Ezgo ST 400 48V Owner'S Manual & Service Manual Download Page 1

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OWNER'S MANUAL

SERVICE GUIDE

ELECTRIC POWERED VEHICLE

612307

ISSUED MAY 2009

400 48V

Summary of Contents for ST 400 48V

Page 1: ...OWNER S MANUAL SERVICE GUIDE ELECTRIC POWERED VEHICLE 612307 ISSUED MAY 2009 400 48V...

Page 2: ...Maintenance position Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition Be sure that this manual remains as part of the permanent servi...

Page 3: ...the E Z GO Division and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL and the E Z GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCI...

Page 4: ...atteries 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 wint...

Page 5: ...Run Tow Maintenance Switch 4 PLASTIC LOADBED 4 MANUAL LIFT BED OPERATION 5 Fig 8 Manual Bed Latch 5 TAILGATE OPERATION 5 OPERATING THE VEHICLE 5 PRECISION DRIVE SYSTEM 6 Regenerative Braking 6 Pedal U...

Page 6: ...Specifications and Bolt Grades 18 BATTERY 18 BATTERY MAINTENANCE 19 At Each Charging Cycle 19 Monthly 19 Electrolyte Level and Water 19 Fig 20 Correct Electrolyte Level 19 Fig 21 Water Purity Table 2...

Page 7: ...SES 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 I am directing that E Z GO Branch personnel Dist...

Page 8: ...uld adversely affect the safety of the vehicle Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment Addi...

Page 9: ...lar and pedestrian traffic Replace damaged or missing warning caution or information labels Keep complete records of the maintenance history of the vehicle The manufacturer cannot anticipate all situa...

Page 10: ...specific safety rules and practices established to meet actual operating terrain and conditions However improper operation faulty maintenance or poor housekeeping may contrib ute to a condition of ins...

Page 11: ...nd re fuel them on the ground If this is not possible use a portable plastic fuel container to refuel equipment on a truck bed or trailer 6 5 Changing and Charging Storage Batteries for Electric Perso...

Page 12: ...ain that the safety interlock system if so equipped is operating properly 7 OPERATING SAFETY RULES AND PRACTICES 7 1 Personnel and Burden Carrier Operator Qualifications Only persons whoa are trained...

Page 13: ...orized speed limits Under normal traffic conditions keep to the right Maintain a safe distance based on speed of travel from a carrier or vehicle ahead and keep the carrier under control at all times...

Page 14: ...m or battery s Battery s shall be charged and serviced per manufacturer s instructions 7 3 4 8 Do not use open flames for checking electrolyte level in storage battery s or liquid level in fuel tanks...

Page 15: ...and connections shall be inspected and maintained per carrier manufacturer s recommendation p Carriers shall be kept in a clean condition to minimize hazards and facilitate detection of components ne...

Page 16: ...ere injury or death Charging must take place in an area that is adequately ventilated minimum of 5 air exchanges per hour To reduce the chance of battery explosion that could result in severe injury o...

Page 17: ...h charging The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away To reduce the possibility of a physical hazard that could result in an electrical shock or e...

Page 18: ...h permits the selection of either F forward R reverse or neu tral the position between forward and reverse Vehicle should be left in neutral with park brake applied locked when unattended Ref Fig 5 on...

Page 19: ...ance position After connecting a battery or any other wiring wait a minimum of 30 seconds before moving the Run Tow Maintenance switch to the Run position The PDS vehicle is equipped with a two positi...

Page 20: ...Static elec tricity is built up during the fueling process and could dis charge causing the gasoline vapor to ignite MANUAL LIFT BED OPERATION Exercise caution while operating the manu al lift bed to...

Page 21: ...eck the area behind the vehicle before operating in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehi cle is in motion PRECISION DRIVE SYSTEM Regenerative Bra...

Page 22: ...oved from the stalled condition Example If all of the following events occur a the system senses that the accelerator pedal is depressed power applied to motor b the brake is engaged so as to prevent...

