Ezgo Valor Owner'S Manual Download | Manualshive

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M

AINTENANCE

27

VEHICLE MAINTENANCE

MAINTENANCE SAFETY

To prevent serious injury or death, follow the procedures and comply with the safety

information in this manual while performing vehicle service or maintenance.

Use the tools shown in the tool list and wear the specified safety equipment when per

-

forming vehicle service or maintenance.
Remove all jewelry before you service the vehicle.
Do not allow loose clothing or hair to contact the moving parts.
Do not touch hot objects.
Make sure that the key switch is in the OFF position and the key is removed before ser

-

vicing the vehicle.
Disconnect the negative battery terminal before servicing the vehicle to prevent acciden

-

tal operation.
The drive wheels must be lifted and supported on jack stands before performing any ser

-

vice to the powertrain when

the motor is in operation.

Chock the wheels and support the vehicle with jack stands. NEVER get under a vehicle

that is supported by a jack. Lift the vehicle according to the manufacturers instructions.
Wear a face shield when working around the battery pack.
Be careful when working around batteries, using solvents or compressed air.
Use insulated tools within the battery area to prevent sparks or battery explosion.
The electrolyte in a battery is an acid solution which can cause burns to the skin and

eyes. Completely clean all electrolyte spills that contact the skin or eyes with clear water.

Contact a physician immediately.
Neutralize electrolyte spills with a solution of 2 teaspoons (10 ml) of sodium bicarbonate

(baking soda) mixed in 1 quart (1 L) of water. Rinse with clean water.
To prevent the risk of battery explosion, keep all flammable materials, open flames or

sparks away from the battery.
Maintain constant awareness that some components are heavy, spring loaded, corro

-

sive, explosive, can cause high amperage or get extremely hot. Battery acid and hydro

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gen gas can cause bodily injury
After you make repairs or do maintenance, test the vehicle in a safe area that is free from

vehicle and pedestrian traffic.

NOTICE: To decrease the risk of damage to the controller or motor, move the run/tow switch to the TOW posi

-

tion before you tow the vehicle.

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Summary of Contents for Valor

Page 1: ...10008970 A ISSUED MAR 2020 OWNER S MANUAL Valor 48V ...

Page 2: ...injury or death The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle Operating servicing and maintaining a passenger vehicle or off road vehicle can expose you to chemicals including phthalates and lead which are known to the State of California to cause cancer and birth defects or other re...

Page 3: ...1 OWNER S MANUAL 48V ELECTRIC VEHICLE Valor Starting MODEL YEAR 2020 MANUFACTURER INFORMATION Textron Specialized Vehicles Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 www ezgo com ...

Page 4: ...cessories department These are original instructions as defined by 2006 42 EC The manufacturer maintains the right to change the design of the vehicle without responsibility to make the changes on units purchased before changes were made The information in this manual can change without notice All information in this owner s manual is based on the latest product information at the time of publicat...

Page 5: ...struction 12 Alcohol or Drugs 12 Passenger 12 Before Operating 12 Load Operation 13 Driving in Reverse 13 Driving a Damaged Vehicle 13 Driving at Maximum Speeds 13 Driving on Pavement 13 Driving on Public Roads 13 Turning 13 Driving Uphill 13 Driving Downhill 13 Stalling on a Hill 13 Tires 14 Slippery Terrain 14 BATTERY CHARGING 14 VEHICLE LIFTING 14 VEHICLE MODIFICATION 14 MAINTENANCE SAFETY 14 F...

Page 6: ...CLE 22 Starting on a Hill 22 ACCELERATING 22 BRAKING 23 Coasting 23 DRIVING WITH A PASSENGER 23 SLIPPERY SURFACES 23 DRIVING UPHILL 24 TRAVERSING HILLSIDES 24 DRIVING DOWNHILL 24 STALLING ON A HILL 24 DRIVING IN REVERSE 25 PARKING THE VEHICLE 25 Maximum Weight Capacity 25 VEHICLE MAINTENANCE MAINTENANCE SAFETY 27 SCHEDULED MAINTENANCE 28 Severe Use Conditions 28 SCHEDULED MAINTENANCE CHART 28 RECO...

