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electric three wheel service vehicle

1. 5 4 6 Use only approved carriers in hazardous loca tions as defined in the appropriate safety standards 5 4 7 Report all accidents involving personnel building structures and equipment 5 4 8 Operators shall not add to or modify the car rier Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 5 4 9 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles access to stairways or fire equipment 5 5 Traveling 5 5 1 Observe all traffic regulations including autho rized 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 car rier under control at all times 5 5 2 Yield the right of way to pedestrians ambu lances fire trucks or other carriers or vehicles in emer gency situations 5 5 3 Do not pass another carrier or vehicle travel ing in the same direction at intersections blind spots or at other dangerous locations 5 5 4 Keep a clear view of the path of travel observe other traffic and personnel and maintain a safe clearance 5 5 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 5 5 6 Ascend or descend grades slow
2. Fig 32 Wiring Diagram GENERAL SPEGIEIGATIONS 3 x ot ek tnt ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE eee 30 Fig 33 Vehicle Dimensions and Incline Specifications Fig 34 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance 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 CAUTION Certain replacement parts can be used independently and or in combination with other accessories to modify an E Z GO manufactured vehicle to permit the vehicle to operate at or in excess of 20mph When an E Z GO manufactured vehicle is modified 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 l
3. do not use have all work performed by authorized personnel Apply hand or foot brake not automatically applied It is your responsibility to keep all labels decals and instructional literature legible and intact Replacement labels decals and literature are available from the factory Your safety and the safety of others around you depends on your conscientious operation of this vehicle Read the following section carefully and thoroughly to become familiar with proper operating procedures Be sure to read and understand the following warnings before attempting to operate the vehicle DO NOT operate this P AZANIN vehicle until this own er s manual is read and understood DO NOT allow untrained or unauthorized persons to operate this vehicle NEVER allow children to operate the vehicle Before using the equipment check all parts and any attachments If a malfunction is found do not use the vehicle until the problem is corrected NEVER carry more than one passenger or a pas senger along with a cargo load Passenger must remain seated in rear at all times during transport Page 8 Passengers MUST NOT stand on rear footrest Keep both hands on steering mechanism when ever possible and keep arms and legs inside vehi cle while moving Passenger must use the hand holds provided with the rear seat Be aware of object haz AWARNINGA ards that can impact the operator or passenger within the confines of the vehicle f
4. A YELLOW jj R B WHITE STOPLIGHT SWITCH POTAY LM 886182 TUG 892894 f C BLUE STOPLIGHT SWITCH N 814005 MINUTE MISER ALL WIRES IN MAIN HARNESS SEAT SWITCH AY 897160 UNLESS NOTED Tenis oe bie Pe MB Be 11 P4 P2 REVERSE ps P7 P WIRE COLOR CHART P3 FORWARD yc P4 MAIN CONTACT 5 P6 0 5V INPUT P7 POT LOW P11 REVERSE INPUT P12 FORWARD INPUT P14 HIGH INPUT CHARGER P16 KEYSWITCH INPUT 24V 892860 REAR 36V 893090 LIGHT Zr X go poo UJ REAR LIGHT COM BL Fig 32 Wiring Diagram Page 26 Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings CIRCUIT BRKR MINUTE MISER 829164 824800 892833 P 893282 893383 WB 884045 TUG LIFTOUT RACK 891693 e EC TUG MM 36V TUG t FRONT BROS 6v 887204 TUG LIFTOUT RACK TO 891657 loPrioNAL CIRCUIT 883078 EC TUG MM quick BRKR H FRONT D SEONNECT 6 BRIDGE 20
5. Cautions and Warnings Oylinder Add to Float Reading d Subtract from Float Reading Thermometer Fig 29 Hydrometer 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 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 Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float Add or subtract four points 004 to the reading for every 10 F 6 C the electrolyte temperature is above or below 80 F 27 C Adjust the reading to Owner s Manual and Service Guide conform with the electrolyte temperature e g if the reading indicates a specific gravity of 1 250 and the electrolyte temperature is 90 F 32 C add four points 004 to the 1 250 which gives
6. 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 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 information 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 Owner s Manual and Service Guide Page vii SAFETY INFORMATION This vehicle con
7. Observe the vehicle stopping location If the vehicle stops in a significantly greater distance than normal or pulls to one side it should be tested again If the vehicle fails the second test it should immediately be removed from service The vehicle needs to be inspected by a qualified mechanic Page 11 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Dry Level Clean Paved Surface Accelerate To Maximum Speed X_N Parking Brake Acceptable E m Line or Marker Stopping Distance Normal Range of Stopping Distance Any vehicles that stop beyond the Acceptable Stopping Distance or pulls to one side should be removed from service and inspected by a qualified mechanic Engage NS Line or Marker Fig 17 Periodic Brake Performance Test Page 12 TIRES Tools List Qty Required Impact wrench 1 2 drive 1 Impact socket 3 4 1 2 drive 1 Torque wrench 1 2 drive ft 1 Wrench T 2 To prevent injury caused FAUNAS Ey IW by a broken socket use only sockets designed for impact wrench use Never use a conventional socket Tire condition should be inspected per the Periodic Ser vice Schedule Ref Fig 22 on page 16 Inflatio
8. This vehicle will give years of satisfactory service provid ing it receives regular maintenance Refer to the Periodic Service Schedule for appropriate service intervals Ref Fig 22 on page 16 Refer to Lubrication Points for appropriate lubrication locations Ref Fig 15 on page 11 NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions Use maximum of three pumps of grease CAUTION for each grease fitting Overgreasing may damage grease seals Putting more than three pumps of grease in a grease fit ting could damage grease seals and cause premature bearing failure Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Wheel bearings and fork pivot Rear axle check and fill View from underside of vehicle Fig 15 Lubrication Points REAR AXLE The only maintenance required for the first five years is the periodic inspection of the lubricant level 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
9. changed accordingly 4 3 3 As required under paras 4 3 1 or 4 3 2 the manufacturer shall be contacted to secure new name plates warnings or instructions which shall then be affixed in their proper place on the carrier 4 4 Fuel Handling and Storage 4 4 4 user shall supervise the storage and han dling of liquid fuels when used to be certain that it is in accordance with appropriate paragraphs of ANSI NFPA 505 and ANSI NFPA 30 4 4 2 Storage and handling of liquefied petroleum gas fuels shall be in accordance with appropriate para graphs of ANSI NFPA 505 and ANSI NFPA 58 If such storage or handling is not in compliance with these stan dards the user shall prevent the carrier from being used until such storage and handling is in compliance with these standards 4 5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 4 5 1 user shall require battery changing and charging facilities and procedures to be in accordance with appropriate paragraphs of ANSI NFPA 505 4 5 2 The user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs of ANSI NFPA 505 are strictly complied with and shall familiarize carrier operators with it 4 6 Hazardous Locations 4 6 1 The user shall determine the hazard classifi cation of the particular atmosphere or location in which the carrier is to be used in accordance with ANSI NFPA 505 4 6 2 The use
10. understand and follow safety label on the instru ment panel The vehicle has been designed to operate in a warehouse or factory environment with semi smooth floors road and ramps Be sure you understand the vehicle its equipment and how to use it safely Although the vehicle has been designed to provide safe and reliable operation main taining good performance depends to a large extent on the operator Vehicle batteries must be fully charged before initial use Hydrogen gas is generat EY INI edas a natural part of the lead acid battery charg ing 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 adequate ly ventilated minimum of 5 air exchanges per hour To reduce the chance of battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc Hydrogen gas is generated in the charging cycle of 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 gas water heaters and furnaces Before a
11. AMP RECTIFIER 6v 24V MINUTE CIRCUIT BREAK 840679 892523 MISER HEADLIGHT mi NOT USED ON STD OR BAT COND METER CONNECTION FOR WIRING EN HORN WITH TUG STEERING WIRE DESTINATIONS WHEEL MOD SAME AS STD METER B W BL BB R FY ta o FORWARD w 2 REVERSE _ HEADLIGHT G e V REVERSE SWITCH HORN BUTTON KEY SWITCH BATTERY WARNING 830640 806791 HORN 886311 DIRECTION MEMORY CONDITION BUZZER 886090 SWITCH 836354 MODULE METER 890000 841852 24V 840526 BATTERIES 36v 841111 LIFTOUT BATTERY B B 24V MINUTE MISER RACK APPLICATION BATTERY ARRANGEMENT SHOWN IN SCHEMATIC CHARGER KT 6 FORWARD REVERSE DIRECTION SWITCH UG BRAKI IGHT SW MINUTE MIS R HORN BUTTON HEADLIGHT Fig 33 Wiring Diagram Owner s Manual and Service Guide Page 27 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become t
