E-Z-GO FLEET PDS GOLF CAR Owner'S Manual And Service Manual Download

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Page vi

Owner’s Manual and Service Guide

TABLE OF CONTENTS

Notes:

Summary of Contents for FLEET PDS GOLF CAR

Page 1: ...ELECTRIC POWERED FLEET GOLF CARS PERSONAL VEHICLES STARTING MODEL YEAR 2001 OWNER S MANUAL AND SERVICE GUIDE 28645 G01 GB REVISED 10 10 02 Ref Fcv 1...

Page 2: ...ke Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessive speed may cause a loss of vehicle contro...

Page 3: ...ut 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 is not liable for errors in thi...

Page 4: ...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 b...

Page 5: ...Switch 4 HORN 4 Fig 8 Horn Button 4 OPERATING THE VEHICLE 4 PRECISION DRIVE SYSTEM 5 Performance Options 5 Fig 9 Performance Options 5 Regenerative Braking 6 Pedal Up Brakng 6 Walk Away Feature 6 Ant...

Page 6: ...APACITIES AND REPLACEMENT PARTS 18 Fig 23 Capacities and Replacement Parts 18 BATTERIES AND CHARGING 19 SAFETY 19 BATTERY 19 BATTERY MAINTENANCE 19 At Each Charging Cycle 19 Monthly 20 Electrolyte Lev...

Page 7: ...le Battery Charger Dimensions 39 LIMITED WARRANTIES 41 DOMESTIC WARRANTY 42 INTERNATIONAL WARRANTY 2001 43 INTERNATIONAL WARRANTY 2002 44 INTERNATIONAL WARRANTY 2003 45 DECLARATION OF CONFORMITY EUROP...

Page 8: ...Page vi Owner s Manual and Service Guide TABLE OF CONTENTS Notes...

Page 9: ...This vehicle conforms to the current applicable standard s for safety and performance requirements These vehicles are designed and manufactured for off road use They do not conform to Federal Motor Ve...

Page 10: ...y Use specified replacement parts Never use replacement parts of lesser quality Use recommended tools Determine that tools and procedures not specifically recommended by the manufacturer will not comp...

Page 11: ...exchanges per hour is considered the minimum requirement Never charge a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane water heaters and furna...

Page 12: ...Owner s Manual and Service Guide SAFETY INFORMATION Page x Notes...

Page 13: ...ch affects capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made...

Page 14: ...ous experience 5 2 3 The user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads c...

Page 15: ...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 re...

Page 16: ...uids 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...

Page 17: ...orm a safety survey peri odically and as conditions warrant to their premises to identify areas where golf cars should not be operated and to identify possible hazards 5 2 1 Steep Grade In areas where...

Page 18: ...atteries the output rate of the battery charger and the amount of time the batteries are on charge Hydrogen emissions are generally considered to be in the area of 10 to 20 cubic liters per car per ch...

Page 19: ...l ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 6 2 8 As required under paragraphs 6 2 6 and 6 2 7 the manufacturer shall be contacte...

Page 20: ...SAFETY INFORMATION Page xviii Owner s Manual and Service Guide Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Notes...

Page 21: ...r 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 a...

Page 22: ...d with a non E Z GO charger refer to the instructions supplied with the charger CONTROLS AND INDICATORS Vehicle controls and indicators consist of key light switch direction selector state of charge m...

Page 23: ...re quickly depress the service brake If key switch is ON and park brake is set depressing the accelerator inadvertently will release the park brake and will cause the vehicle to move which could cause...

Page 24: ...re selecting RUN position THE FOLLOWING CODES REQUIRE THAT THE REAR WHEELS BE RAISED BEFORE PERFORMING TESTS Beep Fault Symptoms Correction Required 1 1 Controller Failure Vehicle will not run Check m...

Page 25: ...behind the vehicle before operat ing in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehicle is in motion PRECISION DRIVE SYSTEM Precision Drive System PDS ve...

Page 26: ...tteries Walk Away Feature Walk Away limits vehicle movement without driver input slowing the vehicle to 2 mph 3 kph and sounding an audible alarm reverse beeper Example If all of the following events...

Page 27: ...ILL Non PDS Vehicle To reduce the possi bility of roll back which could result in severe injury or vehicle damage do not release the service brake until motor has started Do not hold vehicle on hill b...

