Minutemiser Owners Manual

29175-G01
OWNER’S MANUAL
AND SERVICE GUIDE
ELECTRIC POWERED THREE WHEEL

SERVICE VEHICLE
ISSUED APRIL 2005
SAFETY
Read and understand all labels located on the vehicle. For any questions on any of the information, contact a represen-
tative for clarification.
Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-
vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed
on level ground. (See vehicle specification.) Limit speed by applying the service brake.
Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situations that could result in an unsafe condition.
BATTERY WARNING BATTERIES

AND RELATED PARTS
Battery posts, CONTAIN LEAD

terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
WASH HANDS
WASH HANDS AFTER HANDLING!
WARNING: Battery posts, terminals and related
AFTER HANDLING! accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
Be sure that this manual remains as part of the permanent service record should the vehicle be resold.
NOTES, CAUTIONS AND WARNINGS

Throughout this guide NOTE, CAUTION and WARNING Please observe these NOTES, CAUTIONS and WARN-
will be used. INGS; be aware that servicing a vehicle requires
A NOTE indicates a condition that should be mechanical skill and a regard for conditions that could be
observed. hazardous. Improper service or repair may damage the
vehicle or render it unsafe.
A CAUTION indicates a condition that
may result in damage to the vehicle. Battery posts, terminals
! !
and related accessories
A WARNING indicates a contain lead and lead
! ! hazardous condition that compounds. Wash hands after handling.
could result in severe
injury or death.
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

OWNER’S MANUAL
AND SERVICE GUIDE
ELECTRIC POWERED
THREE WHEEL
SERVICE VEHICLE
CUSHMAN MINUTE MISER™
Starting Model Year 2004

Cushman Division of TEXTRON, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the infor-
mation contained in this manual is subject to change without notice.
Cushman 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
this manual.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY 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: 010-1-706-798-4311, FAX: 010-1-706-771-4609
CUSHMAN DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852
Owner’s Manual and Service Guide Page i

NOTES
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local
Distributor, an authorized Branch or the Warranty Department with vehicle serial number
and manufacturer code.
The use of non Original Equipment Manufacturer (OEM) parts may void the warranty.
Overfilling of batteries may void the warranty.
BATTERY PROLONGED STORAGE
All batteries 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 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, such as the battery charger. Disconnect the battery charger cable
from the vehicle batteries when not charging.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
Refer to the ‘Prolonged Storage’ section within the BATTERIES AND CHARGING section of
this manual.
Page ii Owner’s Manual and Service Guide

TABLE OF CONTENTS
GENERAL .................................................................................................................................vii
GENERAL OPERATION ...........................................................................................................vii
MAINTENANCE ....................................................................................................................... viii
VENTILATION ............................................................................................................................ix
GENERAL ..................................................................................................................................xi
STANDARDS AND PUBLICATIONS ......................................................................................... 1
Standards ............................................................................................................................................................1
Publications .........................................................................................................................................................1
BEFORE INITIAL USE ............................................................................................................... 2

Fig. 1 Initial Service Chart ......................................................................................................................2
On Board Charger ...............................................................................................................................................2
IDENTIFICATION ....................................................................................................................... 2
Fig. 2 Model Number, Model Year and Serial Number .........................................................................2
CONTROLS, METERS AND SWITCHES .................................................................................. 2

Fig. 3 Serial Numbers Under Seat ........................................................................................................3
Fig. 4 Controls On Dashboard ...............................................................................................................3
Fig. 5 Controls On Floorboard ..............................................................................................................3
Fig. 6 Horn Switch ................................................................................................................................3
Key Switch ...........................................................................................................................................................3
Fig. 7 Key Switch ..................................................................................................................................4
Direction Selector Switch .....................................................................................................................................4
Fig. 8 Direction Selector Switch .............................................................................................................4
Power ON/Battery Condition Meter .....................................................................................................................4
Headlight (Accessory) ..........................................................................................................................................4
Service/Parking Brake Pedal ...............................................................................................................................4
Fig. 9 Speed Control Pedal ...................................................................................................................4
Speed Control Pedal ............................................................................................................................................5
Horn and Handlebar ............................................................................................................................................5
Handlebar Installation ..........................................................................................................................................5
Seat Switch ..........................................................................................................................................................5
Fig. 10 Seat Switch ...............................................................................................................................5
Hour Meter (Accessory) .......................................................................................................................................5
ADDITIONAL FEATURES .......................................................................................................... 5

