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GENERAL SPECIFICATIONS

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

MODEL: EXPRESS S4
TYPE: ELECTRIC POWERED PERSONNEL CARRIER
MODEL YEAR: 2012

Part No:. 618861

TruCourse Technology:

Programmable to multiple vehcle terrains, with expanded regenerative braking function, and vehicle charger lockout

Solid State continuously variable seperately excited speed controller

Six, 8 Volt Deep Cycle Batteries

Dash mounted direction selector switch (Forward-Neutral-Reverse)

Full torque, reduced speed reverse

Anti-roll back, walkaway braking and alarm

Inductive throttle sensor

Programmable regenerative braking, acceleration and speed

Handheld vehicle diagnostics and rounds tracking

Battery Charger:

PowerWise 48QE high frequency, fully line compensating. 10ft (3m) DC Cord. Underwriters Lab. (U.L.) Listed, (C.S.A. Certified)

Input: 120 Volts AC, 50/60Hz, 8 amps

Output: 48 Volts DC at 13 amps

Motor:

48 Volt DC shunt wound, brazed armature, solid copper windings

Drive Train:

Direct motor shaft connected to transaxle pinion shaft

Electrical System:

48 Volt DC, six, 8 volt deep cycle batteries (117 minute minimum, 170 amp-hour @ 20 hr. discharge rate)

Transaxle:

Differential with helical gears

Brakes:

Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with self-compensating system

Capacity:

Seating for 4 persons. Rear Seat converts to Cargo Bed

Dimensions

Performance

Overall Length

105.3.0 in (267.0 cm)

Seating Capacity

4 Person

Overall Width

48.5 in (123.0 cm)

Dry Weight

685 lb (311kg) (Without Batteries)

Overall Height (No Canopy)

52.4 in (133.0 cm) (Top of steering wheel)

Curb Weight

1050 lb (477kg) Trojan T-875

Overall Height (With Canopy) 74.5.0 in (189.0 cm) (Top of Sun Canopy)

Vehicle load capacity

800 lb (363 kg)

Wheel Base

65.5 in (166.0 cm)

Outside Clearance Circle

19 ft (5.8 m)

Front Wheel Track

38.0 in (97.0 cm)

Intersecting Aisle Clearance

N/A

Rear Wheel Track

38.5 in (98.0 cm)

Speed (Level Ground)

17.5 mph ± 0.5 mph (28.2 kph ± 0.8 kph)

Gnd Clearance @ Differential 5.5 in (14.0 cm)

Towing Capacity

N/A

Load Bed Width

40.0 in (102.0 cm)

Steering & Suspension

Load Bed Length

32.0 in (81.0 cm)

Steering

Self-compensating rack and pinion

Vehicle Power

Front Suspension

Leaf springs with hydraulic shock absorbers

Power Source

48 Volts DC

Rear Suspension

Leaf springs with hydraulic shock absorbers

Motor Type

Shunt Wound

Service Brake

Rear wheel mechanical self-adjusting drum

Horsepower (kW)

3.0 HP (2.2kW) Continuous

Parking Brake

Self-compensating, single point engagement

Electrical System

48 Volt

Front Tires

Trail Wolf 20 x 11 - 10 Uni-directional

Batteries (Qty, Type)

Six, 8 Volt Deep Cycle

Rear Tires

Trail Wolf 20 x 11 - 10 Uni-directional

Key or Pedal Start

Pedal Start

Body & Chassis

Battery Charger

48 VDC PowerWise™
QE, 120 VAC, UL/CSA

Frame

Welded steel with DuraShield™ powder coat

Speed Controller

250 Amp Solid State Controller

Front Body & Finish

Injection Molded TPO

Drive Train

Motor Shaft Direct Drive

Rear Body & Finish

Injection molded TPO

Transaxle

Differential with helical gears

Standard Color

Forest Green

Gear Selection

Dash Mounted Forward-Neutral-Reverse

Rear Axle Ratio

14.76:1

Some items shown may be optional equipment

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

PRODUCT OVERVIEW

Specifications are subject to change without notice

* Field installed accessories may require installation charges

Noise & Vibration

Sound pressure; continued A-weighted equal to or less
than 70 db(A)less
than 2.5 m/s

0.98 m/s

Highest RMS value of weighted acceleration is less
than 2.5 m/s

The uncertainty of measurement is 0.39 m/s

Noise

Vibration, WBV

Vibration, HAV

Measurement methods were applied per the ISO 2631 and ISO 5349
standards under coditions of typical vehicle surfaces.