Page 7: ... the Lubricant Level 35 LUBRICATION 35 BRAKES 36 Periodic Brake Test 36 BATTERY 37 BATTERY DISPOSAL 37 BATTERY CLEANING 38 BATTERY CHARGING AND MAINTENANCE 38 At Each Charging Cycle 38 Monthly 38 Electrolyte Level and Water 39 BATTERY REPLACEMENT 40 BATTERY STORAGE 41 BATTERY CHARGING 42 AC Voltage 42 TROUBLESHOOTING 42 Using A Hydrometer 43 TRANSPORTING THE VEHICLE 44 Hauling the Vehicle 44 SPECI...

Page 8: ...6 TABLE OF CONTENTS ...

Page 9: ...SE This vehicle is designed and manufactured for off road use only Use on public streets roads or highways is illegal in most areas and increases the risk of an accident involving other vehicles and people This vehicle does not meet FMVSS Federal Motor Vehicle Safety Standards for public street road or highway use Check all laws and regulations before choosing an area to operate your vehicle WARRA...

Page 10: ... for the disposal information VEHICLE IDENTIFICATION NUMBERS Record the vehicle identification numbers in the spaces provided below These identification numbers are required when ordering parts from your authorized dealer Vehicle Model Number _________________________________________________________________ Frame PIN __________________________________________________________________________ REPAIR...

Page 11: ... gasoline vehicle put the selector in Forward MAINTENANCE TOWING This vehicle requires regularly scheduled maintenance see the periodic service schedule in owner s manual ONLY qualified personnel should service this vehicle Vehicle is not to be towed consult owner s manual for transport instructions Pressing the accelerator pedal releases the parking brake even when the key is in the OFF position ...

Page 12: ...10 SAFETY ...

Page 13: ...e condition of operation A damaged vehicle or a vehicle that is not functioning properly is dangerous and must not be operated until repairs are made Do not carry a passenger until you have a minimum of two hours driving experience on this vehicle Keep feet legs hands and arms inside the vehicle at all times The driver must keep both hands on the steering wheel and both feet on the floor or pedals...

Page 14: ...valid driver s license is not permitted to operate the vehicle Any person who is below the height of 59 in 150 cm is not permitted to operate the vehicle Leaving the keys in the key switch allows unauthorized operation of the vehicle by someone under 16 years of age an unlicensed driver or someone who does not meet the height requirement Always remove the key when the vehicle is not in operation O...

Page 15: ...visibility operating conditions and your skill and experience level Use the brake to control speed and maintain control of the vehicle Driving on Pavement Driving the vehicle on paved surfaces can affect handling characteristics and increase tire wear If possible avoid driving on paved surfaces If unavoidable drive slowly travel short distances and avoid sudden turns or stops Driving on Public Roa...

Page 16: ... not modify the vehicle to increase the speed or power Any modifications or installation of accessories not approved by the manufacturer can create a safety hazard and increase the risk of injury The warranty will be terminated if the vehicle is modified to increase vehicle speed or power The warranty may be terminated if the original or equivalent replacement parts are not installed on the vehicl...

Page 17: ... ventilated areas Maintain constant awareness that some components are heavy spring loaded corrosive explosive can cause high amperage or get extremely hot Keep your hands face feet and body away from any area that can expose them to injury in the event that an unexpected situation occurs After making repairs or performing maintenance test the vehicle in a safe area that is free from vehicle and p...

Page 18: ...16 SAFETY ...

Page 19: ... bottom left pedal on the floorboard Press the brake pedal to slow the speed or bring the vehicle to a complete stop Parking Brake Pedal The parking brake 3 is the upper pedal It allows the operator to lock the brake when the vehicle is parked to prevent accidental movement To engage the parking brake press the upper pedal until it locks into place Quickly press and release the lower pedal to dise...