12. Grade 2 11 33 75 102 176 169 13 35 80 110 200 320 18 108 149 271 434 18 110 170 280 460 24 149 230 380 624 BOLT SIZE Class 5 8 Grade 2 Class 8 8 Ga Grade 5 8 8 Class 10 9 o9 Grade 8 0 9 Ref Tsp 1 Fig 21 Torque Specifications Owner s Manual and Service Guide Page 15 ELECTRIC THREE WHEEL SERVICE VEHICLE 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 NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY BODY Clean body components as required REVERSE WARNING DEVICE Check operation when direction selector is in reverse TIRES 7 Rearing fo ut eese west and pressure WHEELS Check for bent rims missing or loose lug nuts BATTERIES Recharge to full state of charge after each day s use MONTHLY 20 HOURS includes items listed in previous table amp the following Clean batteries amp terminals with 1 4 cup 60 ml baking soda to 1 1 2 gallons 6 liters BATTERIES water solution rinse with clear water Check charge condition and all connections Check brake performance smooth operation SERVICE PARK BRAKE Adjust if required WIRING Check all wirin
13. R E 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 28 Freezing Point of Electrolyte In winter conditions the battery must be fully charged to prevent the possibility of freezing Ref Fig 28 on page 21 A fully charged battery will not freeze in tempera tures above 75 F 60 C Although the chemical reac tion is slowed in cold temperatures the battery must be stored fully charged and disconnected from any circuit that could discharge the battery For portable chargers disconnect the charging plug from the vehicle receptacle For on board chargers disconnect the charging harness from the batteries The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge The batteries should be tested or recharged at thirty day minimum intervals Battery Charging The battery charger is designed to fully charge the bat tery set If the batteries are severely deep cycled some Page 21 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 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
14. and approximate age Page 24 Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings E Z GO FACTORY SET CONTROLLER PARAMETERS PARAMATER RANGE DEFAULT DESIRED UNITS DESCRIPTION Current Limit Main 20 250 250 250 Amps Maximum current forward speed DH Limit Low Speed 20 250 250 250 Amps Maximum current reverse speed Current Limit Plug 20 250 70 70 Amps Max plug current forward speed ced Limit Low Speed 20 250 70 70 Amps Max plug current reverse speed Current Limit Emergency Max plug current in emergency Reverse 20 250 140 250 Amps LOVBISO Current Limit Low Speed Max plug current in low speed emer Emergency Reverse 20 250 148 250 Amps gency reverse Current Limit Ramp Start 20 250 140 250 Amps Max plug current during ramp start Current Limit Low Speed Max plug current during ramp start in Ramp Start 20 250 140 250 Amps low speed Acceleration Rate 0 3 1 0 8 Sec Time to reach full output from zero output Quick Start 0 6 1 4 0 2 respond to rate of throttle Throttle type type 1 2 3 type 1 type 2 m uen input type 2 0 5V 3 Adjust desired PWM output at 5096 Ramp Shape 20 70 50 50 throttle to vary throttle sensitivity at low speed cun Speed Min 0 25 10 0
15. 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 in Ibs 5 6 Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 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 explo AWARNING A sion that could result in severe personal injury or death extreme care must be used with aerosol con tainers of battery terminal protectant Insulate the metal container to prevent the metal can from con tacting battery terminals which could result in an explosion Use care to connect the battery wires as shown Ref Fig 27 on page 21 Tighten the battery post hardware to 50 70 in lbs 6 8 Nm torque Protect the battery termi nals and battery wire termi
16. be checked and recharged as required or at a minimum of 30 day intervals Refer to the Prolonged Storage section within the BATTERIES AND CHARGING section of this manual Page ii Owner s Manual and Service Guide TABLE OF CONTENTS GENERAL dinner D eese a vii GENBEALOPERATION vecino cde tud edidit as dato vii MAINTENANCE viii VENTILATION e Readies ix GENERAL E xi STANDARDS AND PUBLICATIONS 2 1 Standards east avin alana 1 PUDIICAtIONMS sie 1 BEFORE INITIAE USE rete rone ee een reet ceret rae Pes d de ee een 2 Initial Service Chart rere ie e EF HER eb a PEE Y dva TY eat MER ad 2 On Board Charger e soto te tita e eg Inde c e LC e bite I teet c y P eb aes 2 IDENTIFICATION pm 2 Fig 2 Model Number Model Year and Serial Number sss seas 2 CONTROLS METERS AND SWITCHES 7 2 Fig Serial Numbers Under 22000 3 Fig 4 Controls On Dashboard sse 3 Fig 5 Controls On Floorboard 3 Fig 5 Horn SWilch iis e err eid 3 Key ica cct rta Cerea a ted Dg a Ce onte n
17. bo cb MO ntl Electrolyte Level and Fig 23 Correct Electrolyte Level 2220202000000200 Fig 24 Water Purity Table 220000002 2 22 000000100000000000099 9 nnn nnne nnne Fig 25 Automatic Watering Gun nne nnne nnns nnn Gl aning Batteties 3 ierra deem ende ne RE ie cn deter Fig 26 Preparing Acid Neutralizing Solution Battery Replacemoent kind e denen aea Fig 27 Battery Connections Prolonged Storage te rtt tee en a Eee ird e date d n den e t EN Fig 28 Freezing Point of 2 Battery Charging ne ee TN EH aa od I VEREOR eee ed Voltage qr x EE TROUBLESHOOTING aeae ict a e Rr nte ek ad e Hh 5 Using A Hydrometer DAE Page iv Owner s Manual and Service Guide TABLE OF CONTENTS FIG 29 FIVdrOmaler er t b e 23 Fig 30 Hydrometer Temperature Correction sessi nns 23 Factory Setlingss s t Dot ero m e E RR Et Fig 32 Wiring Diagram
18. charged Always refer to the instructions of the specific charger used Before charging the following should be observed CAUTION 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 connector components are in good condition and free from dirt or debris The charger connector is fully inserted into the vehicle receptacle The charger connector cord set is protected from damage and is located in an area to prevent injury that may result from personnel running over or tripping over the cord set The charger is automatically turned off during the connect disconnect cycle and therefore no electri cal arc is generated at the DC plug receptacle contacts 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 spec
19. dea 3 Key eee e 4 Direction Selector Switch sssssssssssseeeeeeneenee nennen nennt nennen 4 Fig 8 Direction Selector Switch 2 4 Power ON Battery Condition Meter 2 1 1000000 2 24 Headlight nt rr rir t eere ee treno ern ep 4 Service Parking Brake Pedal ceceessecseceeseceeeeeeeeeeseeeceaeceeeaeeeeeaeseseeesaeseaesaeeeeesareeaeeaee 4 Fig 9 Speed Control Pedal sessi 4 Speed Control m ce sed nire eed en NA seen 5 Hotn and Handlebar 2 dre tiri HR EUN SEDET EN ro 5 Handlebar Installation cerent re teri tern e treno err Pe 5 Seat iiid ni ER wantin Wan dan hanya en ei enne rie Ay 5 Fig 10 Seat SWIICh ie renee 25 Hour Meter ACCeSSOLy i c trek er ern tre E ERR RE SERE nO FEE E DNE 5 ADDITIONAL FEATURES nate tenen ti n tea te eee a eed e npe en Battery Charger nier ende eei ere irte He e vere e ere eee ERA Fold Down Backrest Fig 11 Battery Charger 200000 0 0020000 Fig 12 Fold Down Backrest 21 Programmable Speed Controller 1 t ei re Fl eH D tee rate p se d E
20. fire and electrical haz ards as specified per U L 583 The additional components used on EE vehicles include head light guard e rear light guard terminal boots for the circuit breaker motor and forward reverse and main solenoids astatic strap a safety hasp to keep the battery compartment securely closed EE Units function identically to E Units BEFORE ENTERING VEHICLE 1 Check for correct tire inflation 2 Inspect for fluid leaks 3 Be sure everything is properly stored and secured If vehicle has built in charger unplug power cord from electrical outlet and properly store cord under instrument panel prior to moving vehicle If vehicle has a portable charger remove charger plug from vehicle receptacle and properly store cable prior to moving vehicle OPERATING THE VEHICLE CAUTION 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 P AZADIN INI of severe injury or death resulting from loss of vehicle control the following warnings must be observed Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Drive the vehicle only as fast as terrain and safety co
21. mate rials be used Normal cleaning of the vinyl backrest and plastic or rub ber 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 Page 14 with lukewarm or cold water is the best method of pre serving the painted surfaces Do not use hot water strong soap or harsh chemical detergents Rubber parts should be cleaned with nonabrasive house hold cleaner Occasional cleaning and waxing with nonabrasive prod ucts designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used for dust control can collect on the underbody of the vehicle These materials will accel erate corrosion of underbody parts It is recommended that the underbody be flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas should be loosened to ease its removal taking care not to chip or otherwise damage paint TRAILERING To prevent personal inju AWARNING A ry to occupants of other highway vehicles be sure that the vehicle and contents are adequately secured to trailer Do not ride on vehicle being trail
22. mended this manual Adequate preventative maintenance applied at regular intervals is the best guarantee for keeping the vehicle both dependable and economical A TOWING This vehicle is not NE designed to be towed It is recommended that this vehicle be moved by placing the entire vehicle on a trailer flatbed truck or other suit able transport Owner s Manual and Service Guide LIFTING THE VEHICLE Tool List Qty Required Floor Jack rena aste dai 1 Jack stands ee reri ie 4 ecc Em 4 Chain MOIST net oe 1 Some servicing operations may require the vehicle be raised To prevent possible inju PIES or death resulting 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 support ed by a jack Use jack stands and test the stability of the vehicle on the stands Always place chocks in front and behind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process Never attempt to raise the rear wheels of a three wheel vehicle without first raising the front of the vehicle and supporting on jack stands When lifting vehicle position jacks and CAUTION jack stands only on the areas indicated Due to the low ground clearance and short wheel base the vehicle should only be raised enough to remove the front axle or the rear wheels Servic