Battery Charger ...................................................................................................................................................5
Fold Down Backrest .............................................................................................................................................6
Fig. 11 Battery Charger ........................................................................................................................6
Fig. 12 Fold Down Backrest ..................................................................................................................6
Programmable Speed Controller .........................................................................................................................6
EE UNITS ................................................................................................................................... 6
BEFORE ENTERING VEHICLE ................................................................................................. 6
OPERATING THE VEHICLE ...................................................................................................... 6
STARTING THE VEHICLE ......................................................................................................... 7
COASTING ................................................................................................................................. 7
OPERATION .............................................................................................................................. 7
DRIVING THE VEHICLE ............................................................................................................ 8
SERVICING THE ELECTRIC VEHICLE .................................................................................... 9
TOWING ..................................................................................................................................... 9
Owner’s Manual and Service Guide Page iii

TABLE OF CONTENTS
LIFTING THE VEHICLE ............................................................................................................. 9

SAFETY COMPONENTS ......................................................................................................... 10
Seat Switch ....................................................................................................................................................... 10
Thermal Circuit Breaker .................................................................................................................................... 10
Fig. 13 Lifting the Vehicle .................................................................................................................... 10
Parking The Vehicle .......................................................................................................................................... 10
Fig. 14 Parking The Vehicle ............................................................................................................... 10
ROUTINE MAINTENANCE ...................................................................................................... 10

REAR AXLE .............................................................................................................................. 11
Checking the Lubricant Level ............................................................................................................................ 11
Fig. 15 Lubrication Points .................................................................................................................... 11
Fig. 16 Rear Axle Lubricant Check and Fill ......................................................................................... 11
BRAKES ................................................................................................................................... 11
Test Method ...................................................................................................................................................... 11
Fig. 17 Periodic Brake Performance Test ........................................................................................... 12
TIRES ....................................................................................................................................... 12
Tire Repair ........................................................................................................................................................ 13
Wheel Installation .............................................................................................................................................. 13
Fig. 18 Wheel Installation .................................................................................................................... 13
Fig. 19 Wheel Installation .................................................................................................................... 13
LIGHT BULB REPLACEMENT ................................................................................................. 14

CARE AND CLEANING OF THE VEHICLE ............................................................................. 14
TRAILERING ............................................................................................................................ 14
HARDWARE ............................................................................................................................. 15
Fig. 20 Bolt Grades ............................................................................................................................. 15
TORQUE SPECIFICATIONS .................................................................................................. 15

Fig. 21 Torque Specifications .............................................................................................................. 15
PERIODIC SERVICE SCHEDULE .......................................................................................... 16

Fig. 22 Periodic Service Schedule ...................................................................................................... 16
BATTERIES AND CHARGING ................................................................................................. 18

Safety ................................................................................................................................................................ 18
BATTERY ................................................................................................................................. 18
BATTERY MAINTENANCE ...................................................................................................... 18
At Each Charging Cycle .................................................................................................................................... 19
Monthly ............................................................................................................................................................. 19
Electrolyte Level and Water .............................................................................................................................. 19
Fig. 23 Correct Electrolyte Level ......................................................................................................... 19
Fig. 24 Water Purity Table .................................................................................................................. 19
Fig. 25 Automatic Watering Gun ......................................................................................................... 19
Cleaning Batteries ............................................................................................................................................. 19
Fig. 26 Preparing Acid Neutralizing Solution ....................................................................................... 19
Battery Replacement ........................................................................................................................................ 19
Fig. 27 Battery Connections ................................................................................................................ 20
Prolonged Storage ............................................................................................................................................ 20
Fig. 28 Freezing Point of Electrolyte ................................................................................................... 20
Battery Charging ............................................................................................................................................... 21
AC Voltage ........................................................................................................................................................ 21
TROUBLESHOOTING .............................................................................................................. 22
Hydrometer ....................................................................................................................................................... 22
Using A Hydrometer .......................................................................................................................................... 23
Page iv Owner’s Manual and Service Guide

TABLE OF CONTENTS
Fig. 29 Hydrometer ..............................................................................................................................23

Fig. 30 Hydrometer Temperature Correction .......................................................................................23
Fig. 31 Factory Settings .......................................................................................................................30
Fig. 32 Wiring Diagram ........................................................................................................................32
Fig. 32 Wiring Diagram ........................................................................................................................33
GENERAL SPECIFICATIONS ................................................................................................. 29

ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE ................................................ 30
Fig. 33 Vehicle Dimensions and Incline Specifications ........................................................................31
Fig. 34 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance ..................................32
Owner’s Manual and Service Guide Page v

