Ezgo S4 Owner'S Manual Download Page 47

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MAINTENANCE

Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

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.

Hand held watering devices available at an automotive parts store, or automatic watering devices such as the one

included in the E-Z-GO Battery Maintenance Kit (P/N 25587-G01) can be used with an approved water source. These

watering devices are accurate, easy to use and allow for rapid filling. They also maintain the correct electrolyte level

within the battery cells.

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

Water Purity Table

Impurity

Parts Per

Million

Color
Suspended
Total Solids
Calcium & Magnesium Oxides
Iton
Ammonia
Organic & Volatile Matter
Nitrites
Nitrates
Chloride

Clear

Trace

100

5
8

Hand Held Watering Device

Distilled Water

Dispensing valve consistently
fills to a predetermined level

Electrolyte Level

Single Battery Cell

Watering gun similar to the type included in the E-Z-GO

Battery Maintenance Kit

Pure Water

Valve consistently
fills to a predetermined
level

Electrolyte Level

Single Battery Cell

Automatic Watering Gun

NOTICE

Summary of Contents for S4

Page 1: ...Owner s Guide TXT Fleet Electric 633137 ISSUED JULY 2013 REVISED FEBRUARY 2014 ...

Page 2: ...ontrols will be illus trated Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in accordance with the Periodic Service Schedule Repair or replacement parts are available through your E Z GO retailer or Genuine E Z GO Service Parts Depart ment The following information is needed when conta...

Page 3: ...n Inc reserves the right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by E Z GO and therefore is subject to change without notice E Z GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL...

Page 4: ...om any source of electrical drain The battery charger may be left connected to the vehicle to maintain a full charge on the bat teries provided the charger is plugged into an active electrical source If power to the elec trical source is disconnected or interrupted the battery charger will continue to check the charge on the battery pack this will draw power from the battery pack and eventually dr...

Page 5: ...AMETER AND INCLINE INFORMATION 9 INTRODUCTION FEATURES 11 General Information 11 Steering Wheel 11 Brake Pedal 11 Park Brake 11 Accelerator Pedal 11 Cupholder 11 Key Switch Light Switch If Equipped with Lights 12 State of Charge Meter If Equipped 12 Direction Selector 12 Fuse Block If Equipped 12 Charger Receptacle 13 Run Tow Maintenance Storage Switch 13 Seat 14 Hip Restraints 14 Sweater Basket 1...

Page 6: ... Terrain 23 Walk Away Feature 23 Anti Roll Back Feature 23 Anti Stall Feature 23 High Pedal Disable Feature 24 Diagnostic Mode Feature 24 STARTING AND DRIVING 24 Starting Vehicle On A Hill 24 Coasting 25 LABELS AND PICTOGRAMS 25 SUN TOP AND WINDSHIELD IF EQUIPPED 25 MAINTENANCE VEHICLE CLEANING AND CARE 27 COMMON SENSE OPERATION 27 ENVIRONMENTAL CONCERNS 28 Battery Disposal 28 LIFTING THE VEHICLE ...

Page 7: ... AXLE 35 Checking the Lubricant Level 35 LUBRICATION 35 CAPACITIES AND REPLACEMENT PARTS 35 HARDWARE 36 BATTERY CHARGING AND MAINTENANCE 36 Safety 36 Battery Disposal 37 Battery 37 Battery Maintenance 37 At Each Charging Cycle 38 Monthly 38 Electrolyte Level and Water 38 Battery Cleaning 40 Battery Replacement 41 Prolonged Storage 42 Battery Charging 42 AC Voltage 43 Troubleshooting 43 Hydrometer ...

Page 8: ...vi TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 9: ...t tow a single vehicle at speeds in excess of 12 mph 19 kph Do not tow more than three vehicles at a time Do not exceed 5 mph 8 kph while towing multiple vehicles Towing the vehicle at above the recommended speed may result in personal injury and or damage to the vehicle and other property If the vehicle is to be used in a commercial environment signs similar to the ones illustrated should be used...

Page 10: ...nal 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 web site for the U S Department of Transportation at Dockets and Regulation then to Title 49 of the Code of Federal Regulations Transportation All vehicles can be used for a variety of tasks beyond the original intended use of th...

Page 11: ...ed when traveling down an incline Use extra care and reduced speed when driving in poor conditions or on poor surfaces Stay in designated areas where provided and avoid steep slopes Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Make sure the direction selector is in correct position before depressin...