23. 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 more restrictive Owner s Manual and Service Guide Page ix SAFETY INFORMATION Notes Page x Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings GENERAL The following text is provided as recommended by part II of ASME ANSI B56 8 1988 The manufacturer strongly endorses the contents of this specification PART Il FOR THE USER 4 GENERAL SAFETY PRACTICES 4 1 Introduction 4 1 1 Like other machines carriers can cause injury if improperly used or maintained Part Il contains broad safety practices applicable to carrier operations Before operation the user shall establish such additional spe cific safety practices as may reasonably be required for safe operation 4 2 Stability 4 2 1 Experience has shown that this vehicle which complies with this standard is stable when properly operated and when operated in accordance with spec
24. protective com ponents a seat switch and a thermal circuit breaker Seat Switch Removing body weight from the vehicle seat will cause the seat switch to interrupt electrical power to the control ler You must remain seated during vehicle operation Thermal Circuit Breaker The thermal circuit breaker prevents overloading of the drive motor Should the vehicle be stopped by the open ing of the circuit breaker turn the vehicle off to avoid an accidental start when the breaker resets The breaker automatically resets after approximately 20 seconds An audible click will sound when the breaker resets If the circuit breaker continues to open a problem exists within the circuit or the vehicle is overloaded Do not operate the vehicle until the problem is resolved Page 10 If the circuit breaker PENNEY should open while driv ing on an incline imme diately apply the service and parking brakes to prevent loss of vehicle control Parking The Vehicle To park the vehicle complete the following steps before leaving the operator s seat 1 Stop the vehicle and move the direction selector switch to the NEUTRAL position 2 Apply the parking brake 3 Turn the key switch to the vertical OFF position and remove the key When parking the vehicle on an incline the NOTE front wheel should be curbed whenever possi ble Ref Fig 14 on page 10 Uphill Fig 14 Parking The Vehicle ROUTINE MAINTENANCE
25. reduced speed Always bring vehicle to a complete stop before shifting the direction selector See GENERAL SPECIFICATIONS for standard vehicle load and occupant capacity NOTE 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 To prevent personal AWARNINGA injury or death observe the following Before working on the vehicle remove all jewelry rin
26. safeguards against inherent fire hazards Type EE Units have addi tional safeguards against such hazards Users operators and service persons should be familiar with the following standards and publications Standards The material may be obtained from the address shown Factory Mutual Approval Standard Class 7820 Electric Battery Powered Trucks Types E and EE ADDRESS Factory Mutual Research Corp 1151 Boston Providence Highway Norwood Massachusetts 02062 USA National Fire Protection Association ANSI NFPA 505 Powered Industrial Trucks ADDRESS National Fire Protection Association Batterymarch Park Quincy Massachusetts 02269 USA e ANSI ASME B56 8 Personnel and Burden Carriers ADDRESS American National Standards Institute Inc 1430 Broadway New York New York 10018 USA Owner s Manual and Service Guide e ANSI UL 583 Electric Battery Powered Industrial Trucks ADDRESS American National Standards Institute Inc 1430 Broadway New York New York 10018 USA OR Underwriters Laboratories Inc 333 Pfingsten Road Northbrook Illinois 60062 USA This Electric Vehicle complies with ANSI B56 8 as it applies to OSHA for Powered Industrial Trucks under the Type E and EE classifications This vehicle has been approved by Factory Mutual Research Corporation To meet the manufacturer portions of the OSHA require ments as stated in section 1910 178 Paragraph a3 Powered Industrial Trucks must bear the appr
27. the Lubricant Level With the vehicle on level ground clean the area around the check fill plug and remove plug Ref Fig 16 on page 11 The correct lubricant level is just below the bottom of the threaded hole If lubricant is low add as required Add lubricant slowly until lubricant starts to seep from the hole Install the check fill plug In the event that the lubri cant is to be replaced the vehicle must be elevated and the oil pan removed or the oil siphoned out through the check fill hole Owner s Manual and Service Guide Fig 16 Rear Axle Lubricant Check and Fill BRAKES Service brakes in accordance with the Periodic Service Schedule Ref Fig 22 on page 16 After the vehicle has been put into service it is recommended that the brakes be checked by performing the following test Test Method To prevent severe injury N or death resulting from operating a vehicle with improperly operating brake system the braking sys tem must be properly maintained All driving brake tests must be done in a safe location with regard for the safety of all personnel Over time a subtle loss of performance may NOTE take place Therefore it is important to estab lish the normal braking distance with a new vehicle Determine the braking performance of the vehicle by engaging the parking brake ata common point on a flat dry clean paved surface while traveling at maximum speed Ref Fig 17 on page 12
28. they work when used properly and when used improperly and surface condi tions grade and other conditions of the environment in which the carrier is to be operated e operational performance tests and evaluations during and at completion of the program 5 3 Personnel and Burden Carrier Operator Responsibility 5 3 4 Operators shall abide by the following safety rules and practices in paras 5 4 5 5 5 6 and 5 7 5 4 General 5 4 4 Safeguard the pedestrians at all times Do not drive carrier in a manner that would endanger anyone 5 4 2 Riding on the carrier by persons other than the operator is authorized only on personnel seat s provided by the manufacturer All parts of the body shall remain within the plan view outline of the carrier 5 4 3 When a carrier is to be left unattended stop 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 Block the wheels if machine is on an incline 5 4 4 A carrier is considered unattended when the operator is 25 ft 7 6 m 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 25 ft 7 6 m of the carrier still in his view he still must have controls neutralized and the parking brake s set to prevent movement 5 4 5 Maintain a safe distance from the edge of ramps and platforms
29. 0 oil as required REAR AXLE A Replace lubricant after 5 years Fig 22 Periodic Service Schedule Owner s Manual and Service Guide Page 17 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings BATTERIES AND CHARGING Safety NOTE Always observe the following warnings when working on or near batteries To prevent burns or bat A WARNIN c tery explosion that could result in severe personal injury or death keep all smoking materials open flame or sparks away from the batteries Hydrogen gas is formed when charging batteries Do not charge batteries without adequate ventila tion 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 lift ing techniques when moving them Always lift the battery with a com mercially available battery lifting device Use care not to tip batteries when removing or installing them spilled electrolyte can cause burns and damage The electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extend
30. 29175 G01 Textron Company OWNER S MANUAL AND SERVICE GUIDE ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE ISSUED APRIL 2005 SAFETY Read and understand all labels located on the vehicle For any questions on any of the information contact a represen tative for clarification 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 vehicle specification Limit speed by applying the service brake Catastrophic 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 vehicle control is costly is considered abuse and will not be covered under warranty If the vehicle is to be used in a commercial environment signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition BATTERY WARNING BATTERIES AND RELATED PARTS CONTAIN LEAD WARNING WARNING 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 l
31. 6 1 1 Carriers may become hazardous if mainte nance is neglected Therefore maintenance facilities trained personnel and procedures shall be provided Such facilities may be on or off the premises Page xiii SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 6 2 Maintenance Procedures 6 2 1 Maintenance and inspection of all carriers shall be performed in conformance with the manufac turer s recommendations and the following practices a A scheduled preventive maintenance lubrication and inspection system shall be followed b Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers c Before undertaking maintenance or repair follow the manufacturer s recommendations for immobilizing the carrier d Block chassis before working underneath it e Before disconnecting any part of the engine fuel system of a gasoline or diesel powered carrier with grav ity feed fuel systems be sure shutoff valve is closed and run engine until fuel system is depleted and engine stops running f Before disconnecting any part of the engine fuel system of LP gas powered carriers close the LP gas cyl inder valve and run the engine until fuel in the system is depleted and the engine stops running g Operation to check performance of the carrier shall be conducted in an authorized