TABLE OF CONTENTS
Notes:
Page vi Owner’s Manual and Service Guide

SAFETY INFORMATION
This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures
developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible
service from the product. To reduce the chance of personal injury and/or property damage, the following instructions
must be carefully observed:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z-
GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured
vehicle is modified an any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER
FERERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of
Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer
MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for
LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the
requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in the
places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final
Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPER-
ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, 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, Distributors and Dealers advise all customers to adhere to this
SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has rea-
son 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 Internet at the website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
GENERAL
Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. The manufacturer strongly suggests that the owner-operator read this entire manual paying
particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees
and other operators be encouraged to do the same.
If you have any questions, contact your closest representative or write to the address on the back cover of this publica-
tion, Attention: Product Service Department.
E-Z-GO Division of TEXTRON Inc., reserves the right to make design changes without obligation to make these
changes on units previously sold and the information contained in this 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 this manual.
Owner’s Manual and Service Guide Page vii

SAFETY INFORMATION
This vehicle conforms to the current applicable standard for safety and performance requirements.
These vehicles do not conform to Federal Motor Vehicle Safety Standards and are not equipped for operation on public
streets.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
Never use the chassis or body as a ground connection.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and
disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the
vehicle.
GENERAL OPERATION
Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
Always read and observe all warnings and operation instruction labels affixed to the vehicle.
Always follow all safety rules established in the area where the vehicle is being operated.
Always reduce speed to compensate for poor terrain or conditions.
Always apply service brake to control speed on steep grades.
Always maintain adequate distance between vehicles.
Always reduce speed in wet areas.
Always use extreme caution when approaching sharp or blind turns.
Always use extreme caution when driving over loose terrain.
Always use extreme caution in areas where pedestrians are present.
MAINTENANCE
Always maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
Always ensure that mechanics performing repairs are trained and qualified to do so.
Always follow the manufacturer’s directions if you do any maintenance on your vehicle. Be sure to disable the vehicle
before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery
wire.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by short-
ing the battery terminals or associated wiring. Remove the batteries or cover exposed terminals with an insulating
material.
Page viii Owner’s Manual and Service Guide

SAFETY INFORMATION
Always check the polarity of each battery terminal and be sure to rewire the batteries correctly.
Always use specified replacement parts. Never use replacement parts of lesser quality.
Always use recommended tools.
Always determine that tools and procedures not specifically recommended by the manufacturer will not compromise
the safety of personnel nor jeopardize the safe operation of the vehicle.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a
jack. Lift the vehicle in accordance with the manufacturer’s instructions.
Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the 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.
Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of
both vehicular and pedestrian traffic.
Always replace damaged or missing warning, caution or information labels.
Always keep complete records of the maintenance history of the vehicle.
VENTILATION
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 proper ventilation. Five air
exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the recepta-
cle when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable
electrical code (whichever is more restrictive).
Owner’s Manual and Service Guide Page ix

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

SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
GENERAL manual without the manufacturer’s prior written authori-

zation. Where authorized modifications have been made,
The following text is provided as recommended by part II
the user shall ensure that capacity, operation, warning,
of ASME/ANSI B56.8-1988. The manufacturer strongly
and maintenance instruction plates, tags, or decals are
endorses the contents of this specification.
changed accordingly.
4.3.3 As required under paras. 4.3.1 or 4.3.2, the
PART II manufacturer shall be contacted to secure new name-
FOR THE USER plates, warnings, or instructions which shall then be
affixed in their proper place on the carrier.
4 GENERAL SAFETY PRACTICES 4.4 Fuel Handling and Storage