Page 12: ...d on steep grades Maintain adequate distance between vehicles Reduce speed in wet areas Use extreme caution when approaching sharp or blind turns Use extreme caution when driving over loose terrain Use extreme caution in areas where pedestrians are present MAINTENANCE ALWAYS Replace damaged or missing warning caution or information labels Maintain the vehicle in accordance with the manufacturer s ...

Page 13: ...affic Keep complete records of the maintenance history of the vehicle VENTILATION ALWAYS Charge the vehicle in a well ventilated area Charge in an area free of flammable liquids and items Charge a vehicle in an area that is free from flame or spark Pay particular attention to natural gas or propane water heaters and furnaces Use a dedicated 15 amp circuit for each battery charger DO NOT permit oth...

Page 14: ...position before towing WAIT 30 seconds after reconnecting batteries BEFORE turning key switch to REVERSE FORWARD or NEUTRAL positions ALWAYS turn key to OFF before disconnecting or reconnecting battery wires ELECTRICAL ARC or BATTERY EXPLOSION can occur if key is not in the OFF position To disable electrical system turn key switch to OFF and remove battery wires DO NOT alter or tamper with this un...

Page 15: ...rance Circle 19 0 ft 5 8 m Front Wheel Track 34 0 in 86 cm Speed Level Ground 10 2 14 8 mph 16 4 23 8 kph Rear Wheel Track 38 5 in 98 cm Towing Capacity 3 Golf Cars with Approved Permanent Tow Bar Ground Clearance at Differential 4 5 in 11 cm Steering Suspension Vehicle Power Steering Self compensating rack and pinion Power Source 48 Volts DC Front Suspension Leaf springs with hydraulic shock abso...

Page 16: ...ly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 8 VEHICLE DIMENSIONS 66 0 in 168 cm 91 0 in 231 cm 4 5 in 11 0 cm Ground Clearance Front 34 0 in 86 cm Rear 38 5 in 97 cm 46 5 in 118 cm 47 0 in 119 cm 67 5 in 171 cm ...

Page 17: ...hly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers TURNING DIAMETER AND INCLINE INFORMATION TURNING CLEARANCE DIAMETER 19 ft 5 8 m RECOMMENDED MAX RAMP 25 GRADE or 14 MAX RECOMMENDED MAX SIDE TILT 25 GRADE or 14o o MAX ...

Page 18: ...10 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 19: ...the driver seat is used to steer the vehicle 2 Brake Pedal The brake pedal is located on the floor to the left of the accelerator pedal The brake pedal is a combination brake and park brake to activate the brake depress the lower part of the pedal to slow or stop the vehicle 3 Park Brake The foot operated park brake is located along the top of the brake pedal To engage the park brake push down on ...

Page 20: ...tate of Charge Meter If Equipped The state of charge meter is located on the dash panel beside the key switch It indicates the amount of usable power in the batteries with F indicating a full charge on the battery pack and E indicating the battery pack needs to be charged 8 Direction Selector To prevent loss of control do not move vehicle direction selec tor while the vehicle is in motion Moving t...

Page 21: ... no longer function Before attempting to tow vehicle move the Run Tow Maintenance Storage switch to the Tow Maintenance Storage position Failure to do so will damage the controller or motor Before disconnecting or connecting a battery or any other wiring move the Run Tow Maintenance Storage switch to the Tow Maintenance Storage position After connecting a battery or any other wiring wait a minimum...

Page 22: ...en basket behind the seat back for carrying sweaters jackets or small packages 15 Bag Well Large bag well with straps to secure golf bags 16 Glove Box Compartments and Ball Holders Glove box compartments with golf ball holders one on each side of the instrument panel provide storage space for small items 17 Sun Top If Equipped The sun top offers some protection from sun or light rain 18 Battery Co...

Page 23: ...15 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers INTRODUCTION ...

Page 24: ...16 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 25: ... placed on the frame weld tube The other PART A and PART B is located on the crossmember section of the chassis on the driver side seat back support To access it raise the seat and lift up the flap on the access panel Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manufacture date code serial number and vehicle model manufacture date code an...

Page 26: ...r death Charging must take place in an area that is adequately ventilated minimum of 5 air exchanges per hour To reduce the chance of a battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc Hydrogen gas is generated in the charging cycle of batteries and is explo...