Page 23: ...ed on level ground see vehicle specification Limit speed by releasing the accelerator and applying service brake Severe damage to the drive train components due to excessive speed may result from driv...

Page 24: ...enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle These mate rials will cause corros...

Page 25: ...seconds Over inflation could cause the tire to separate from the wheel or cause the tire to explode Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS secti...

Page 26: ...ty of premature bulb failure do not touch new bulbs with bare fingers Use clean dry tissue or paper towel to handle the glass portion of the bulb For vehicles with headlights mounted in cowl locate th...

Page 27: ...attempt any type of servicing opera tions before reading and understanding all notes cautions and warnings in this manu al Any servicing requiring adjustments to be made to the powertrain while the mo...

Page 28: ...brication locations Ref Fig 17 on page 17 To prolong vehicle life some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures...

Page 29: ...connections 3 Check battery water WIRING 3 Check all wiring for loose connections and broken missing insulation CHARGER RECEPTACLE Clean connections keep receptacles free of dirt and foreign matter AC...

Page 30: ...rrain road surface condition actual vehicle weight accessories installed and vehicle speed No specific braking distance can be reliably specified The test is conducted by latch ing the parking brake t...

Page 31: ...hanic who should refer to the TROU BLESHOOTING section in the Technician s Repair and Service Manual REAR AXLE The rear axle is provided with a lubricant level check fill plug located on the bottom of...

Page 32: ...Service Manual for specific torque values Generally three grades of hardware are used in the vehi cle Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware...

Page 33: ...rs of battery terminal pro tectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which could result in an explosion Wrap wrenches with vinyl...

Page 34: ...ater 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 20 on page 19 This level...

Page 35: ...s before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from the top of batteries to another area of the vehicle or storage facility where it will atta...

Page 36: ...a solution of sodium bicarbonate baking soda and brush clean if required To prevent battery explosion that could result in severe personal injury or death extreme care must be used with aerosol contai...

Page 37: ...ery charger is designed to fully charge the bat tery set If the batteries are severely deep cycled some automatic battery chargers contain an electronic module that may not activate and the battery ch...

Page 38: ...ttery 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 n...

Page 39: ...s 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...

Page 40: ...Page 27 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS...

Page 41: ...olid State continuously variable seperately excited speed controller Eight 6 Volt Deep Cycle Batteries Dash mounted direction selector switch Forward Neutral Reverse Full torque reduced speed reverse...

Page 42: ...FICATIONS Owner s Manual and Service Guide Fig 28 Vehicle Dimensions ST 400 48V 111 5 in 283 cm 65 5 in 166 cm Rear 38 in 96 5 cm Front 38 5 in 97 8 cm 7 5 in 19 cm 30 5 in 77 cm 44 5 in 113 cm 49 5 i...

Page 43: ...ide GENERAL SPECIFICATIONS Fig 29 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX TURNING CLEA...

Page 44: ...Page 31 Owner s Manual and Service Guide WARRANTY LIMITED WARRANTIES...

Page 45: ...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 46: ...Appendix A 1 Owner s Manual and Service Guide LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS...

Page 47: ...ograms 20 1 21 22 Pb35493 G01 28203 G01 On Battery Under Seat WARNING Windshields do not provide protection from golf balls or other flying objects EGWHL14 See Following Pages For Explanation Of Picto...

Page 48: ...WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY DO NOT RIDE IN LOAD BED DANGER OF EXPLOSION DO NOT FILL GAS CAN IN...

Page 49: ...MINAL 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 LANDFILL DO NOT DRIVE ON...

Page 50: ...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 POWERED VEHICLE IN PARK APPLY...

Page 51: ...Appendix A 6 Owner s Manual and Service Guide LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD 51 Ref Pic 1 4 NOTE All Pictograms may not apply to your product...

Page 52: ...Appendix B 1 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY...

Page 53: ...Appendix B 2 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION...

Page 54: ...omponents 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 c...

Page 55: ...Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 GET EZGO 1 888 438 3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Copyrighted Material This manual...

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