4.4.1 The user shall supervise the storage and han-
4.1 Introduction
dling of liquid fuels (when used) to be certain that it is in
4.1.1 Like other machines, carriers can cause injury accordance with appropriate paragraphs of ANSI/NFPA
if improperly used or maintained. Part II contains broad 505 and ANSI/NFPA 30.
safety practices applicable to carrier operations. Before
4.4.2 Storage and handling of liquefied petroleum
operation, the user shall establish such additional spe-
gas fuels shall be in accordance with appropriate para-
cific safety practices as may reasonably be required for
graphs of ANSI/NFPA 505 and ANSI/NFPA 58. If such
safe operation.
storage or handling is not in compliance with these stan-
4.2 Stability dards, the user shall prevent the carrier from being used
until such storage and handling is in compliance with
4.2.1 Experience has shown that this vehicle, which these standards.
complies with this standard, is stable when properly
operated and when operated in accordance with specific 4.5 Changing and Charging Storage Batteries for
safety rules and practices established to meet actual Electric Personnel and Burden Carriers
operating terrain and conditions. However, improper
operation, faulty maintenance, or poor housekeeping 4.5.1 The user shall require battery changing and
may contribute to a condition of instability and defeat the charging facilities and procedures to be in accordance
purpose of the standard. Some of the conditions which with appropriate paragraphs of ANSI/NFPA 505.
may affect stability are failure of the user to follow safety 4.5.2 The user shall periodically inspect facilities
practices; also, ground and floor conditions, grade, and review procedures to be certain that appropriate
speed, loading, the operation of the carrier with improper paragraphs of ANSI/NFPA 505, are strictly complied
loads, battery weight, dynamic and static forces, and the with, and shall familiarize carrier operators with it.
judgement exercised by the carrier operator.
(a) The user shall train carrier operators to adhere 4.6 Hazardous Locations
strictly to the operating instructions stated in this Stan- 4.6.1 The user shall determine the hazard classifi-
dard. cation of the particular atmosphere or location in which
(b) The user shall survey specific operating conditions the carrier is to be used in accordance with ANSI/NFPA
and environment, and establish and train carrier opera- 505.
tors to comply with additional, specific safety practices. 4.6.2 The user shall permit in hazardous areas only
those carriers approved and of the type required by
4.3 Nameplates, Markings, Capacity, and Modifica- ANSI/NFPA 505.
tions
4.3.1 The user shall maintain in a legible condition 4.7 Lighting for Operating Areas
all nameplates, warnings, and instructions which are 4.7.1 The user, in accordance with his responsibility
supplied by the manufacturer. to survey the environment and operating conditions, shall
4.3.2 The user shall not perform any modification or determine if the carrier requires lights and, if so, shall
addition which affects capacity or safe operation, or equip the carrier with appropriate lights in accordance
make any change not in accordance with the owner’s with the manufacturer’s recommendations.
Owner’s Manual and Service Guide Page xi

SAFETY INFORMATION
4.8 Control of Noxious Gases and Fumes turer;

4.8.1 When equipment powered by internal com- (b) emphasis on safety of passengers, material loads,
bustion engines is used in enclosed areas, the atmo- carrier operator, and other employees;
sphere shall be maintained within limits specified in the (c) general safety rules contained within this Standard
American Conference of Governmental Industrial and the additional specific rules determined by the user
Hygienists publication, “Threshold Limit Values for in accordance with this Standard, and why they were for-
Chemical Substances and Physical Agents in the Work- mulated;
room Environment”. This shall be accomplished by venti-
lation provided by the user, and/or the installation, use, (d) introduction of equipment, control locations and
and proper maintenance of emission control equipment functions, and explanation of how they work when used
recommended or provided by the manufacturer of the properly and when used improperly, and surface condi-
equipment. tions, grade, and other conditions of the environment in
which the carrier is to be operated;
4.9 Warning Device(s) (e) operational performance tests and evaluations
4.9.1 The user shall make periodic inspections of during, and at completion of, the program.
the carrier to be certain that the sound-producing and/or
visual device(s) are maintained in good operating condi- 5.3 Personnel and Burden Carrier Operator
tion. Responsibility
4.9.2 The user shall determine if operating condi- 5.3.1 Operators shall abide by the following safety
tions require the carrier to be equipped with additional rules and practices in paras. 5.4, 5.5, 5.6, and 5.7.
sound-producing and/or visual devices and be responsi-
ble for providing and maintaining such devices, in accor- 5.4 General
dance with the manufacturer’s recommendations. 5.4.1 Safeguard the pedestrians at all times. Do not
drive carrier in a manner that would endanger anyone.
5.4.2 Riding on the carrier by persons other than the
5 OPERATING SAFETY RULES AND operator is authorized only on personnel seat(s) provided
PRACTICES by the manufacturer. All parts of the body shall remain
within the plan view outline of the carrier.
5.1 Personnel and Burden Carrier Operator
Qualifications 5.4.3 When a carrier is to be left unattended, stop
carrier, apply the parking brake, stop the engine or turn
5.1.1 Only persons who are trained in the proper
off power, turn off the control or ignition circuit, and
operation of the carrier shall be authorized to operate the
remove the key if provided. Block the wheels if machine
carrier. Operators shall be qualified as to visual, auditory,
is on an incline.
physical, and mental ability to safely operate the equip-
ment according to Section 5 and all other applicable 5.4.4 A carrier is considered unattended when the
parts of this Standard. operator is 25 ft. (7.6 m) or more from the carrier which
remains in his view, or whenever the operator leaves the
5.2 Personnel and Burden Carrier Operator’s carrier and it is not within his view. When the operator is
Training dismounted and within 25 ft. (7.6 m) of the carrier still in
5.2.1 The user shall conduct an operator’s training his view, he still must have controls neutralized, and the
program. parking brake(s) set to prevent movement.
5.2.2 Successful completion of the operator’s train- 5.4.5 Maintain a safe distance from the edge of
ing program shall be required by the user before opera- ramps and platforms.
tion of the carrier. The program shall be presented in its 5.4.6 Use only approved carriers in hazardous loca-
entirety to all new operators and not condensed for those tions, as defined in the appropriate safety standards.
claiming previous experience. 5.4.7 Report all accidents involving personnel,
5.2.3 The user should include in the operators’ train- building structures, and equipment.
ing program the following: 5.4.8 Operators shall not add to, or modify, the car-
(a) instructional material provided by the manufac- rier.
Page xii Owner’s Manual and Service Guide

