E-Z-GO 28809-G01 Owner'S Manual And Service Manual Download

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GASOLINE POWERED REFRESHMENT VEHICLE

ISSUED APRIL 2005

OWNER’S MANUAL

AND SERVICE GUIDE

28809-G01

Summary of Contents for 28809-G01

Page 1: ...GASOLINE POWERED REFRESHMENT VEHICLE ISSUED APRIL 2005 OWNER S MANUAL AND SERVICE GUIDE 28809 G01...

Page 2: ...le mat riel brouilleur du Canada For any questions on material contained in this manual contact an authorized representative for clarification Read and understand all labels located on the vehicle Alw...

Page 3: ...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...

Page 4: ...e governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle sp...

Page 5: ...TIAL USE 5 Fig 5 Initial Service Chart 5 CONTROLS AND INDICATORS 5 KEY LIGHT SWITCH 6 Fig 6 Key Light Switch Low Oil Pressure Light and Fuel Gauge 6 DIRECTION SELECTOR 6 CHOKE 6 Fig 7 Direction Select...

Page 6: ...Fig 26 Blowing Out Oil Filter 19 Fig 27 Add Engine Oil 20 STARTER GENERATOR BELT TENSION 20 Fig 28 Checking Belt Tension with Gauge 20 Fig 29 Checking Belt Tension Manually 20 Adjusting the Belt 21 Fi...

Page 7: ...cle Dimensions Incline Specifications and Turning Clearance Diameter 30 LIMITED WARRANTIES 31 DOMESTIC WARRANTY 32 INTERNATIONAL WARRANTY 2004 33 FEDERAL EMISSION COMPONENT DEFECT WARRANTY 35 CALIFORN...

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

Page 9: ...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 10: ...e environment Additionally speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always Use the vehicle in a responsible manner and maintain the...

Page 11: ...ea that is free of both vehicular and pedestrian traffic Replace damaged or missing warning caution or information labels Keep complete records of the maintenance history of the vehicle The manufactur...

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

Page 13: ...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 manual without the manufacturer s prior written autho...

Page 14: ...l 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 instructio...

Page 15: ...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...

Page 16: ...kage 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...

Page 17: ...e possibility of severe injury and or damage to the unit Be sure hands and fingers are clear of unit while placing unit on frame The refreshment unit is shipped on a pallet While resting on pallet the...

Page 18: ...ent points and canopy frame juncture Ref Fig 3 on page 4 With the aid of assistants pull canopy taut over canopy frame Fold mounting flap up inside canopy frame as shown Secure each mounting flap to i...

Page 19: ...side of the bever age container is to be used for consumable ice only Ref Fig 1 on page 2 This compartment is equipped with it s own drain per FDA requirements and should not be used for canned goods...

Page 20: ...ead all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Fig 3 Canopy Installation 20 21 21 22 22 21 21 20 22 21 21 23 Top Mounting...

Page 21: ...t on the operator Hydrogen gas is generat ed as 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...

Page 22: ...n selector Located on the seat support panel this lever permits the selection of either F forward or R reverse Ref Fig 7 on page 6 Vehicle should be left in F when unat tended CHOKE The choke is used...

Page 23: ...life of brake compo nents COMBINATION SERVICE AND PARK BRAKE PEDAL The brake pedal incorporates a park brake feature Ref Fig 9 on page 7 To engage push down on the upper section of the pedal until it...

Page 24: ...ng the first hours of operation As internal moving parts are run in oil consumption should gradually decrease until the rate of consumption stabilizes Check the oil level per the Periodic Service Sche...

Page 25: ...face To reduce the possible loss of vehicle control and severe drivetrain damage speeds should be limited to no more than the maximum governed speed on level ground see GENERAL SPECIFICATIONS Limit s...

Page 26: ...tree limbs Keep arms and legs inside of vehicle while it is moving 12 VOLT POWER OUTLET Overuse of accessories may drain the battery and leave insufficient reserve to start the vehicle A 12 volt power...

Page 27: ...rk plug boots never the wires Dry all connec tions with forced air Reinstall the wires REPAIR LIFTING THE VEHICLE Tool List Qty Required Floor jack 1 Jack stands 4 Chocks 4 Some servicing operations m...

Page 28: ...g into the turf For vehicles being used on paved or hard sur faces tire inflation pressure should be in the higher allowable range but under no condition should inflation pressure be higher than recom...

Page 29: ...use and replace with a new auto motive type fuse Headlight and taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department VEHICLE WITH A DISC...

Page 30: ...ins locked in the neutral position To unlock the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction selector...