Содержание Express L4 - Electric

Страница 1: ...622014 Owner s Guide ISSUED JULY 2011 REVISED JUNE 2012 ...

Страница 2: ...ces in controls will be illustrated 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 E Z GO Genuine Service Parts The following information is needed when contacting...

Страница 3: ...he 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 Division of Textron Inc and therefore is subject to change without notice E Z GO Division of Textron Inc DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DI...

Страница 4: ...rate of self discharge varies depending on the ambient temperature 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 batteries must be clean fully charged and disconnected from any source of electrical drain The battery charger may be left connected to the vehicle to maintain a f...

Страница 5: ...e thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers SECTION PAGE NO SAFETY 1 1 GENERAL SPECIFICATIONS 2 1 INTRODUCTION 3 1 OPERATING PROCEDURES 4 1 MAINTENANCE 5 1 DELCARATION OF CONFORMITY APPENDIX A 1 ...

Страница 6: ...Page iv 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 ...

Страница 7: ...familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 1 TITLE PAGE NO SAFETY 1 3 NOTICES CAUTIONS WARNINGS AND DANGERS 1 3 GENERAL 1 4 GENERAL OPERATION 1 5 MAINTENANCE 1 5 VENTILATION 1 6 LABELS AND PICTOGRAMS 1 7 ...

Страница 8: ...1 2 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1 ...

Страница 9: ... that could result in an unsafe condition Observe these NOTICES CAUTIONS WARNINGS and DANGERS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe NOTICES CAUTIONS WARNINGS AND DANGERS Throughout this guide NOTICE CAUTION WARNING and DANGER will be used Please observe th...

Страница 10: ... important to the SAFE USE AND OPERATION of the product All customers should adhere to this SAFETY RESTRICTION in connection with the use of all E Z GO products new and used the Distributor or Dealer has reason to believe may be operated in personal 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...

Страница 11: ...the vehicle in a responsible manner and maintain the vehicle in safe operating condition read and observe all warnings and operation instruction labels affixed to the vehicle follow all safety rules established in the area where the vehicle is being operated Leave the vehicle when there is a risk of lightning reduce speed to compensate for poor terrain or conditions apply service brake to control ...

Страница 12: ...e skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low ...

Страница 13: ...n can occur if key is not in the OFF position To disable electrical system turn key switch to OFF and To disable electrical system turn key switch to OFF and remove battery wires remove battery wires DO NOT alter or tamper with this unit Unauthorized DO NOT alter or tamper with this unit Unauthorized modifications can result in SERIOUS INJURY or damage modifications can result in SERIOUS INJURY or...

Страница 14: ... CENTER OF GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAVITY MAXIMUM HEIGHT x in x in xx cm xx cm MAX LOAD MAX LOAD XXX LBS XXX LBS XXX KG XXX KG WARNING MAXIMUM LOAD CENTER OF GRAVITY KEEP LOAD AS FAR FORWARD AS POSSIBLE DO NOT RIDE IN LOAD BED KEEP HANDS FINGERS AWAY FROM DUMP BED DO NOT STAND BEHIND DUMP BED 1 13 14 2 3 4 5 6 7 8 14û 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MA...

Страница 15: ...INALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE LOW OIL PRESSURE 17 18 19 20 21 22 23 24 25 26 27 DO NOT DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON HIGHWAY WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY USE CARE LIFTING USE INSULATED TOOLS 28 29 30 31 32 WEAR EYE PROTECTION NO SMOKING HOT SURFACE 33 34...