32. 96 Speed at min throttle setting Low Speed 40 100 60 55 926 Max speed in reverse High Speed 40 100 100 100 96 Max speed in forward Emergence Reverse Speed 25 100 100 100 96 Speed during emergency reverse Delays HPD and SRO from brake Sequencing Delay 0 3 0 0 Sec after controller is enabled On plug current dependent upon Variable Plug On Off On On throttle position Off fixed Option to disable controller if throttle High Pedal Disable HPD 0 2 0 1 is applied before brake or keyswitch input KSI Return To OM SRO type 0 1 2 Ye 9000 eue Prevents high speed mode if HSS in Anti tiedown On Off On Off not released after brake Fig 31 Factory Settings Owner s Manual and Service Guide Page 25 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings MAIN CONTACT 24V 841208 850756 36 841112 y 887885 840765 TERMINAL 887855 892458 891653 CONTROLLERR 890495 R 892671 886649 1891655 892901 HOUR METER 886802 TAILLIGHT 892676 dn d
33. E UNITS M M 6 BEFORE ENTERING VEHICLE esses lt en nnns 6 OPERATING tc Dae bau dec edid 6 STARTING THE VEHICLE Sitat patio 7 iut teret tarte eter t aes 7 ct ex una edd uen RARE cabs coge bev EY M OR XAR ue did 7 DRIVING THE VEHICLE sc dte ADU E aes teed 8 SERVICING THE ELECTRIC 9 TOWING Se 252 E 9 Owner s Manual Service Guide Page iii TABLE OF CONTENTS LIFTING un ntt eret ted tee e e d e Ee 9 SAFETY COMPONENTS Switch E Thermal Circuit Breaker Fig 13 Liflingthe Vehicle nace ee ER E Repo e Lg e 10 Parking The Velilcle o etie eere hein aeree 10 Lig 14 ParkingsTheVehlcle ici nete tei en eR RU DES eiue iron 10 ROUTINE MAINTENANCE _ 10 BEAR AXEE vai ba Checking the il uibricant ere RUE OM Ren rents Fig 15 Lubrication Pointss o
34. E VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings If the selector is moved to the REVERSE posi NOTE tion a backup warning alarm will sound until the vehicle is again placed in NEAUTRAL or FORWARD SERVICING THE ELECTRIC VEHICLE To prevent severe injury or death resulting from improper servicing tech niques observe the following Warnings Do not attempt any type of servicing operations before reading and understanding all notes cau tions and warnings in this manual Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with the entire vehicle raised Wear eye protection when working on the vehicle In particular use care when working around batteries or using solvents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads from the batteries before removing any heavy gauge battery wires To prevent the possibility of motor disintegration never operate vehicle at full throttle for more than 4 5 seconds while vehicle is in a no load condi tion Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling It is in the best interest of both vehicle owner and servic ing dealer to carefully follow the procedures recom
35. N 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 010 1 706 798 4311 FAX 010 1 706 771 4609 CUSHMAN DIVISION OF TEXTRON INC 1451 MARVIN GRIFFIN ROAD AUGUSTA GEORGIA USA 30906 3852 Owner s Manual and Service Guide Page i NOTES To obtain a copy of the limited warranty applicable to the vehicle call or write a local Distributor an authorized Branch or the Warranty Department with vehicle serial number and manufacturer code The use of non Original Equipment Manufacturer OEM parts may void the warranty Overfilling of batteries may void the warranty BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of electrical drain such as the battery charger Disconnect the battery charger cable from the vehicle batteries when not charging As with all electric vehicles the batteries must
36. a corrected reading of 1 254 Similarly if the temperature was 70 F 21 C subtract four points 004 from the 1 250 to give a corrected reading of 1 246 Ref Fig 30 on page 23 Electrolyte Temperature Above 80 F 27 C Electrolyte temperature 90 F 32 C Hydrometer reading 1 250 1 250 004 1 254 corrected specific gravity lt EXAMPLE 1 EXAMPLE 2 Electrolyte Temperature Below 80 F 27 C Electrolyte temperature 70 F 21 Hydrometer reading 1 250 1 250 004 1 246 corrected specific gravity Fig 30 Hydrometer Temperature Correction Page 23 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 5 Test each cell and note the readings corrected to 80 F or 27 C A variation of fifty points between any two cell readings example 1 250 1 200 indicates a problem with the low reading cell s As a battery ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the battery providing all cells are within fifty points of each other Since the hydrometer test is in response to a vehicle exhibiting a performance problem the vehicle should be recharged and the test repeated If the results indicate a weak cell the battery or batteries should be removed and replaced with a good battery of the same brand type
37. al conduc tors and connections shall be inspected and maintained in conformance with manufacturers recommended pro cedures q Carriers shall be kept in a clean condition to mini mize fire hazards and facilitate detection of loose or defective parts r Modifications and additions which affect capacity and safe machine operation shall not be performed by the customer or user without manufacturer s prior written authorization where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly s 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 Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings STANDARDS AND PUBLICATIONS This unit is not a motor vehicle within the definition of the National Traffic Motor Vehicle Safety Act It is not designed or manufactured for use on roads streets or highways and is not appropriate for such use This unit is not meant to be licensed as a motor vehicle The Electric 3 wheel service vehicle is available as Type E and Type EE Units Type E Units are electrically powered units having minimum acceptable
38. area where safe clear ance exists h Before commencing operation of the carrier follow the manufacturer s instructions and recommended pro cedures i Avoid fire hazards and have fire protection equip ment present in the work area Do not use an open flame to check level or leakage of fuel battery electrolyte or coolant Do not use open pans of fuel or flammable cleaning fluids for cleaning parts j Properly ventilate the work area K Handle LP gas cylinders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for use Brakes steering mechanisms speed and direc tional control mechanisms warning devices lights gov ernors guards and safety devices shall be inspected regularly and maintained in a safe operating condition m Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the orig inal approved safe operating features n Fuel systems shall be checked for leaks and condi tion of parts If a leak is found action shall be taken to Page xiv prevent the use of the carrier until the leak has been eliminated 0 The carrier manufacturer s capacity operation and maintenance instruction plates tags or decals shall be maintained in legible condition p Batteries motors speed and directional control lers limit switches protective devices electric
39. aw 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 this 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
40. ce Kit can be used with an approved water source Ref Fig 25 on page 20 These watering devices are fast and accurate to use and Page 19 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings maintain the correct electrolyte level within the battery cells Watering gun similar to the type included in the E Z GO Battery Maintenance Kit Valve consistently fills to a predetermined level Electrolyte Level Single Battery Cell Pure Water Fig 25 Automatic Watering Gun The watering device should only be used if the NOTE electrolyte level is less than 1 2 13 mm above top of plates Cleaning Batteries When cleaning the outside of the batteries and terminals do not use a water hose without first spraying with a solu tion of sodium bicarbonate baking soda and water to neutralize any acid deposits Use of a water hose without first neutralizing any acid will move acid from the top of the batteries to another area of the vehicle or storage facility where it will attack the metal structure or the concrete asphalt floor After hosing down the batteries a residue will be left on the batteries which is conductive and will contribute to the discharge of the batteries To prevent battery damage be sure that CAUTION all battery caps are tightly installed The correct cleaning technique is to spray th
41. charging system for dirt or debris Charge the batteries after each days use Monthly Inspect all wiring for fraying loose terminations corrosion or deterioration of insulation Check that the electrolyte level is correct and add suitable water as required Clean the batteries and wire terminations Electrolyte Level and Water The correct level of the electrolyte is 1 2 13 mm above the plates in each cell Ref Fig 23 on page 19 Vent Cap Expansion Space 1 4 to 3 8 mr d Gas Vent 6 to 10 mm n Vent a EE 1 2 13 mm Electrolyte level should be at least 1 2 13 mm above the plates and Plates 1 4 to 3 8 6 to 10 mm below vent Fig 23 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 Owner s Manual and Service Guide CAUTION 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
42. cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas however this loss is minimal If the battery electrolyte level is too high the electrolyte will block the vent tube and the gas will force it out of the vent tube and battery cap The water will evaporate but the sulfuric acid will remain where it can damage vehicle components and the storage facility floor Sulfuric acid loss will weaken the concentration of acid within the 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 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 24 on page 19 Parts Per Million Impurity Suspended Total Solids Organic amp Volatile Matter Nitrites Nitrates Chloride Fig 24 Water Purity Table Even if the water is colorless odorless tasteless and fit for drinking the water should be analyzed to see that it does not exceed the impurity levels specified in the table Automatic watering devices such as the one included in the Battery Maintenan