Page 27: ... be mounted on a platform above the ground or in such a manner as to per mit the maximum air flow underneath and around the charger Portable chargers are shipped with the vehicles Prior to vehicle or charger operation the charger must be removed and mounted on a platform or wall above the ground to permit maximum air flow around and underneath the charger A dedicated circuit is required for the ch...

Page 28: ...are several possible conditions that will generate errors Some errors will require human intervention to first resolve the problem and then reset the charger by unplugging the DC cord from the vehicle If the AC voltage is interrupted and restored the charger will turn back on automatically LED Operation Codes SHORT GREEN FLASH less than 80 charged LONG GREEN FLASH more than 80 charged SOLID GREEN ...

Page 29: ...attery cell after charging and add dis tilled water as required to the level specified by the battery manufacturer Follow the safety instructions recom mended by the battery manufacturer 2 Make sure the charger connections to the battery terminals are tight and clean Check for any deformations or cracks in the plastic parts Check the charger harness for chaffing and rubbing Inspect all wiring for ...

Page 30: ...FF position and remove key Make sure that the direction selector is in correct position before attempting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operating in reverse All occupants must be seated Keep entire body inside vehicle and hold on w...

Page 31: ... of the following events occur the vehicle has been stopped for more than 1 5 seconds the accelerator pedal has been released for more than one second the vehicle begins to roll above 2 mph 3 kph the Walk Away feature will limit speed to approximately 2 mph 3 kph and the warning beeper will sound When the accelerator pedal is depressed the Walk Away feature and warning beeper will be overridden an...

Page 32: ...d Remove the charger plug from the vehicle receptacle and properly store the cable prior to moving the vehicle To operate the vehicle Apply the service brake place the key in the key switch and turn it to the ON N position Move the direction selector to the direction desired Release the park brake by depressing the service brake pedal until the park brake releases Slowly depress the accelerator pe...

Page 33: ...D PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings The SAFETY Section of this manual explains the labels that are used on this vehicle SUN TOP AND WINDSHIELD IF EQUIPPED The sun top does not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects The sun top and windshield p...

Page 34: ...26 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 35: ...clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle These materials will cause corrosion of underbody parts unless flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas ...

Page 36: ...ills place residue in acid resistant containers with absorbent material sand or earth and dis pose of in accordance with local state and federal regulations for acid and lead compounds Contact local and or state environmental officials regarding disposal information LIFTING THE VEHICLE Some servicing operations may require the front wheels the rear wheels or the entire vehicle to be raised Use ext...

Page 37: ...the vehicle Lower the vehicle by reversing the lifting sequence WHEELS AND TIRES A tire explosion can cause severe injury or death Never exceed the inflation pressure rating on the tire sidewall To reduce the possibility of tire explosion pressurize tire with small amounts of air applied inter mittently to seat beads Due to the low volume of the small tires overinflation can occur in sec onds Neve...

Page 38: ...fitted with low pressure tubeless tires mounted on one piece rims therefore the most cost effective way to repair a puncture in the tread is to use a commercial tire plug Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel If the tire is flat remove the wheel and inflate the tire to the maximum recommen...

Page 39: ...low it to slide down the harness and out of the way Rotate bulb socket a quarter turn counterclockwise to unlock Pull out bulb and socket Insert new bulb and rotate socket a quarter turn clockwise to secure Slide locking ring over new bulb socket and onto back of light housing Taillight Remove two phillips head screws securing lens and pull lens out of housing to access the taillight bulb Remove t...

Page 40: ...0 kph If the vehicle is to be transported at highway speeds the sun top must be removed and the seat bottom secured When transporting vehicle below highway speeds check for tightness of hardware and cracks in sun top at mounting points The rated capacity of the trailer or truck must exceed the weight of the vehicle see GENERAL SPECIFICATIONS for vehicle weight and load plus 1000 lbs 454 kg Secure ...

Page 41: ... manual Preventative maintenance applied at recommended intervals is the best guarantee for keeping the vehi cle both dependable and economical Before any electrical service is performed the Run Tow Maintenance Storage switch must be placed in the Tow Maintenance Storage position If a power wire battery motor or controller is disconnected for any reason the Run Tow Maintenance Storage switch must ...