Страница 16: ...SE Q AN AUDIBLE DEVICE WILL SOUND Q DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK Q APPLY PARKING BRAKE Q TURN KEY TO OFF Q MOVE DIRECTION SELECTOR TO FORWARD P N TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK Q APPLY PARKING BRAKE Q TURN KEY TO OFF Q MOVE DIRECTION SELECTOR TO NEUTRAL 39 40 41 ON OFF ON POSITION OFF POSITION HEADLIGHTS UNLOCKED 43 44 ...

Страница 17: ...1 11 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers SAFETY 1 ...

Страница 18: ...1 12 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1 ...

Страница 19: ...ghly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TITLE PAGE NO EXPRESS S4 Vehicle Specifications 2 3 EXPRESS L4 Vehicle Specifications 2 4 Vehicle Dimensions and Incline Information 2 5 Vehicle Turning Diameter 2 6 ...

Страница 20: ...2 2 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 2 ...

Страница 21: ...le load capacity 800 lb 363 kg Wheel Base 65 5 in 166 0 cm Outside Clearance Circle 19 ft 5 8 m Front Wheel Track 38 0 in 97 0 cm Intersecting Aisle Clearance N A Rear Wheel Track 38 5 in 98 0 cm Speed Level Ground 17 5 mph 0 5 mph 28 2 kph 0 8 kph Gnd Clearance Differential 5 5 in 14 0 cm Towing Capacity N A Load Bed Width 40 0 in 102 0 cm Steering Suspension Load Bed Length 32 0 in 81 0 cm Steer...

Страница 22: ...5 in 166 0 cm Vehicle load capacity 19 ft 5 8 m Front Wheel Track 38 0 in 97 0 cm Outside Clearance Circle N A Rear Wheel Track 38 5 in 98 0 cm Intsecting Aisle Clearance 15 9 mph 0 5 mph 25 6 kph 0 8 kph Gnd Clearance Differential 5 5in 14 0 cm Speed Level Ground N A Load Bed Width 40 0 in 102 0 cm Steering Suspension Load Bed Length 32 0 in 81 0 cm Steering Self compensating rack and pinion Vehi...

Страница 23: ...ticular attention to all Notices Cautions Warnings and Dangers 2 Front 38 5 in 98 0 cm Rear 38 0 97 0 cm 74 5 in 189 0 cm 52 4 in 133 0 cm 105 3 in 267 0 cm 65 5 in 166 0 cm 5 5 in 14 0 cm EXPRESS S4 EXPRESS L4 48 5 in 123 0 cm RECOMMENDED MAX SIDE TILT 25 or 14o MAX RECOMMENDED MAX RAMP GRADE 25 or 14o MAX ...

Страница 24: ...Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 6 2 TURNING CLEARANCE DIAMETER EXPRESS S4 EXPRESS L4 19 0 ft 5 8 m 19 0 ft 5 8 m ...

Страница 25: ...2 7 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS 2 ...

Страница 26: ...2 8 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 2 ...

Страница 27: ...Meter 3 3 Direction Selector 3 3 Accelerator Pedal 3 3 Brake and Park Brake 3 5 Horn 3 5 Rear View Mirror 3 5 Front Seats 3 5 Hip Restraint 3 5 Brake Light Turn Signal 3 5 Grab Handles Front Passenger 3 5 Weather Enclosure 3 5 Glove Box 3 5 Cup Holder 3 5 Steering Wheel 3 5 Charger with DC to DC Converter 3 6 Charger Receptacle 3 6 Battery Compartment 3 6 Run Tow Switch 3 7 Ash Tray 3 7 Convertibl...

Страница 28: ...3 2 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3 ...

Страница 29: ...ng the key and the headlight is operated by turning the key switch beyond ON position To prevent inadvertent operation of the vehicle when left unattended the key should be turned to the OFF position and removed 2 State of Charge Meter The vehicle is equipped with a state of charge meter located in the dash panel The state of charge meter indicates the amount of usable power in the batteries The s...

Страница 30: ... Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 3 4 3 7 10 H ORN OFF ON 2 3 12 Park Brake PARK Brake H ORN 4 5 6 1 8 9 ...