43. 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 OPERATION The SAFETY WARNING decal shown is located on the upper portion of the right kick panel All information on the decal is of the utmost importance This decal and all others must remain on the vehicle Failure to heed these warnings may result in personal or fatal injury to you or others and may also result in equipment and or property damages Before operating vehicle Read and understand operator s manual located under seal Page 7 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings All occupants must be seated in factory approved seats switches spark do not operate in explosive or commuatible atmosphere While operating vehicle Keep body inside vehicle passenger must be seated and use hand holds provided Sudden sharp turns unbalanced or top heavy loads can cause upset Cargo must be secured to platform Avoid sudden starts and stops to avoid unseating of passengers Adjust speed to conditions Before leaving vehicle Set direction selector to OFF position Turn key to vertical OFF position and remove If malfunction occurs or adjustment is needed
44. e Diamond pattern body with Durashield Industrial Yellow powder coat paint STANDARD COLOR Industrial Yellow LOAD BED koe rtt n beet erani 22 3 4 b8cm x 28 1 2 72cms x 4 10cms LOAD BED FEATURES Removable panel for powertrain access LIGHTING Standard Rear brake light TIRES Standard tere eet 4 80 x 8 Industrial Load Range B TIRE PRESSURE seen 60 psi 415 kPa WEIGHT with batteries 690 Ibs 315 kg OPERATING CONTROLS amp INSTRUMENTATION Removable key deadman accelerator control direction selector audible reverse warning BATTERY CHARGER aee nde Lestronic built in 24 V 120 VAC fully automatic line compensating 25 DC output at 24 volts 60 Hz UL recognized CSA certified RANGE Noriirial tt tbt 35 miles b6kms max Specifications subject to change without notice Page 30 Owner s Manual and Service Guide GENERAL SPECIFICATIONS 22 75 in 58 cm m 28 5 in 73 cm 53 in 135 cm 85 in 216 cm RECOMMENDED MAXIMUM RAMP GRADE RECOMMENDED MAXIMUM SIDE TILT 25 or 14 MAXIMUM 25 or 14 MAXIMUM Fig 33 Vehicle Dimensions and Incline Specifications Owner s Manual and Service Guide Page 31 GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER 130 in 330 cm Handlebar 154 in 391 cm INTERSECTING AISLE CLEARANCE Fig 34 V
45. e Ue Fig 16 Rear Axle Lubricant Check and Fill BRAKES edicere den Maa Pere c f PR 11 Test Method ood eae e A eed eM dd dA UA det 11 Fig 17 Periodic Brake Performance Test 12 Ferr PEE PE c E pobre mnm EO EA m PERDE TUM Tire Replica de ure nO e ED UC EOD Hike niae D obe e Ae ree Re Wh heellastallaton RE Fig 18 Wheel Installation Fig 19 Wheel Installation LIGHT BULB REPLACEMENT 1225 il hio Maa lide Ditis CARE AND CLEANING OF THE VEHICLE 2 14 TRALERING hx eo eaten erede x He pe ER DN qe e 14 la AEiB cic 15 FIG 20 BOE GIAO RP 15 TORQUE SPECIFICATIONS 15 FIGs 21 TOlQUC SDCCIICALIONS sere dae reo en eee ta Pe anie 15 PERIODIC SERVICE SCHEDULE 2 nennen nnns 16 Fig 22 Periodic Service Schedule o et ie de RR e etd 16 BATTERIES AND 0 lt inneren 18 UVP 18 E Ba ceeds ae aed ies aot ares eee ee tie te 18 BATTERY At Each Gharging Cycle getan cite in bets bro t esee d e
46. e 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 becomes The higher the density the higher the state of charge To prevent battery explo sion that could result in severe personal injury or death never insert a metal thermometer into a bat tery Use a hydrometer with a built in thermometer that is designed for testing batteries Specific gravity is the measurement of a liquid that is compared to a baseline The baseline is water which is assigned a base number of 1 000 The concentration of sulfuric acid to water in a new golf car battery is 1 280 which means that the electrolyte weighs 1 280 times the weight of the same volume of water A fully charged bat tery will test at 1 275 1 280 while a discharged battery will read in the 1 140 range NOTE Do not perform a hydrometer test on a battery that has just been watered The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80 F 27 C High quality hydrometers are equipped with an internal Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes
47. e 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 The solution should consist of 1 4 cup 60 ml of sodium bicarbonate baking soda mixed with 1 1 2 gallons 6 liters of clear water Ref Fig 26 on page 20 Page 20 In addition to the batteries special attention should be paid to metallic components adjacent to the batteries which should also be sprayed with the sodium bicarbon ate baking soda solution 1 1 2 gallons 6 liters Clear Water 1 4 60 Sodium Bicarbonate Baking Soda Non Metalic Wand 2 gallon 7 5 liter N Garden Sprayer N Fig 26 Preparing Acid Neutralizing 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 in order to remove any residue that could cause the self discharge of the battery Rinse the entire area with low pressure clear water All of the items required for com plete battery cleaning and watering are contained in the Battery Maintenance Kit Cleaning should take place once a month or more often under extreme conditions Battery Replacement Remove battery hold downs and cables Lift out batteries with a commercially available lifting device If the batteries have been cleaned and any acid in the battery rack area neutralized
48. ead compounds chemicals known to cause cancer and reproductive harm APPLY BRAKE TO LIMIT SPEED APPLY BRAKE TO LIMIT SPEED APPLY BRAKE WASH HANDS TO LIMIT SPEED AFTER HANDLING Be sure that this manual remains as part of the permanent service record should the vehicle be resold NOTES CAUTIONS AND WARNINGS Throughout this guide NOTE CAUTION and WARNING will be used NOTE A NOTE indicates a condition that should be observed CAUTION A CAUTION indicates a condition that may result in damage to the vehicle A WARNING indicates a A WARNING A hazardous condition that could result in severe injury or death Please observe these NOTES CAUTIONS and WARN INGS 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 Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling NOTES CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER OWNER S MANUAL AND SERVICE GUIDE ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE CUSHMAN MINUTE MISER Starting Model Year 2004 Cushman 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 Cushman Division of TEXTRO
49. econds Be sure to install the valve dust cap after checking or inflat ing Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Tire Repair The vehicle is fitted with tubeless tires mounted on one piece rims Generally the most cost effective way to repair a flat tire resulting from a puncture in the tread portion of the tire is to use a commercial tire plug NOTE Tire plug tools and plugs are available at most automotive parts outlets and have the advan tage of not requiring the tire be removed from the rim 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 specifications If tire is to be removed from or mounted on rim the tire changing machine manufacturer s recommendations must be followed to reduce possibility of personal injury To prevent injury be FNAC INE sure mounting demount ing machine is anchored to floor Wear OSHA approved safety equipment when mounting demounting tires Follow all instructions and safety warnings provided by the mounting demounting machine manufacturer Wheel Installation Do not tighten lug nuts to more than CAUTION 85 ft Ibs 115 Nm torque It is importan
50. ector switch to neutral position turn key to OFF position and remove key STARTING THE VEHICLE To start the vehicle Place the key in the key switch and turn to the ON position Move the direction selector to Owner s Manual and Service Guide the direction desired release park brake and press the accelerator pedal to start the vehicle NOTE 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 Releasing the accelerator slows the vehicle To stop the vehicle more quickly depress the brake pedal To avoid component damage the vehi CAUTION cle must be brought to a complete stop before shifting the direction selector switch Do not hold vehicle on hill by using accelerator and motor Leav ing motor in a stalled condition for more than 3 4 seconds will cause permanent damage to motor COASTING To prevent injury or death resulting from coasting at above recom mended speeds limit speed with service brake On steep hills ramps it is possible for vehicles to coast at faster than normal speeds that may be encountered on a flat surface To prevent loss of vehicle control speeds should be limited to no more than the maximum speed on level ground see GENERAL SPECIFICATIONS Limit speed by releasing the accelerator pedal and apply ing pressure to the heel of the pedal Severe damage to the drive train components
51. ed flushing with clear water Contact a physician immediately Always wear a safety shield or approved safety goggles when adding water or charg 2 ing batteries Any electrolyte spills should be neutralized with a solution of 1 4 cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and flushed with water Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle Expelled electrolyte may cause personal injury and damage to the vehicle and storage facility At Each Charging Cycle Page 18 Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from shorting out a battery which could result in an explosion and severe personal injury or death Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which could result in an explosion 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