Page 20: ...and debris before connecting the charger cord CANOPY TOP AND WINDSHIELD IF EQUIPPED The canopy top does not provide protection from rollover or falling objects The windshield does not provide protection from tree branches or moving objects To prevent damage to the vehicle do not hold on to the canopy top struts The canopy top and windshield provide some protection from the elements but do not keep...

Page 21: ...er charge a vehicle near gas water heaters or furnaces Charge batteries Perform the following pre ride inspection PRE RIDE INSPECTION Inspect and verify that the vehicle is in safe operating condition before each use to decrease the risk of an accident Check the items in the table to help ensure safe and reliable operation Item Check Page Batteries Check charge level Brake system pedal travel Chec...

Page 22: ... damage to the charger and possible fire keep the air fins clear The power AC cord has a plug with a ground post Do not remove cut or bend the ground post The off board or portable charger must have a dedicated 15 amp AC circuit refer to the charger manual for appropri ate circuit protection The charger should be placed in an area that permits good air flow around and under the char ger Read and f...

Page 23: ...contin ues Anti Roll Back Feature Anti Roll Back like Walk Away limits reverse motion of the vehicle down a slope to less than 2 mph 3 kph See Walk Away Feature for more information An alarm will not be activated should the anti roll back feature engage Anti Stall Feature Anti Stall protection prevents motor damage if the vehicle is stalled against an object or on a hill Example If all of the foll...

Page 24: ...vehicle on a hill Doing so for more than 3 4 seconds will cause permanent damage to motor To decrease the risk of permanent damage to the drive system do not allow roll back when you start the vehicle on a hill 1 Press the brake pedal with your left foot when releasing the parking brake Keep pressure on the pedal to pre vent the vehicle from rolling back 2 Press the accelerator pedal with your rig...

Page 25: ... back against the seat both feet on the floor Do not allow more than one passenger in the vehicle Do not allow a passenger to ride anywhere on the vehicle except the passenger seat Travel at speeds appropriate for your skills your passenger s skills and the operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to the passenger Handling characteristics ...

Page 26: ... are losing control of the vehicle steer downhill if possible to regain control DRIVING DOWNHILL When carrying cargo or towing a trailer the weight of the load will increase the braking distance required to slow or stop the vehicle Not allowing for increased braking dis tance under load can cause an accident or injury When driving down a hill follow these guidelines Avoid excessively steep hills C...

Page 27: ...ed garage Park the vehicle away from any source of flame or sparks including any appliance with a pilot light Park the vehicle on a flat surface if possible If parking on an incline is unavoidable be sure to chock the to keep the vehicle from rolling 1 Press the brake to stop the vehicle 2 Engage the parking brake 3 Turn the key switch to OFF 4 Remove the key from the switch to prevent unauthorize...

Page 28: ...26 OPERATION ...

Page 29: ...e manufacturers instructions Wear a face shield when working around the battery pack Be careful when working around batteries using solvents or compressed air Use insulated tools within the battery area to prevent sparks or battery explosion The electrolyte in a battery is an acid solution which can cause burns to the skin and eyes Completely clean all electrolyte spills that contact the skin or e...

Page 30: ...rips in cold weather prolonged heavy load operation Item Interval perform at interval that comes first Remarks Page Hours Calendar Overall vehicle condition Pre ride Inspect Batteries Daily Charge daily after use Steering Pre ride Check for smooth and free operation Front suspension Pre ride Inspect Check for leaks and loose or missing hardware Rear suspension Pre ride Inspect Check for leaks and ...

Page 31: ... smooth operation and acceptable stopping distance 36 Front wheel alignment 60 3 Months Check for unusual tire wear Rear Suspension 60 3 Months Check for shock oil leakage worn bushings loose or missing hardware S General lubrication 50 3 Months Lubricate all fittings pivots cables etc where required 29 Rear axle 500 5 years Replace fluid Motor coupling 20 000 Amp Hours 5 years Add anti seize comp...