SAFETY INFORMATION
5.4.9 Carriers shall not be parked or left unattended smooth, sweeping motion.
such that they block or obstruct fire aisles, access to
stairways, or fire equipment. 5.6 Loading
5.6.1 Handle only stable and safely arranged loads.
5.5 Traveling When handling off-center loads which cannot be cen-
5.5.1 Observe all traffic regulations, including autho- tered, operate with extra caution.
rized speed limits. Under normal traffic conditions keep
5.6.2 Handle only loads within the capacity of the
to the right. Maintain a safe distance, based on speed of
carrier as specified on the nameplate.
travel, from a carrier or vehicle ahead; and keep the car-
rier under control at all times. 5.6.3 Handle loads exceeding the dimensions used
to establish carrier capacity with extra caution. Stability
5.5.2 Yield the right of way to pedestrians, ambu-
and maneuverability may be adversely affected.
lances, fire trucks, or other carriers or vehicles in emer-
gency situations. 5.7 Operator Care of Personnel and Burden
5.5.3 Do not pass another carrier or vehicle travel- Carriers
ing in the same direction at intersections, blind spots, or 5.7.1 At the beginning of each shift during which the
at other dangerous locations. carrier will be used, the operator shall check the carrier
5.5.4 Keep a clear view of the path of travel, condition and inspect the tires, warning devices, lights,
observe other traffic and personnel, and maintain a safe battery(s), speed and directional controllers, brakes, and
clearance. steering mechanism. If the carrier is found to be in need
5.5.5 Slow down or stop, as conditions dictate, and of repair, or in any way unsafe, the matter shall be
activate the sound-producing warning device at cross reported immediately to the designated authority and the
aisles and when visibility is obstructed at other locations. carrier shall not be operated until it has been restored to
safe operating condition.
5.5.6 Ascend or descend grades slowly.
5.7.2 If during operation the carrier becomes unsafe
5.5.7 Avoid turning, if possible, and use extreme in any way, the matter shall be reported immediately to
caution on grades, ramps, or inclines; normally travel the designated authority, and the carrier shall not be
straight up and down. operated until it has been restored to safe operating con-
5.5.8 Under all travel conditions the carrier shall be dition.
operated at a speed that will permit it to be brought to a
5.7.3 Do not make repairs or adjustments unless
stop in a safe manner.
specifically authorized to do so.
5.5.9 Make starts, stops, turns, or direction rever-
5.7.4 The engine shall be stopped and the operator
sals in a smooth manner so as not to shift the load,
shall leave the carrier while refueling.
endanger passengers, or overturn the carrier.
5.7.5 Spillage of oil or fuel shall be carefully and
5.5.10 Do not indulge in dangerous activities, such as
completely absorbed or evaporated and fuel tank cap
stunt driving or horseplay.
replaced before starting engine.
5.5.11 Slow down when approaching, or on, wet or
5.7.6 Do not operate a carrier with a leak in the fuel
slippery surfaces.
system or battery(s).
5.5.12 Do not drive carrier onto any elevator unless
5.7.7 Do not use open flames for checking electro-
specifically authorized to do so. Approach elevators
lyte level in storage battery(s) or liquid level in fuel tanks.
slowly, 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
6 MAINTENANCE PRACTICES
advisable that all other personnel leave the elevator
before a carrier is allowed to enter or exit. 6.1 Introduction
5.5.13 Avoid running over loose objects, potholes, 6.1.1 Carriers may become hazardous if mainte-
and bumps. nance is neglected. Therefore, maintenance facilities,
5.5.14 To negotiate turns, reduce speed to improve trained personnel, and procedures shall be provided.
stability, then turn hand steering wheel or tiller in a Such facilities may be on or off the premises.
Owner’s Manual and Service Guide Page xiii