52. eding the dimensions used to establish carrier capacity with extra caution Stability and maneuverability may be adversely affected 5 7 Operator Care of Personnel and Burden Carriers 5 7 1 At the beginning of each shift during which the carrier will be used the operator shall check the carrier condition and inspect the tires warning devices lights battery s speed and directional controllers brakes and steering mechanism If the carrier is found to be in need of repair or in any way unsafe the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating condition 5 7 2 f during operation the carrier becomes unsafe in any way the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating con dition 5 7 3 Do not make repairs or adjustments unless specifically authorized to do so 5 7 4 The engine shall be stopped and the operator shall leave the carrier while refueling 5 7 5 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before starting engine 5 7 6 Do not operate a carrier with a leak in the fuel system or battery s 5 7 7 not use open flames for checking electro lyte level in storage battery s or liquid level in fuel tanks 6 MAINTENANCE PRACTICES 6 1 Introduction
53. ehicle Turning Clearance Diameter and Intersecting Aisle Clearance Page 32 Owner s Manual and Service Guide NOTE Read and understand the following warnings before attempting to operate the vehicle To prevent personal AWARNINGA injury or death observe the following When vehicle is to be left unattended release ped al completely move direction selector to neutral turn key to OFF position and remove key Drive vehicle only as fast as terrain and safety considerations allow Consider the terrain and traffic conditions Consider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of direction may result in a loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc All travel should be directly up or down hills Use extra care when driving the vehicle across an incline Stay in designated areas and avoid steep slopes Use the parking brake whenever the vehicle is parked Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Make sure the direction selector is in correct posi tion before attempting to start the vehicle Slow down before and during turns All turns should be executed at
54. en leaving the vehicle seat FORWARD NEUTRAL REVERSE Fig 8 Direction Selector Switch To prevent unexpected AWARNING A vehicle movement when you or other persons next operate the vehicle ALWAYS place the direction selector switch in the NEUTRAL position when leav ing the vehicle seat Remove the key to prevent unauthorized use of the vehicle Page 4 Power ON Battery Condition Meter The power on battery condition meter indicates whether power is supplied to the unit and the state of battery charge The meter illuminates only when power is being supplied The meter scale is a 10 bar LED light emitting diode displaying the state of charge successively bar by bar from full to empty e At 70 of discharge a flashing light signals an energy reserve alert e At 80 of discharge a double flashing light sig nals as empty alarm The batteries should be fully charged before using the vehicle Headlight Accessory The headlight can be pivoted on the mounting as required Push the headlight switch on the dash panel to turn the headlight on or off Service Parking Brake Pedal The service and parking brakes are combined in the left pedal on the floorboard Depressing the pedal will slow or stop the vehicle Once the vehicle has stopped the parking brake can be engaged by pressing the front por tion of the pedal The floorboard catch should engage in the first notch of the parking brake l
55. ered Always check that the vehicle and contents are ade quately secured before trailering the vehicle The rated capacity of the trailer must exceed the weight of the vehi cle and load plus 400 pounds 180 kg see GENERAL SPECIFICATIONS section for vehicle weight Secure the vehicle to the trailer using ratchet tie downs Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE 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 21 on page Grade 2 Grade 5 15 Use care when tightening fasteners and refer to the Technician s Repair and Service Manual for specific torque values Generally two grades of hardware are used in the vehi TORQUE SPECIFICATIONS cle Grade 5 hardware can be identified by the three marks on the hexagonal head Unmarked hardware is Fig 20 Bolt Grades ALL TORQUE FIGURES ARE IN FT LBS Nm Unless otherwise noted in text tighten all hardware in accordance with this chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners BOLT SIZE a 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 8 15 55 75 130 125
56. forms to the current applicable standard for safety and performance requirements These vehicles do not conform to Federal Motor Vehicle Safety Standards and are not equipped for operation on public streets 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 alteration which would adversely affect the safety of the vehicle 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 A
57. g for loose connections and broken missing insulation ACCELERATOR Check for smooth movement STEERING Check for excessive play tightness of all hardware and bent or loose components REAR AXLE Check for oil leakage add lubricant SAE 80 90 oil as required 10 Oz 3L Capacity QUARTERLY 50 HOURS includes items listed in previous tables amp the following FRONT FORK Check for damage to axle and loose or missing hardware FRONT WHEEL ALIGNMENT Check for unusual tire wear align if required Check for bent binding linkage rods ERVICE PARK BRAKE 5 MEA Check for damage or wear Fig 22 Periodic Service Schedule Page 16 Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings otes SEMI ANNUAL 125 HOURS includes items listed in previous tables amp the following Clean and adjust see Technician s Repair and Service Manual ERVICE PARK BRAKE S CE S nage 1 ician s Repai Service M BODY STEERING Lubricate use wheel bearing grease ANNUAL 250 300 HOURS includes i listed i bles amp the following Adjust see Technician s Repair and Service Manua Pack use lithium based wheel bearing grease FRONT WHEEL BEARINGS Check lubricant add lubricant SAE 80 9
58. gs NOTE Install the wheel assembly with the valve stem on the same side as the wheel retaining nuts To prevent possible inju AWARNINGA ry always deflate the tire completely before removing from the wheel When reinstalling the front wheel assembly always place the axle and retaining washer over the axle locks as shown and tighten the axle nuts Tighten axle nuts to 100 to 120 ft Ibs 130 to 156 Nm torque Failure to follow the procedure may allow the axle to drop resulting in loss of vehicle control Removing and Reinstalling Rear Tire 1 Remove the wheel retaining nuts and remove the wheel assembly from the hub 2 Completely deflate the tire then remove from wheel 3 Reinstall the tire and wheel by reversing above sequence and tighten wheel retaining nuts Tighten to 70 to 80 ft Ibs 95 to 108 5 Nm torque 4 Make sure the valve stem is located toward the out side LIGHT BULB REPLACEMENT To replace the headlight bulb pivot the headlight forward and remove the two Phillips head screws from back side and separate light assembly Place new light bulb in place and secure with screws previously removed To replace the taillight bulb remove hardware securing lens and remove lens Install replacement bulb CARE AND CLEANING OF THE VEHICLE CAUTION To prevent cosmetic damage do not use any abrasive or reactive solvents to clean plastic parts It is important that proper techniques and cleaning
59. gs watch necklaces etc Be sure no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise entire 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 ventila tion 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 CUSHMAN A Textron Company 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 010 1 706 798 4311 FAX 010 1 706 771 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
60. hocks 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 potential 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
61. horoughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Notes Page 28 Owner s Manual and Service Guide GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner s Manual and Service Guide Page 29 GENERAL SPECIFICATIONS ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE BATTERY MONITORING LED State of charge meter BATTERIES eroe Oi ad 6 volt deep cycle 105 minute minimum 225 amp hour 20 hour discharge rate SPEED Programmable Solid state 250 amp capacity MOTOR c 24 VDC series wound 1 5 hp 1 1 kW 2800 rpm amp 4 3 hp 3 2 kW 1200 rpm brazed armature and solid copper windings REAR AXL Ei noi c tree tee dte edes Bevel gear with spur and helical gearreduction with input pinion shaft directly connected to motor shaft BRAKES siones a uM IUE d Dual rear wheel self adjusting mechanical drum brakes PARKING BRAKE sss Toe lock combined with service brake FRONT SUSPENSION Rubber mounted torque arm REAR SUSPENSION seen Coil springs and hydraulic shock absorber STEERIBNG teo erret Ee ER Eu Handlebar connected directly to front fork SEATING Driver and rear facing passenger 550 Ibs 250 kg including operator accessories amp cargo 10 1 2 mph 17 kph Welded tubular steel powder coated Durashield Non
62. ific safety rules and practices established to meet actual operating terrain and conditions However improper operation faulty maintenance or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard Some of the conditions which may affect stability are failure of the user to follow safety practices also ground and floor conditions grade speed loading the operation of the carrier with improper loads battery weight dynamic and static forces and the judgement exercised by the carrier operator a The user shall train carrier operators to adhere strictly to the operating instructions stated in this Stan dard b The user shall survey specific operating conditions and environment and establish and train carrier opera tors to comply with additional specific safety practices 4 3 Nameplates Markings Capacity and Modifica tions 4 3 4 user shall maintain in a legible condition all nameplates warnings and instructions which are supplied by the manufacturer 4 3 2 user shall not perform any modification or addition which affects capacity or safe operation or make any change not in accordance with the owner s Owner s Manual and Service Guide manual without the manufacturer s prior written authori zation Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are