Page 28: ...inyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water and mild detergent is required to preserve the...

Page 29: ...cle install chocks in front and behind each front wheel Ref Fig 10 on page 9 Center the jack under the rear frame crossmember Raise the vehicle enough to place a jack stand under the outer ends of the...

Page 30: ...rts outlets and have the advan tage of not requiring the tire be removed from the wheel If the tire is flat remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immer...

Page 31: ...ehicles at a time Do not exceed 5 mph 8 kph while towing multiple vehicles Towing the vehicle at above recommended speed may result in severe injury and or damage to vehicle and other property Tow bar...

Page 32: ...rn off all electrical loads from the battery before removing battery wires Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench short ing out a battery which could result in an...

Page 33: ...To access it raise the seat and lift up the flap on the access panel Ref Fig 15 on page 13 Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manu...

Page 34: ...des items listed in previous table the following BATTERIES Clean batteries terminals See BATTERY CLEANING Check charge condition and all connections WIRING Check all wiring for loose connections and b...

Page 35: ...sh the acceptable stopping distance by testing a new or known to be good vehicle and recording the stopping location or stopping distance For fleets of vehi cles several vehicles should be tested when...

Page 36: ...uld refer to the TROU BLESHOOTING section in the Technicain s Repair and Service Manual REAR AXLE The only maintenance required for the first five years is the periodic inspection of the lubricant lev...

Page 37: ...17 PDS SYSTEM TEST At monthly intervals test the PDS system by allowing the vehicle to roll down an incline with the accelerator pedal released Braking force should be felt at approximately 2 mph 3 kp...

Page 38: ...ered wet and require approximately 80 of the torque required for dry fasteners 4 5 8 11 15 20 24 33 35 47 55 75 75 102 130 176 125 169 190 258 Grade 5 Grade 8 6 8 13 18 23 31 35 47 55 75 80 108 110 14...

Page 39: ...e to the vehicle and storage facility Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which c...

Page 40: ...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 flo...

Page 41: ...and water This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or plastic spray bottle The solution should consist of the ingredients shown in the illustrat...

Page 42: ...at 90 F 32 C will lose 002 of specific gravity each day If a fully charged battery has a specific gravity of 1 275 and the battery is allowed to sit unused it will become partially discharged When it...

Page 43: ...urers have different requirements Consult the battery manufacturer or a manufacturer representative for specific require ments The second reason is to determine why a particular vehi cle does not perf...

Page 44: ...op or bottom of the cylinder 3 Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float 4 Add or subtract four points 004 to the...

Page 45: ...turns off while the handle is moved back and forth check plug for a broken red wire in DC cord Fig 31 Hydrometer Temperature Correction 160 71 1 032 030 150 65 6 028 026 140 60 0 024 022 130 54 4 020...

Page 46: ...ATION AND SERVICE INFORMATION Page 26 Owner s Manual and Service Guide Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings No...

Page 47: ...Page 27 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS...

Page 48: ...ONTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning BATTERY CHARGER PowerWiseTM 36V 110 120 VAC Fully Automatic Line Compensating 21 amp DC out...

Page 49: ...kPa WEIGHT Without Batteries 550 lbs 250 kg OPERATING CONTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning BATTERY CHARGER PowerWiseTM portabl...

Page 50: ...TING CONTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning State of Charge Meter FEATURES Center Basket BATTERY CHARGER PowerWiseTM portable ful...

Page 51: ...Without Batteries 550 lbs 250 kg OPERATING CONTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning State of Charge Meter FEATURES Center Basket B...

Page 52: ...TIRES 18 x 8 00 10 4 Ply Rated Load Range B TIRE PRESSURE 20 25 psi 140 170 kPa WEIGHT Without Batteries 550 lbs 250 kg OPERATING CONTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Di...

Page 53: ...NTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning State of Charge Meter FEATURES Center Basket BATTERY CHARGER PowerWiseTM portable fully auto...

Page 54: ...t Batteries 550 lbs 250 kg OPERATING CONTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning State of Charge Meter FEATURES Center Basket BATTERY...

Page 55: ...18 x 8 00 10 4 Ply Rated Load Range B TIRE PRESSURE 20 25 psi 140 170 kPa WEIGHT Without Batteries 550 lbs 250 kg OPERATING CONTROLS INSTRUMENTATION Removable Key Deadman Accelerator Control Direction...

