packed in closed areas should be loosened to ease it s removal taking care not to chip or otherwise damage paint REPAIR Lifting the Vehicle Tool List Qty Required Floor Jack Dt te neas 1 JACK SLAMS PL 4 Ice ees 4 Some servicing operations may require the front wheels
97. y part Il of ANSI ITSDF B56 8 2005 The manufacturer strongly endorses the contents of this specification 6 GENERAL SAFETY PRACTICES 6 1 Introduction 6 1 1 Like other machines carriers can cause injury if improperly used or maintained Part Il contains broad safety practices applicable to carrier operation Before operation the user shall establish such additional specific safety prac tices as may reasonably be required for safe operation 6 1 2 Premise review The user shall periodically review their premises and as conditions warrant identify areas where carriers should not be operated and to identify possible hazards such as the following examples a Steep Grade In areas where steep grades exist carrier operation should be restricted to the designated vehi cle s pathways where possible and shall be identified with a suitable warning giving the following information Warning steep grade Wet Areas Wet areas could cause a carrier to lose traction and could affect steering stability and braking Sharp Turns Blind Spots Bridge Approaches Sharp turns blind spots bridge approaches and other poten tially hazardous areas shall be identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard d Loose Terrain Loose terrain could cause a carrier to lose traction and could affect steering stability and braking
98. y where it will attack the metal structure or the concrete asphalt floor Additionally con ductive residue will remain on the batteries and contrib ute to their self discharge To reduce the possibility of battery explosion that could result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame or sparks away from the battery The correct cleaning technique is to spray the top and sides of the batteries with a solution of sodium bicarbon ate baking soda and water This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or plastic spray bottle The solution should consist of the ingredients shown in the illustration Ref Fig 22 on page 21 In addition special attention should be paid to metal components adjacent to the bat teries which should also be sprayed with the solution Page 20 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 1 1 2 gallons 6 liters 1 quart Clear Water 1 liter Clear Water 1 4 Cup 60 ml 2 Teaspoons Sodium Bicarbonate 10 ml Baking Soda Sodium OR Bicarbonate Baking Sod lt gt Baking Soda Metallic z F Plastic 2 Gallon Spray 7 5 liter Bottle Garden Sprayer Ref Pns 1 Fig 22 Preparing Acid Neutrali
99. zing Solution Allow the solution to sit for at least three minutes Use a soft bristle brush or cloth to wipe the tops of the batteries to remove any conductive residue Rinse the entire area with low pressure clear water Do not use a pressure washer All of the items required for complete battery cleaning and watering electric vehicles only are con tained the Battery Maintenance Kit P N 25587 G01 Battery Watering Cleaning amp Replacement The 48V model is equipped with swing out battery racks to make the batteries accessible for watering cleaning and removal Starting with model year 2007 the 2 passenger model of the 36V vehicle is equipped with swing out battery racks 2005 amp 2006 models require that the load bed be removed to acces the battery set The 4 passenger 36V model requires that the load bed be removed to access the battery set Before any electrical service is performed on 48 V PDS model vehicles the Run Tow Maintenance switch must be placed in the Tow Maintenance position If a power wire battery motor or controller is discon nected for any reason on the PDS model vehicle the Run Tow Maintenance switch must be left in the Tow Maintenance position for at least 30 seconds after the circuit is restored Remove battery hold downs and cables Lift out batteries with a commercially available lifting device Owner s Manual and Service Guide

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