Страница 31: ...elease when the service brake pedal is depressed Use the lower section of the brake pedal to operate the service brake system 6 Horn The horn button is located on the driver s side floorboard depressing the button will sound the vehicle s horn 7 Rear View Mirror The rear view mirror is a two position mirror manually adjusted for day and nighttime conditions Sun Top kit is required to install rear ...

Страница 32: ... is used to charge battery while vehicle is parked and the DC to DC converter is used to power accessories 17 Charger Receptacle The charging cord is to be connected to this receptacle while the vehicle is being charged 18 Battery Compartment The battery compartment can be accessed by raising the front seat to perform battery maintenance and access the Run Tow switch 14 13 22 16 H ORN 19 18 15 21 ...

Страница 33: ... a minimum of 30 seconds before moving the Run Tow Mainte nance switch to the Run position The Run Tow switch should always be returned to the TOW position after moving a stalled vehicle If the switch is left in the RUN position for an extended period of time it will drain the batteries The Run Tow switch is located under the seat on the passenger side of the vehicle With the switch in TOW MAINTEN...

Страница 34: ...or death could result if they should fall out or the vehicle is involved in an accident or sudden maneuver To prevent damage to rear seat be sure to move any obstructing accessories mounted to rear handrail when folding seat up or down The cargo platform is accessed by folding the rear seat down Be careful when loading the vehicle Tie down loads to prevent shifting Do not overload vehicle The carg...

Страница 35: ...3 9 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers INTRODUCTION 3 ...

Страница 36: ...3 10 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3 ...

Страница 37: ... 6 LED Fault Codes 4 6 Maintenance Instructions 4 7 OPERATING THE VEHICLE 4 7 TruCourse Technology 4 8 General 4 8 TruCourse Technology System Performance options Diagnostics 4 8 Changing Performance Options 4 9 Operation 4 9 Regenerative Braking 4 10 Pedal Up Braking 4 11 Terrain 4 11 Walk Away Feature 4 11 Anti Roll Back Feature 4 11 Anti Stall Feature 4 11 High Pedal Disable Feature 4 12 Diagno...

Страница 38: ...he 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 manufac ture date code serial number and vehicle model mustacture date code serial number ...

Страница 39: ...attery 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 explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating pro...

Страница 40: ...ic precautions such as recommended rates of charge and removing or not removing cell caps while charging Portable chargers must 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 o...

Страница 41: ...ged and the DC plug can be removed to permit use of the vehicle Understanding the Charger Plugging the charger into the vehicle s charger receptacle will lock the vehicle out of operation When the charger is plugged into the vehicle s charger receptacle the charger will automatically turn on and the charger s LED and the vehicle receptacle s LED will start flashing GREEN to indicate the batteries ...

Страница 42: ...ture Fault battery temperature is greater than 122 F 50 C or less than 14 F 10 C TWO RED FLASHES Two flashes a pause and then again two flashes and a pause Battery Voltage Fault Battery pack is less than 48 0 Volts or more than 67 2 Volts Battery pack is too discharged or over charged for the charger to work THREE RED FLASHES Three flashes a pause and then again three flashes and a pause Battery C...

Страница 43: ...ity of severe injury or death resulting from loss of vehicle control the fol lowing warnings must be observed When driving vehicle consider the terrain traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc Stay in designated areas and avo...

Страница 44: ...le until the throttle is depressed again or the vehicle stops This is the strongest of the two compression braking options This is 12 8 mph 20 6 kph option This option is enabled when the blue plug is installed 3 The Golf Mild Hill performance option This option includes all of the driving features of the Steep Hill option except that the compression braking feel is milder and the flat ground comp...

Страница 45: ...ctivated With the switch in RUN position the controller is activated the electronic braking feature and warning beeper features are activated TCT vehicles operate only in the RUN position If all of the following events occur with the switch in RUN position a the vehicle has been stopped for more than one second b the accelerator pedal has been released for more than one sec ond c the vehicle begin...

Страница 46: ... Mode option features different degrees of regenerative breaking that takes place anytime that accel erator pedal is released The Steep Hill option will rapidly slow the vehicle to a stop unless the accelerator pedal is depressed The Mild Hill option will slow the vehicle to a stop at a slower rate unless the accelerator pedal is depressed The TCT has a low power consumption unit but it will drain...