Page 31: ...eutralized with a solution of 2 teaspoons 10 ml sodium bicarbon ate baking soda dissolved in 1 quart 1 liters of water and flushed with water Aerosol containers of battery terminal protectant must be...

Page 32: ...OIL Check and add if required DO NOT OVERFILL STARTER GENERATOR BELT Check for tension wear cracks MONTHLY 20 HOURS includes items listed in previous table the following WIRING Check all wiring for lo...

Page 33: ...d smooth movement lubricate shaft with light oil if required KING PINS Check for excessive play and tightness of retaining nuts STEERING ASSEMBLY Check bellows and pinion seal for damage or grease lea...

Page 34: ...oil is within the safe operating range as indicated on the dipstick Do not operate vehicle if oil level is below the safe area indicated on the dipstick Ref Fig 21 on page 18 Oil should be added to b...

Page 35: ...engine damage Wear eye protection to reduce the possi bility of splashed solvent contacting the eyes when cleaning oil filter Clean the filter by washing in any shop degreaser and brushing the metal...

Page 36: ...r for oil leaks Check the oil level again with the vehicle on level ground Oil should be added to bring the level into the safe oper ating range Do not overfill The engine can be operated safely as lo...

Page 37: ...attery explosion that could result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame or sparks away from the battery The correct clean...

Page 38: ...dry clean paved surface Ref Fig 32 on page 22 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 aggre...

Page 39: ...plugs Remove the check plug The correct lubricant level is just below the bottom of the threaded hole Ref Fig 39 on page 26 If lubricant is to be added remove the fill plug and add lubricant using a...

Page 40: ...in poor con dition or poor quality fuel could also contribute to the problem PROLONGED STORAGE To reduce the possibility of severe injury or death resulting from a possi ble explosion Do not handle fu...

Page 41: ...re when tightening fasteners and refer to the Technician s Repair and Service Manual for specific torque values Generally three grades of hardware are used in the vehi cle Grade 5 hardware can be iden...

Page 42: ...6 0 gal 22 5 L 87 Octane 1 1 2 qt 1 4 L 40 oz 1 2 L 15 amp P N 35212 G01 P N 20209 G3 912 P N 74005 G01 1157 P N 21759 G1 P N 26591 G01 P N 72368 G01 Panel Filter P N 28463 G01 Canister Filter NGK BPR...

Page 43: ...Page 27 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS...

Page 44: ...release accelerator kick off Optional hydraulic front disc brakes FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic shock a...

Page 45: ...ATIONS Owner s Manual and Service Guide Fig 40 Vehicle Dimensions 47 in 118 5 cm 25 in 64 cm 48 in 122 cm 77 in 196 cm 114 in 290 cm 53 in 135 cm Front 37 5 in 95 cm Rear 38 in 97 cm 72 in 182 cm 47 i...

Page 46: ...ice Guide GENERAL SPECIFICATIONS Fig 41 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter TURNING CLEARANCE DIAMETER 22 ft 6 7 m RECOMMENDED MAX RAMP GRADE 25 or 14 MAX RECOMMEN...

Page 47: ...Page 31 Owner s Manual and Service Guide VEHICLE WARRANTIES VEHICLE WARRANTIES...

Page 48: ...LE WARRANTIES 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 ve...

Page 49: ...TY 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 ARISING FRO...

Page 50: ...Page 34 Owner s Manual and Service Guide VEHICLE WARRANTIES Notes...

Page 51: ...or assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retar...

Page 52: ...s not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF...

Page 53: ...GO Division of Textron Augusta Georgia herein E Z GO to which FUJI supplies the engine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to ex ce...

Page 54: ...any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service fac...

Page 55: ...mes recommended in the 2004 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely...

Page 56: ...Page 40 Owner s Manual and Service Guide VEHICLE WARRANTIES CALIFORNIA 2004...

Page 57: ...Page 41 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY...

Page 58: ...Page 42 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION...

Page 59: ...Appendix A 1 LABELS AND PICTOGRAMS Owner s Manual and Service Guide LABELS AND PICTOGRAMS...

Page 60: ...Pictogram 28 28203G01 See Following Pages For Explanation Of These Pictograms 20 1 21 22 Pb35493 G01 28203 G01 On Battery Under Seat WARNING Keep entire body inside car 27653G01 See Following Pages Fo...

Page 61: ...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 62: ...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 63: ...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 64: ...Appendix A 6 Owner s Manual and Service Guide LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD 51 Ref Pic 1 4...

Page 65: ...ere 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 con...

Page 66: ...cal Communications Department E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US North America Technical Assistance Warranty Phone 1 800 774 3946 FAX...

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