Page 56: ...4 Drink Holders Tee Ball Storage LIGHTING HORN Single Halogen Light Bar Tail Brake Lights Horn TIRES 18 x 8 50 8 4 Ply Rated Load Range B TIRE PRESSURE 18 22 psi 124 152 kPa WEIGHT Without Batteries 6...

Page 57: ...d Service Guide Fig 36 Vehicle Dimensions NOTE Shaded Area Indicates SHUTTLE 2 2 65 5 in 166 cm 92 5 in 235 cm 105 in 267 cm 46 5 in 118 cm Front 33 5 in 85 cm Rear 38 in 97 cm 49 in 124 cm 67 in 170...

Page 58: ...GENERAL SPECIFICATIONS Fig 37 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter TURNING CLEARANCE DIAMETER 19 ft 5 8 m RECOMMENDED MAX RAMP 25 GRADE or 14o MAX RECOMMENDED MAX S...

Page 59: ...table Battery Charger Dimensions Sized for 3 16 in 5 mm Bolt REAR SIDE 10 ft DC Cord 3 m FRONT 9 1 8 in 23 cm 2 1 4 in 6 cm 7 3 4 in 20 cm 10 7 8 in 28 cm 6 3 4 in 17 cm 4 7 8 in 12 cm 8 3 16 in 21 cm...

Page 60: ...Page 40 Owner s Manual and Service Guide GENERAL SPECIFICATIONS Notes...

Page 61: ...Page 41 Owner s Manual and Service Guide WARRANTY LIMITED WARRANTIES...

Page 62: ...WARRANTY DOMESTIC WARRANTY U S AND CANADA To obtain a copy of the limited warranty applicable to the vehicle call or write a local distributor authorized Branch or the Warranty Department with vehicle...

Page 63: ...BILITY OR FITNESS FOR A PARTICULAR PURPOSE E Z GO WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISIN...

Page 64: ...ABILITY OR FITNESS FOR A PARTICULAR PURPOSE TGTSP WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISIN...

Page 65: ...FITNESS FOR A PARTICULAR PURPOSE TGTSP WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISING FROM ANY...

Page 66: ...Page 46 Owner s Manual and Service Guide WARRANTY Notes...

Page 67: ...Page 47 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY...

Page 68: ...Page 48 Owner s Manual and Service Guide DECLARATION OF CONFORMITY...

Page 69: ...Page 49 DECLARATION OF CONFORMITY Owner s Manual and Service Guide...

Page 70: ...Page 50 Owner s Manual and Service Guide DECLARATION OF CONFORMITY...

Page 71: ...Page 51 DECLARATION OF CONFORMITY Owner s Manual and Service Guide...

Page 72: ...Page 52 Owner s Manual and Service Guide DECLARATION OF CONFORMITY...

Page 73: ...Page 53 DECLARATION OF CONFORMITY Owner s Manual and Service Guide...

Page 74: ...Page 54 Owner s Manual and Service Guide DECLARATION OF CONFORMITY Notes...

Page 75: ...Appendix A 1 LABELS AND PICTOGRAMS Owner s Manual and Service Guide LABELS AND PICTOGRAMS...

Page 76: ...smoothly To release parking PARK brake depress service lower brake pedal To stop release accelerator pedal and apply service brake Before leaving vehicle turn key OFF move the direction selector to n...

Page 77: ...tor if required 4 3 Solenoid drop out Vehicle stops Check solenoid wiring replace if required THE FOLLOWING CODES REQUIRE THAT THE VEHICLE BE OPERATED UNDER LOAD WHILE PERFORMING TESTS Beep Fault Symp...

Page 78: ...m LOAD CENTER OF GRAVITY MAXIMUM HEIGHT 14 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL MAX xxx lbs xxx kg SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY DO...

Page 79: ...NECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE DO NOT DISPOSE OF BATTERIES IN...

Page 80: ...OUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD P N TO LEAVE AN ELECTRIC POWER...

Page 81: ...il 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 t...

Page 82: ...ut the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc P O Box 388 Augusta Georgia 30903 0388 USA Inside USA Phone 1 800 241 585...

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