SAFETY INFORMATION
6.2 Maintenance Procedures prevent the use of the carrier until the leak has been
6.2.1 Maintenance and inspection of all carriers eliminated.
shall be performed in conformance with the manufac- (o) The carrier manufacturer’s capacity, operation,
turer’s recommendations and the following practices. and maintenance instruction plates, tags, or decals shall
(a) A scheduled preventive maintenance, lubrication, be maintained in legible condition.
and inspection system shall be followed. (p) Batteries, motors, speed and directional control-
lers, limit switches, protective devices, electrical conduc-
(b) Only qualified and authorized personnel shall be
tors, and connections shall be inspected and maintained
permitted to maintain, repair, adjust, and inspect carriers.
in conformance with manufacturers recommended pro-
(c) Before undertaking maintenance or repair, follow cedures.
the manufacturer’s recommendations for immobilizing
(q) Carriers shall be kept in a clean condition to mini-
the carrier.
mize fire hazards and facilitate detection of loose or
(d) Block chassis before working underneath it. defective parts.
(e) Before disconnecting any part of the engine fuel (r) Modifications and additions which affect capacity
system of a gasoline or diesel powered carrier with grav- and safe machine operation shall not be performed by
ity feed fuel systems, be sure shutoff valve is closed, and the customer or user without manufacturer’s prior written
run engine until fuel system is depleted and engine stops authorization; where authorized modifications have been
running. made, the user shall ensure that capacity, operation,
(f) Before disconnecting any part of the engine fuel warning, and maintenance instruction plates, tags, or
system of LP gas powered carriers, close the LP gas cyl- decals are changed accordingly.
inder valve and run the engine until fuel in the system is (s) Care shall be taken to ensure that all replacement
depleted and the engine stops running. parts are interchangeable with the original parts and of a
(g) Operation to check performance of the carrier shall quality at least equal to that provided in the original
be conducted in an authorized area where safe clear- equipment.
ance exists.
(h) Before commencing operation of the carrier, follow
the manufacturer’s instructions and recommended pro-
cedures.
(i) Avoid fire hazards and have fire protection equip-
ment present in the work area. Do not use an open flame
to check level or leakage 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 dam-
age, such as dents, scrapes, or gouges, may danger-
ously weaken the tank and make it unsafe for use.
(l) Brakes, steering mechanisms, speed and direc-
tional control mechanisms, warning devices, lights, gov-
ernors, guards, and safety devices shall be inspected
regularly and maintained in a safe operating condition.
(m) Special carriers or devices designed and
approved for hazardous area operation shall be
inspected to ensure that maintenance preserves the orig-
inal approved safe operating features.
(n) Fuel systems shall be checked for leaks and condi-
tion of parts. If a leak is found, action shall be taken to
Page xiv Owner’s Manual and Service Guide

ELECTRIC THREE WHEEL SERVICE VEHICLE
STANDARDS AND PUBLICATIONS • ANSI/UL 583; Electric Battery Powered Industrial

Trucks
This unit is not a motor vehicle within the definition of the ADDRESS:
National Traffic Motor Vehicle Safety Act. It is not American National Standards Institute, Inc.
designed or manufactured for use on roads, streets, or 1430 Broadway
highways, and is not appropriate for such use. This unit New York, New York 10018 USA
is not meant to be licensed as a motor vehicle.
The Electric 3 wheel service vehicle is available as Type OR
"E" and Type "EE" Units. Type "E" Units are electrically
powered units having minimum acceptable safeguards Underwriters Laboratories Inc.
against inherent fire hazards.Type "EE" Units have addi- 333 Pfingsten Road
tional safeguards against such hazards. Northbrook, Illinois 60062 USA
Users, operators and service persons should be familiar This Electric Vehicle complies with ANSI B56.8 as it
with the following standards and publications: applies to OSHA for Powered Industrial Trucks under the
Standards Type E and EE classifications. This vehicle has been
approved by Factory Mutual Research Corporation. To
(The material may be obtained from the address shown). meet the manufacturer portions of the OSHA require-
• Factory Mutual Approval Standard: ments (as stated in section 1910.178, Paragraph a3)
Class # 7820; Electric Battery Powered Trucks, Powered Industrial Trucks must bear the approval mark
Types E and EE. of either UL (Underwriters Laboratory) or FM (Factory
ADDRESS: Mutual) or other nationally recognized testing laborato-
Factory Mutual Research Corp. ries.
1151 Boston--Providence Highway
Norwood, Massachusetts 02062 USA Publications
• National Fire Protection Association: Additional operator’s manuals and parts manuals are
ANSI/NFPA #505; Powered Industrial Trucks. available for a minimum charge.
ADDRESS:
Parts Manual 29177-G01
National Fire Protection Association
Batterymarch Park Repair Manual 29178-G01
Quincy, Massachusetts 02269 USA
Thank you for this purchase. The vehicle is equipped
• ANSI/ASME B56.8 with an electronic speed control unit that is the most
Personnel and Burden Carriers advanced in the industry. Before driving the vehicle, we
ADDRESS: ask you to spend some time reading this Owner’s Man-
American National Standards Institute, Inc. ual and Service Guide. This guide contains information
1430 Broadway that will assist you in maintaining your highly reliable
New York, New York 10018 USA vehicle. Some illustrations may show items that are
optional for your vehicle.
Most of the service procedures in this guide can be