63. ification 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 service representative for specific requirements The second reason is to determine why a particular vehi cle does not perform adequately Performance problems Page 22 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 partic 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 replaced with a good battery of the same brand type and approximate age Hydrometer A hydrometer P N 50900 G1 is used to test the state of charge of a battery cell Ref Fig 29 on page 23 This is performed by measuring the density of th
64. ing that requires access to the underside of the vehicle should be accom plished by raising the front of the vehicle with a chain hoist attached to the front frame members Always use an additional safety chain to prevent injury should the hoist malfunction To remove a wheel or the front axle loosen the hard ware Position a jack in the location indicated and care fully raise the front of the vehicle Position the jack stands as shown Use care not to place the jack or stands where they could interfere with wiring or linkages Slowly lower the jack and test the stability of the vehicle To raise the rear of the vehicle first raise the front of the vehicle as previously described and support on jack stands Then position the jack in the position shown at the rear of the vehicle Carefully raise the rear of the vehicle with the jack and place two jack stands in the position shown Slowly lower the jack and check that the vehicle is securely supported by the jack stands before proceeding Lower the vehicle by reversing the lifting sequence Page 9 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Turn wheel as shown to permit jack placement Place jack along the flat edge of footrest View from underside of vehicle Fig 13 Lifting the Vehicle SAFETY COMPONENTS The vehicle electrical circuit includes two
65. lways 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 battery 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 c
66. ly 5 5 7 Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up and down 5 5 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 5 5 9 Make starts stops turns or direction rever sals in a smooth manner so as not to shift the load endanger passengers or overturn the carrier 5 5 10 Do not indulge in dangerous activities such as stunt driving or horseplay 5 5 11 Slow down when approaching or on wet or slippery surfaces 5 5 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 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a Owner s Manual and Service Guide smooth sweeping motion 5 6 Loading 5 6 1 Handle only stable and safely arranged loads When handling off center loads which cannot be cen tered operate with extra caution 5 6 2 Handle only loads within the capacity of the carrier as specified on the nameplate 5 6 3 Handle loads exce
67. n pres sures should be checked when the tires are cool When removing wheels with an impact wrench use only impact sockets Regular sockets are not designed for impact pressures exerted by power tools A tire explosion can cause severe injury or death Never exceed inflation pressure rating on tire sidewall To prevent tire explosion pressurize tire with small amount of air applied intermittently to seat beads Never exceed the tire manufacturer s rec ommendation when seating a bead Protect face and eyes from escaping air when removing valve core Use caution when inflating tires Due to the low volume of these small tires overinflation can occur in a matter of seconds Overinflation could cause the tire to separate from the wheel or cause the tire to explode either of which could cause personal injury Use caution when inflating tires Due to the low volume of these small tires overinflation can occur in a matter of seconds Overinflation could cause the tire to separate from the rim or cause the tire to explode either of which could cause personal injury See GENERAL SPECIFICATIONS section for recom mended tire inflation pressure Under no condition should inflation pressure be higher than recommended on tire sidewall All three tires should have the same pressure for optimum handling characteristics Be careful not to overinflate Due to the low volume of these small tires overinflation can occur in a matter of s
68. nals with a commercially avail able protective coating t Front of Vehicle RED to Fuse inside Console BLK to BL to BL to Charger ESC Charger Solenoid Fig 27 Battery Connections Prolonged Storage Battery charger and controller must be CAUTION disconnected since they will contribute to the premature discharge of batteries Other electronic devices may need to be disconnected 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 C will lose 002 of specific gravity each day If a fully charged battery has a specific gravity of 1 275 and the battery is Owner s Manual and Service Guide allowed to sit unused it will become partially discharged When it reaches 1 240 which it will do in less than twenty days it should be recharged If a battery is left in a discharged state sulfating takes place on and within the plates This condition is not reversible and will cause permanent damage to the battery In order to prevent damage the battery should be recharged A hydrometer can be used to determine the specific gravity and there fore the state of charge of a battery E L E R L Y T E T E R T U
69. new vehicle is put into operation it is recom mended that the items listed in the INITIAL SERVICE CHART be performed Ref Fig 1 on page 2 ITEM SERVICE OPERATION Check operation and adjust if necessary Check air pressure see SPECIFICATIONS Fig 1 Initial Service Chart Page 2 On Board Charger The on board charger is wired directly to the batteries only requiring it be plugged into a dedicated 15 amp AC outlet to be operational When charge cycle is complete replace cord in appropriate area under cargo deck IDENTIFICATION The product model number model year and serial num ber must appear on all correspondence concerning this unit These identification numbers appear on the decal attached to the left side of the kick panel Ref Fig 2 on page 2 Fig 2 Model Number Model Year and Serial Number 1 Model Number Model Year and Serial Number The vehicle serial number is located under the seat Ref Fig 3 on page 3 CONTROLS METERS AND SWITCHES The controls meters and switches consist of key switch direction selector switch power on battery condition meter headlight accessory standard on EE models not shown service parking brake pedal speed control pedal horn seat switch hour meter accessory not shown Located under rear deck Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with thi
70. nsiderations allow Consider the terrain traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel eic Avoid extremely rough terrain Avoid driving fast down hill A sudden stop or change of direction may result in loss of control Use service brake to control speed when traveling down an incline Slow down before and during turns All turns should be executed at reduced speed All travel should be directly up or down hills Use extra care when driving the vehicle across any incline Stay in designated areas and avoid steep slopes To reduce the possibility of severe injury or death result ing from improper vehicle operation the following warnings must be observed Refer to GENERAL SPECIFICATIONS for 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 Always bring the vehicle to a complete stop before shifting the direction selector Check the area behind the vehicle before operat ing in reverse Always 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 vehi cle is to be left unattended set parking brake ped al completely move direction sel
71. ock catch when the brake is properly adjusted Ref Fig 9 on page 4 DEPRESS TO ENGAGE PARKING BRAKE CATCH DEPRESS TO RELEASE PARKING BRAKE FRONT OF VEHICLE i FLOORBOARD ee pu 4 PARKING BRAKE LOCK CATCH FIRST NOTCH FLOORBOARD CATCH Fig 9 Speed Control Pedal To release the parking brake depress the service park ing brake pedal Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings ALWAYS apply the park ES N ing brake when the vehi cle is to be left unattended The parking brake is NOT automatically applied Speed Control Pedal Depressing the speed control pedal starts the motor releasing the pedal stops the motor Operation with the pedal fully depressed gives maximum speed but is recommended only when the vehicle can be operated safely For slower speeds depress the pedal as required NOTE Reverse speed is half of forward speed To prevent loss of vehi cle control NEVER exceed safe operating speed ALWAYS adjust speed to conditions Horn and Handlebar The horn button switch is attached to the handlebar on the standard equipment vehicle A vehicle equipped with optional wheel type steering will have the horn button located on the right side of the Steering console AWARNINGA Depress the button to sound the ho
72. or example low hanging tree branches or laterally protruding objects Make sure the operating area is clear of debris Use extreme care when backing up Make sure no one is behind you Back the vehicle carefully at a reasonable speed NEVER use the vehicle in or near an area where there is explosive dust or fumes The electrical system of the unit creates sparks which can ignite explosive materials Adjust your speed to current driving conditions Travel directly up or down inclines DO NOT travel across the face of any incline ramp grade or slope Avoid driving fast down hill A sudden stop or change of direction can result in loss of control Use the service brake to control speed when trav eling down an incline NEVER overload the vehicle See identification decal on kick panel for rated capacity Position loads carefully so they cannot shift or tip over suddenly Distribute loads evenly over the rear area Keep loads low to avoid top heaviness DRIVING THE VEHICLE Make sure you are properly seated in the opera tor s seat Make sure the direction selector switch is in the NEUTRAL position Apply the parking brake if it isn t already applied by depressing the front portion of the service park ing brake pedal Insert the key in the key switch and turn it to the ON position Move the direction selector switch to the desired direction Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVIC
73. oval mark of either UL Underwriters Laboratory or FM Factory Mutual or other nationally recognized testing laborato ries Publications Additional operator s manuals and parts manuals are available for a minimum charge Parts Manual 29177 G01 Repair Manual 29178 G01 Thank you for this purchase The vehicle is equipped with an electronic speed control unit that is the most advanced in the industry Before driving the vehicle we ask you to spend some time reading this Owner s Man ual and Service Guide This guide contains information that will assist you in maintaining your highly reliable vehicle Some illustrations may show items that are optional for your vehicle Most of the service procedures in this guide can be accomplished by an individual using common automotive hand tools Refer to an authorized service representative for information on servicing the vehicle in accordance with the Periodic Service Schedule To facilitate maintenance a Service Parts Manual and a Technician s Repair and Service Manual is available from a local Distributor an authorized Branch or the Ser vice Parts Department When ordering parts or request ing information for your vehicle provide vehicle model serial number and manufacture code Page 1 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings BEFORE INITIAL USE Read
74. r shall permit in hazardous areas only those carriers approved and of the type required by ANSI NFPA 505 4 7 Lighting for Operating Areas 4 7 4 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 in accordance with the manufacturer s recommendations Page xi SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 4 8 Control of Noxious Gases and Fumes 4 8 1 When equipment powered by internal com bustion engines is used in enclosed areas the atmo sphere shall be maintained within limits specified in the American Conference of Governmental Industrial Hygienists publication Threshold Limit Values for Chemical Substances and Physical Agents in the Work room Environment This shall be accomplished by venti lation provided by the user and or the installation use and proper maintenance of emission control equipment recommended or provided by the manufacturer of the equipment 4 9 Warning Device s 4 9 1 The user shall make periodic inspections of the carrier to be certain that the sound producing and or visual device s are maintained in good operating condi tion 4 9 2 The user shall determine if operating condi tions require the carrier to be equipped with additional
75. rger cord Ref Fig 11 on page 6 Page 5 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings M 3 amp Fig 11 Battery Charger Fold Down Backrest The backrest is easily positioned to provide seating for a passenger or in a raised position for cargo To lower the backrest lift it upward and toward the front of the vehicle When the pins on either side have cleared the slots slowly lower the backrest into position Reverse the procedure when raising the backrest Ref Fig 12 on page 6 COMBINATION BACKREST 3 AND SEAT Fig 12 Fold Down Backrest To prevent possible inju ry make sure the seat is in the lowered position when carrying a passenger Raise the seat if no pas senger will be carried DO NOT allow a passenger to stand on the rear step Page 6 Programmable Speed Controller The vehicle is equipped with a programmable speed con troller which provides a variety of diagnostic data and can be used to change factory speed settings For infor mation about diagnostics troubleshooting adjustments and factory settings see pages 27 30 of this manual EE UNITS This vehicle is available in EE versions EE Units meet all the requirements of E Units and provide addi tional safeguards against inherent
76. rn The horn will not sound when the key is in off position Handlebar Installation CAUTION If the handlebar is factory installed make sure the retaining nut is tight Otherwise install the fork spindle key handle lockwasher and nut Tighten the nut to 50 ft Ibs 68 Nm torque Failure to install the fork spindle key and to tight en the handlebar retain ing nut may allow the handlebar to come loose resulting in loss of vehicle steering control Seat Switch The seat switch located under the operator s seat allows the vehicle to function only when the seat is in position and the operator is properly seated Should the operator leave the seat during operation the vehicle will stop Ref Fig 10 on page 5 Owner s Manual and Service Guide Fig 10 Seat Switch To prevent unexpected vehicle movement NEV ER operate the vehicle if the seat switch is malfunctioning Hour Meter Accessory The hour meter located in the motor compartment behind the speed controller records the number of hours the vehicle has been operated ADDITIONAL FEATURES Additional features include a built in battery charger a fold down backrest and a programmable speed control ler Battery Charger The standard vehicle is equipped with a built in 24 volt 25 amp DC 120 volt AC 60 Hz fully automatic charger located under the driver s seat There is also a storage area under the seat for the cha
77. s vehicle Pay particular attention to all Notes Cautions and Warnings Fig 5 Controls On Floorboard 1 Service Parking Brake Pedal 2 Speed Control Pedal Ref Fig 6 on page 3 shows the horn button and handle bar Fig 3 Serial Numbers Under Seat 1 Serial Numbers Under Seat Ref Fig 4 on page 3 and Ref Fig 5 on page 3 show the controls on the dash and the floorboard Fig 4 Controls On Dashboard 1 Key Switch Fig 6 Horn Switch 2 Direction Selector Switch 1 Handlebar 3 Power On Battery Condition Meter 2 Horn 4 Headlight Switch Key Switch The key switch located in the vehicle dash supplies or interrupts power to the vehicle electrical system Owner s Manual and Service Guide Page 3 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings ON POSITION Supplies power OFF POSITION Interrupts power Ref Fig 7 on page 4 Do Fig 7 Key Switch 1 On Position 2 Off Position To prevent unexpected vehicle movement or unauthorized use always turn the key switch to the OFF position and remove the key when the vehicle is not in use Direction Selector Switch The direction selector switch located on the dash panel controls the direction of vehicle movement The panel is marked with FORWARD NEUTRAL and REVERSE positions Push to the NEUTRAL position wh
78. 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 BATTERY MAINTENANCE Tool List Qty Required Insulated wrench 9 16 1 Battery CalTIer eode eese mee rere ees 1 Hydrometer P N 50900 01 1 Battery maintenance kit P N 25587 G01 1 Owner s Manual and Service Guide ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings To reduce the possibility 4 of fire never attach a battery charger to a vehi cle that is to be unattended beyond the normal charg ing cycle Overcharging could cause damage to the vehicle batteries and result in extreme overheating The charger should be checked after 24 hours and unplugged after the charge cycle is complete Before charging the batteries inspect all plugs recepta cles of the battery
79. sound producing and or visual devices and be responsi ble for providing and maintaining such devices in accor dance with the manufacturer s recommendations 5 OPERATING SAFETY RULES AND PRACTICES 5 1 Personnel and Burden Carrier Operator Qualifications 5 1 1 Only persons who are trained in the proper operation of the carrier shall be authorized to operate the carrier Operators shall be qualified as to visual auditory physical and mental ability to safely operate the equip ment according to Section 5 and all other applicable parts of this Standard 5 2 Personnel and Burden Carrier Operator s Training 5 2 1 The user shall conduct an operator s training program 5 2 2 Successful completion of the operator s train ing program shall be required by the user before opera tion of the carrier The program shall be presented in its entirety to all new operators and not condensed for those claiming previous experience 5 2 3 The user should include in the operators train ing program the following a instructional material provided by the manufac Page xii turer b emphasis on safety of passengers material loads carrier operator and other employees 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 for mulated d introduction of equipment control locations and functions and explanation of how
80. t to follow the cross sequence NOTE 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 18 on page 13 Then tighten lug nuts to 50 85 ft Ibs 70 115 Nm torque in 20 ft Ibs 30 Nm increments following the same cross sequence pattern Owner s Manual and Service Guide Tire style may vary Fig 18 Wheel Installation Removing and Reinstalling Front Tire To remove and reinstall the front tire complete the fol lowing steps and Ref Fig 19 on page 13 Fig 19 Wheel Installation Front Axle Lock Axle Nut Retaining Washer Wheel Retaining Nut Valve Stem GN ou Loosen the axle nuts and lower entire wheel hub and axle assembly from front fork Remove the four wheel retaining nuts 2 Completely deflate the tire then remove from wheel 3 Reinstall tire and wheel by reversing the above sequence and tighten wheel retaining nuts Tighten to 70 to 80 ft Ibs 95 to 108 5 Nm torque 4 Position the large flat washer located on the ends of the axle above the front axle locks 5 Tighten axle nuts to 100 to 120 ft Ibs 130 to 156 Nm torque Page 13 ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnin

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