Page 32: ...ground Lifting Front 1 Chock the rear wheels to keep the vehicle from rolling back ward 2 Put a jack under the center of the front axle 3 Raise the vehicle with the jack 4 Install jack stands under the front frame cross member as shown 5 Lower the vehicle until it rests on the jack stands 6 Remove the jack 7 Confirm that the vehicle is stable on the jack stands before proceeding with any service L...

Page 33: ... apply wax or polish to matte finish surfaces Use clean or new cloths and pads for polishing Old or reused cloths and pads can contain dirt particles that will scratch the finish TIRES Follow the tire maintenance procedures as instructed in this manual and on the labels on the vehicle Always use the approved size and type of replacement tires See VEHICLE SPECIFICATIONS on page 45 for the proper ti...

Page 34: ...he tire See Tire Pressure on page 11 Tire Replacement Tire replacement requires a tire mounting machine and must be done by a qualified tire center or an authorized dealer WHEELS Worn improperly inflated improper sized or incorrectly installed tires will affect vehicle handling and could cause an accident resulting in severe injury or death To decrease the risk of component damage do not tighten t...

Page 35: ...ny bulbs are burned out Poor light ing reduces visibility that could cause an accident resulting in severe injury or death NOTICE Replacement bulbs are available from a local Distributor an authorized Branch or the Service Parts Department Halogen Headlight Bulb Replacement Light components can get hot if they have been in operation Allow the lights to cool before servicing to prevent burns to the...

Page 36: ...t bottom to access the PDM 2 Open the PDM to access the fuses 3 Remove the old fuse and replace with a new fuse of the same type and size 4 Fuses are available from a local Distributor an autho rized Branch or the Service Parts Department CONTROLLER SYSTEM TEST At monthly intervals test the controller by allowing the vehicle to roll down an incline with the accelerator pedal released Braking force...

Page 37: ...ded hole If lubricant is low add lubricant as required Add lubricant slowly until lubricant starts to seep from the hole Install the check fill plug In the event that the lubricant is to be replaced the oil pan must be removed or the oil siphoned through the check fill hole LUBRICATION Do not use more than three pumps of grease in a grease fitting at any one time Excess grease can cause grease sea...

Page 38: ... important to establish a base to test with The test is conducted by engaging the park brake instead of the brake pedal to eliminate different pedal pressures to include affects of linkage mis adjustment and provide a more accurate test NOTICE You must have enough space to accelerate to maximum speed before engaging the parking brake Use a marker to indicate the predetermined line to engage the pa...

Page 39: ... is explosive Make sure that the key switch is in the OFF position and all electrical accessories are off before you start to work on the vehicle Be careful when you use aerosol containers near the battery terminals Use a container with insulation to prevent an explosion Turn off all accessories before disconnecting from the battery terminal Always wear a safety shield or approved safety goggles w...

Page 40: ... 2 tsp 10 ml baking soda 1 quart 1 liter water Wash all metal components near the battery 7 Allow the solution to set a minimum of three minutes Use a soft bristle brush or cloth to clean the top of each bat tery to remove residue that can cause the discharge of the battery 8 Rinse with tap water and dry with shop towels 9 After the batteries are clean and dry coat the terminals with a commerciall...

Page 41: ...e water will dry but the sulphuric acid will stay and damage the vehicle components and surface below the vehicle Sulphuric acid loss will weaken the amount of acid within the elec trolyte and decrease the life of the battery Over the life of the battery a large amount of water is used The water added to the batteries must be clean and with out contamination Unclean water decreases the life of the...

Page 42: ...e battery hold downs and cables 2 Remove the batteries with a commercially available lifting device 3 If the batteries have been cleaned and the acid in the battery rack area is neutralized as recommended no cor rosion to the battery racks or surrounding area should be present If any corrosion remains remove it with a putty knife and a wire brush Wash the area with a sodium bicarbonate baking soda...