Page 42: ... or distances recorded Over time a subtle loss of performance may take place therefore it is important to establish the standard with a new vehicle Drive the vehicle at maximum speed on a flat dry clean paved surface Quickly depress the brake pedal to latch the parking brake at the line or marker in the test area and remove foot from pedal The vehicle should stop aggressively The wheel brakes may ...

Page 43: ...ow add lubricant as required Add lubricant slowly until lubricant starts to seep from the hole Install the check fill plug In the event that the lubricant is to be replaced the oil pan must be removed or the oil siphoned through the check fill hole LUBRICATION Do not use more than three 3 pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease m...

Page 44: ...tteries Hydrogen gas is formed when charging batteries Do not charge batteries without adequate ven tilation 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 the vehicle Never disconnect a circuit under load at a battery terminal ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 ...

Page 45: ... and severe per sonal injury or death Battery Disposal Lead acid batteries are recyclable Return whole scrap batteries to distributor manufacturer or lead smelter for recy cling For neutralized spills place residue in acid resistant containers with absorbent material sand or earth and dis pose of in accordance with local state and federal regulations for acid and lead compounds Contact local and o...

Page 46: ...rced out of the battery due to gassing and a decrease in volume of the electrolyte that results from the charging cycle DO NOT overfill batteries The charging cycle will expel electrolyte and result in component damage A battery being charged will gas with the majority of the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulph uric a...

Page 47: ...ccurate easy to use and allow for rapid filling They also maintain the correct electrolyte level within the battery cells The watering device should only be used if the electrolyte level is less than 1 2 13 mm above top of plates Water Purity Table Impurity Parts Per Million Color Suspended Total Solids Calcium Magnesium Oxides Iton Ammonia Organic Volatile Matter Nitrites Nitrates Chloride Clear ...

Page 48: ...insing battery To reduce the possibility of damage to electrical components while cleaning do not use a pressure washer Cleaning should occur per the Periodic Service Schedule When cleaning the outside of the batteries and terminals do not use a water hose without first spraying the batteries with a solution of baking soda sodium bicarbonate and water to neutralize any acid deposits Use of a water...

Page 49: ... for at least 30 seconds after the circuit is restored Remove battery hold downs and cables Lift out batteries with a commercially available lifting device If the batteries have been cleaned and any acid in the battery rack area neutralized as recommended no corrosion to the battery racks or surrounding area should be present Any corrosion found should be immediately removed with a putty knife and...

Page 50: ...ully charged battery will not freeze in temperatures above 75 F 60 C Although the chemical reaction is slowed in cold temperatures the battery must be stored fully charged and disconnected from any circuit that could discharge the battery The controller should be disconnected from the batteries by setting the Run Tow Maintenance Storage switch located under the passenger seat to the TOW MAINTENANC...

Page 51: ...s rep resentative for specific requirements The second reason is to determine why a particular vehicle does not perform adequately Performance problems may result in a vehicle that runs slowly or in a vehicle that is unable to operate for the time required A new battery must mature before it will develop its maximum capacity Maturing may take up to 100 charge discharge cycles After the maturing ph...

Page 52: ... 004 to the reading for every 10 F 6 C the electrolyte temperature is above or below 80 F 27 C Adjust the reading to conform with the electrolyte temperature e g if the reading indicates a specific gravity of 1 250 and the electrolyte temperature is 90 F 32 C add four points 004 to the 1 250 which gives a corrected reading of 1 254 Similarly if the temperature was 70 F 21 C subtract four points 00...

Page 53: ...45 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers MAINTENANCE ...

Page 54: ...46 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 55: ...on Brakes aggressive stop test C A C A C A C A Park Brake operation does it hold on a hill C A C A C A C A Accelerator smooth operation Charger Receptacle inspect charger connector and receptacle at each charge Wiring loose connections broken or missing insulation Direction Selector attachment and mechanism C A C A C A C A Steering Assembly excessive play loose or missing hard ware Tie Rods excess...

Page 56: ...48 PERIODIC SERVICE SCHEDULE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 57: ...A APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers APPENDIX A DECLARATION OF CONFORMITY ...

Page 58: ...APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers B ...

Page 59: ...C APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers ...

Page 60: ...D APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 61: ......

Page 62: ... 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine E Z GO Parts Accessories Department or at www shopezgo com Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc...

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