Страница 47: ... than one second c the vehicle begins to roll above 2 mph 3 kph the electronic braking will limit speed to approximately 2 mph 3 kph and the warning beeper will sound When the accelerator pedal is depressed the electronic braking and warning beeper will be overridden and normal vehicle operation resumes Any unusual situation sensed by the TruCourse Technology system will cause a similar response T...

Страница 48: ...connected 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 accele...

Страница 49: ...s Labels and 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 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 pr...

Страница 50: ...4 14 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 4 4 4 4 ...

Страница 51: ... 7 LIGHT BULB REPLACEMENT 5 8 FUSE REPLACEMENT 5 8 TRANSPORTING VEHICLE 5 9 Towing 5 9 Hauling 5 9 SERVICE AND MAINTENANCE 5 9 ROUTINE MAINTENANCE 5 10 Tire Inspection 5 10 Brakes 5 10 PERIODIC BRAKE TEST FOR MECHANICAL BRAKES 5 11 REAR AXLE 5 11 Checking the Lubrican Level 5 11 LUBRICATION 5 12 HARDWARE 5 12 PERIODIC SERVICE SCHEDULE 5 13 BATTERY CHARGING AND MAINTENANCE 5 14 Safety 5 14 Battery ...

Страница 52: ...5 2 MAINTENANCE 5 AC Voltage 5 19 Troubleshooting 5 19 HYDROMETER 5 20 Using Hydrometer 5 21 BATTERY CGARGER MAINTENANCE 5 21 PROLONGED STORAGE 5 22 ...

Страница 53: ...mmercial plastic polish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use of a commercially available vinyl rubber cleaner The painted surfaces of the veh...

Страница 54: ...ed terrain When driving at full speed on a dirt road loose surfaces or wet grass vehicle stopping distance will increase If the vehicle is fully loaded it will take longer to stop than with no load When operating vehicle in wet weather conditions remember that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit If wet the brakes will lose much of the...

Страница 55: ...icle Tool List Qty Tool List Qty Floor jack 1 Jack stands 4 Wheel Chocks 4 Remove payload from vehicle before lifting No person s should be in or on the vehicle while lifting To raise the entire vehicle install chocks in front and behind each front wheel Center the jack under the rear frame crossmember Raise the vehicle enough to place a jack stand under the outer ends of the rear axle Lower the j...

Страница 56: ...uld be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for rec ommended tire inflation pressure For outdoor applications with major use on grassy areas the following should be considered On hard turf it is desirable to have a slightly higher inflation pressure On very soft turf a lower pres sure reduces the possibility of tires cutting into the turf For vehicles being...

Страница 57: ...lve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten the lug nuts 1 in a cross sequence pattern Tighten the lug nuts to 50 to 85 ft lbs 68 to 115 Nm torque in 20 ft lbs 27 Nm increments following the cross sequence pattern Unidirectional Tires Some vehicles may be fitted with unidirectional tires These tires may be identified by a directional arrow on the sidewall Be s...

Страница 58: ... a quarter turn clockwise to secure Similarly replace the turn signal light bulb locate bulb socket on backside of light bar and turn bulb socket a quarter turn counterclockwise to unlock and pull out bulb and socket Insert new bulb and rotate socket a quarter turn clockwise to secure To replace the tail and brake light bulb remove hardware securing lens and remove lens Install replacement bulb FU...

Страница 59: ...the seat bottom secured When transporting vehicle below highway speeds check for tightness of hardware and cracks in sun top at mounting points Always remove windshield when transporting Always check that the vehicle and contents are adequately secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehicle see GENERAL SPECIFICATIONS for vehicle weight ...

Страница 60: ...le owner and service technician to carefully follow the procedures recommended in this manual Preventative maintenance applied at recommended intervals is the best guarantee for keeping the vehicle both dependable and economical This vehicle will give years of satisfactory service providing it receives regular maintenance Refer to the Periodic Service Schedule for appropriate service intervals ROU...