Page 43: ...st be charged again If a battery stays in a discharged state sulfating occurs on and within the plates This condition is not reversible and will cause permanent damage to the battery To prevent dam age the battery must be charged again Use a hydrometer to find the specific gravity and the state of charge of a bat tery In winter conditions the battery must be completely charged to prevent the risk ...

Page 44: ...ferent manufacturers have different requirements Refer the bat tery manufacturer or the manufacturer s representative for specified requirements Find the reason a vehicle does not perform adequately Performance problems can cause a vehicle to run slowly or can not operate for the time needed A new battery must mature before it develops its maximum capacity Maturing can take 100 or more charge and ...

Page 45: ...temperature e g if the reading indi cates a specific gravity of 1 250 and the electrolyte tem perature is 90 F 32 C add four points 004 to the 1 250 which gives a corrected reading of 1 254 Simi larly if the temperature is 70 F 21 C subtract four points 004 from the 1 250 to give a corrected reading of 1 246 5 Test each cell and note the readings corrected to 80 F or 27 C A variation of fifty poin...

Page 46: ...h If the vehicle is being hauled on a trailer or truck at highway speeds the canopy top must be removed If the vehicle is being hauled on a trailer or truck below highway speeds check that canopy top hardware is tight and there are no cracks in the canopy top at the mounting points The rated capacity of the hauling trailer or truck must be more than the weight of the vehicle and load plus 1000 lbs...

Page 47: ...h 0 5 mph 31 0 kph 0 8 kph Drivetrain Motor Shaft Direct Drive Transaxle Differential with helical gears Gear Selection Forward Neutral Reverse Rear Axle Ratio 12 44 1 Seating Capacity 2 Passenger Dry Weight 555 lb 247 kg Curb Weight 923 lb 414 kg Dash IP Storage Capacity 1 123 in 18 403 cm Vehicle Load Capacity 800 lb 363 kg Outside Clearance Circle 19 ft 5 8 m Towing Capacity N A Steering Self c...

Page 48: ...46 SPECIFICATIONS Rear Body and Finish Injection Molded TPO Available Body Colors Flame Red Black Available Seat Colors Black Tan Some items shown may be optional equipment ...

Page 49: ...MAINTENANCE LOG 47 MAINTENANCE LOG Record periodic maintenance in the following maintenance log DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 50: ...48 MAINTENANCE LOG DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 51: ...MAINTENANCE LOG 49 DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 52: ...50 MAINTENANCE LOG DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 53: ... fluids capacities 29 recommended 29 fuse replacement 34 G glove box 18 H hauling vehicle 44 headlights 33 high pedal disable feature 21 hip restraints 17 K key switch 17 L labels safety 9 lifting vehicle 14 30 lubricants recommended 29 lubrication 35 M maintenance brakes 36 chart 28 fluid capacities 29 rear axle 35 recommended fluids and lubricants 29 scheduled 28 maintenance items 29 manufacture...

Page 54: ...y surfaces 23 specifications vehicle 45 speed control 20 starting and stopping 22 starting on hill 22 state of charge SOC meter 17 steering wheel 17 storage compartments 18 switches key 17 T tires 31 pressure 11 32 repair 32 replacement 32 transporting the vehicle 44 V vehicle cleaning 31 hauling 44 identification numbers 8 lifting 14 specifications 45 starting and stopping 22 transporting 44 W wa...

Page 55: ...position before pressing the accelera tor pedal Decrease speed before and during turns Bring the vehicle to a complete stop before moving the direction selector See SPECIFICATIONS on page 45 for the vehicle load and seat capacity NOTICE Read the following maintenance information and warnings before servicing or repairing the vehicle Follow the procedures and comply with the safety information in t...

Page 56: ...thout the express permission of Textron Specialized Vehicles Technical Publications Department Operating servicing and maintaining a passenger vehicle or off road vehicle can expose you to chemicals including phthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure wear gloves and wash your hands frequently whe...

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