accomplished by an individual using common automotive
hand tools. Refer to an authorized service representative
for information on servicing the vehicle in accordance
with the Periodic Service Schedule.
To facilitate maintenance, a Service Parts Manual and a

Technician’s Repair and Service Manual is available
from a local Distributor, an authorized Branch or the Ser-
vice Parts Department. When ordering parts or request-
ing information for your vehicle, provide vehicle model,
serial number and manufacture code.
Owner’s Manual and Service Guide Page 1

BEFORE INITIAL USE On Board Charger

Read, understand and follow safety label on the instru- The on board charger is wired directly to the batteries,
ment panel. The vehicle has been designed to operate in only requiring it be plugged into a dedicated 15 amp AC
a warehouse or factory environment with semi-smooth outlet to be operational. When charge cycle is complete,
floors, road and ramps. replace cord in appropriate area under cargo deck.
Be sure you understand the vehicle, its equipment and

how to use it safely. Although the vehicle has been IDENTIFICATION
designed to provide safe and reliable operation, main- The product model number, model year and serial num-
taining good performance depends to a large extent on ber must appear on all correspondence concerning this
the operator. unit. These identification numbers appear on the decal
Vehicle batteries must be fully charged before initial use. attached to the left side of the kick panel.(Ref Fig. 2 on
page 2).
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 must take place in an area that is adequate-
ly ventilated (minimum of 5 air exchanges per hour).
To reduce the chance of 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. 1
Hydrogen gas is generated in the charging cycle of bat-
teries 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 proper ventilation.
Five air exchanges per hour is considered the minimum Fig. 2 Model Number, Model Year and Serial Number
requirement. 1. Model Number, Model Year and Serial Number.
Never charge a vehicle in an area that is subject to flame The vehicle serial number is located under the seat. (Ref
or spark. Pay particular attention to natural gas or pro- Fig. 3 on page 3)
pane gas water heaters and furnaces.
Before a new vehicle is put into operation, it is recom-
mended that the items listed in the INITIAL SERVICE
CONTROLS, METERS AND SWITCHES
CHART be performed (Ref Fig. 1 on page 2). The controls, meters and switches consist of:
• key switch
ITEM SERVICE OPERATION • direction selector switch
• power on/battery condition meter
Batteries Charge batteries • headlight (accessory; standard on EE models; not
Seats Remove protective plastic covering shown)
Brakes Check operation and adjust if necessary • service/parking brake pedal
• speed control pedal
Tires Check air pressure (see SPECIFICATIONS)
• horn
• seat switch
Fig. 1 Initial Service Chart • hour meter (accessory; not shown. Located under
rear deck.)
Page 2 Owner’s Manual and Service Guide

1
1
Fig. 5 Controls On Floorboard

1. Service/Parking Brake Pedal
Fig. 3 Serial Numbers Under Seat
2. Speed Control Pedal
1. Serial Numbers Under Seat.
(Ref Fig. 6 on page 3) shows the horn button and handle-
(Ref. Fig. 4 on page 3) and (Ref. Fig. 5 on page 3) show
bar.
the controls on the dash and the floorboard.
2
3
1 2 1
Fig. 4 Controls On Dashboard

1. Key Switch Fig. 6 Horn Switch
2. Direction Selector Switch 1. Handlebar
3. Power On/Battery Condition Meter 2. Horn
4. Headlight Switch Key Switch
The key switch, located in the vehicle dash, supplies or
interrupts power to the vehicle electrical system.