Страница 61: ...may or may not lock Observe the vehicle stopping loca tion or measure the vehicle stopping distance from the point at which the brakes were latched The vehicle should stop within the normal range of stopping distances If the vehicle stops more than 4 ft 1 2 m beyond the acceptable stopping dis tance or pulls to one side the vehicle has failed the test and should be tested again If the vehicle fail...

Страница 62: ...fied by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head Metric hardware is marked on the head with 8 8 or 10 9 Unmarked hardware is Grade 2 Lubrication Points View from Underside of Vehicle Rack Ball Joint ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten all hardware...

Страница 63: ... for loose connections and broken missing insulation CHARGER RECEPTACLE Clean connections keep receptacles free of dirt and foreign matter ACCELERATOR Check for smooth movement SERVICE BRAKE MECHANICAL BRAKES HYDRAULIC BRAKES Conduct brake performance test PARK BRAKE Check brake performance and adjust if required DIRECTION SELECTOR Check attachment tighten if required STEERING ASSEMBLY Check for a...

Страница 64: ...or approved safety goggles when adding water or charging batteries Any electrolyte spills should be neutralized with a solution of 1 4 cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and flushed with water Overfilling batteries may result in electrolyte being spilled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehi cle...

Страница 65: ...t can reduce the life of the battery BATTERY MAINTENANCE Tool List Qty Tool List Qty Insulated Wrench 9 16 1 Battery Carrier 1 Hydrometer 1 Battery Maintenance Kit P N 25587 G01 1 At Each Charging Cycle To reduce the possibility of fire never attach a battery charger to a vehicle that is to be unattend ed beyond the normal charging cycle Overcharging could cause damage to the vehicle batteries and...

Страница 66: ...y Over the life of the battery a considerable amount of water is consumed It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction The water must be distilled or purified by an efficient filtration system Water that is not distilled should be analyzed and if required filtration installed to permit the water to ...

Страница 67: ...cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and flushed with water Always wear a safety shield or approved safety goggles when adding water or charging batteries Battery Cleaning To prevent battery damage be sure that all battery caps are tightly installed To reduce the possibility of damage to vehicle or floor neutralize acid before rinsing battery To red...

Страница 68: ...r extreme conditions After batteries are clean and dry the termi nals should be coated with a commercially available protectant Aerosol containers of battery terminal protectant must be used with extreme care Insulate the metal container to prevent the can from contacting the battery terminals Battery Replacement Before any electrical service is performed on TruCourse technology model vehicles the...

Страница 69: ...to the instruc tions of the specific charger used Before charging the following should be observed Do not overfill batteries The charging cycle will expel electrolyte and result in component damage The electrolyte level in all cells must be at the recommended level and cover the plates The charging must take place in an area that is well ventilated and capable of removing the hydrogen gas that is ...

Страница 70: ...g the density of the electrolyte which is accomplished by measuring the specific gravity of the electrolyte The greater the concentration of sulfuric acid the more dense the electrolyte becomes The higher the density the higher the state of charge To prevent battery explosion that could result in severe personal injury or death never insert a metal thermometer into a battery Use a hydrometer with ...

Страница 71: ...vity 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 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 points between any two cell readings example 1 250 1 200 indi...

Страница 72: ...ible and will cause permanent damage to the battery In order to prevent damage the battery should be recharged A hydrometer P N 50900 G1 can be used to determine the specific gravity and therefore the state of charge of a battery In winter conditions the battery must be fully charged to pre vent the possibility of freezing A fully charged battery will not freeze in temperatures above 75 F 60 C Alt...

Страница 73: ...5 23 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers MAINTENANCE 5 ...

Страница 74: ...5 24 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5 ...

Страница 75: ...ead all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers TABLE OF CONTENTS FOR APPENDIX A TITLE PAGE NO DECLARATION OF CONFORMITY A 3 ...

Страница 76: ...A 2 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 ...

Страница 77: ...A 3 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers DECLARATION OF CONFORMITY ...

Страница 78: ...APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers A 4 DECLARATION OF CONFORMITY CONTINUED ...

Страница 79: ...A 5 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers APPENDIX A ...

Страница 80: ...A 6 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 ...

Страница 81: ......

Страница 82: ... of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA 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 ...

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