ON POSITION: Supplies power Power ON/Battery Condition Meter

OFF POSITION: Interrupts power (Ref Fig. 7 on page 4) The power on/battery condition meter indicates whether
power is supplied to the unit and the state of battery
1 charge. The meter illuminates only when power is being
supplied.
The meter scale is a 10--bar LED (light emitting diode)
2
displaying the state of charge successively, bar by bar,
from full to empty.
• At 70% of discharge, a flashing light signals an
“energy reserve” alert.
• At 80% of discharge, a double flashing light sig-
nals as “empty” alarm. The batteries should be
fully charged before using the vehicle.
Fig. 7 Key Switch Headlight (Accessory)

1. On Position The headlight can be pivoted on the mounting as
required. Push the headlight switch on the dash panel to
2. Off Position
turn the headlight on or off.
To prevent unexpected
! !
vehicle movement or Service/Parking Brake Pedal
unauthorized use, The service and parking brakes are combined in the left
always turn the key switch to the OFF position and pedal on the floorboard. Depressing the pedal will slow
remove the key when the vehicle is not in use. or stop the vehicle. Once the vehicle has stopped, the
parking brake can be engaged by pressing the front por-
Direction Selector Switch
tion of the pedal.
The direction selector switch, located on the dash panel,
controls the direction of vehicle movement. The panel is The floorboard catch should engage in the first notch of
marked with FORWARD, NEUTRAL and REVERSE the parking brake lock catch when the brake is properly
positions. Push to the NEUTRAL position when leaving adjusted. (Ref. Fig. 9 on page 4).
the vehicle seat.
DEPRESS TO ENGAGE
PARKING BRAKE CATCH
FORWARD DEPRESS TO
RELEASE PARKING
BRAKE
NEUTRAL
FRONT OF VEHICLE
REVERSE
FLOORBOARD
Fig. 8 Direction Selector Switch
To prevent unexpected PARKING BRAKE
LOCK CATCH
! ! vehicle movement when FIRST NOTCH
you or other persons FLOORBOARD CATCH
next operate the vehicle, ALWAYS place the direction
selector switch in the NEUTRAL position when leav-
ing the vehicle seat. Fig. 9 Speed Control Pedal
Remove the key to prevent unauthorized use of the To release the parking brake, depress the service/park-
vehicle. ing brake pedal.

ALWAYS apply the park-

! !
ing brake when the vehi-
cle is to be left
unattended. The parking brake is NOT automatically
applied.
Speed Control Pedal
Depressing the speed control pedal starts the motor;
releasing the pedal stops the motor.
Operation with the pedal fully depressed gives maximum
speed but is recommended only when the vehicle can be
operated safely. For slower speeds, depress the pedal as
required.
Reverse speed is half of forward speed.
To prevent loss of vehi-

! !
cle control, NEVER Fig. 10 Seat Switch
exceed safe operating To prevent unexpected
speed. ALWAYS adjust speed to conditions. ! !
vehicle movement, NEV-
Horn and Handlebar ER operate the vehicle if
the seat switch is malfunctioning.
The horn button switch is attached to the handlebar on
the standard equipment vehicle. Hour Meter (Accessory)
A vehicle equipped with optional wheel type steering will The hour meter, located in the motor compartment,
have the horn button located on the right side of the behind the speed controller, records the number of hours
steering console. the vehicle has been operated.
Depress the button to sound the horn. The horn will not
sound when the key is in off position. ADDITIONAL FEATURES
Handlebar Installation Additional features include a built-in battery charger, a
fold down backrest and a programmable speed control-
If the handlebar is factory installed,
ler.
make sure the retaining nut is tight.
Otherwise install the fork spindle key, handle, lockwasher and Battery Charger
nut. Tighten the nut to 50 ft. lbs. (68 Nm) torque.
The standard vehicle is equipped with a built-in 24 volt,
Failure to install the fork 25 amp DC, 120 volt AC, 60 Hz, fully automatic charger,
! ! spindle key and to tight- located under the driver’s seat. There is also a storage
en the handlebar retain- area under the seat for the charger cord. (Ref Fig. 11 on
ing nut may allow the handlebar to come loose, page 6).
resulting in loss of vehicle steering control.
Seat Switch
The seat switch, located under the operator’s seat,
allows the vehicle to function only when the seat is in
position and the operator is properly seated. Should the
operator leave the seat during operation, the vehicle will
stop.(Ref. Fig. 10 on page 5).

Programmable Speed Controller

1 The vehicle is equipped with a programmable speed con-
troller, which provides a variety of diagnostic data and
can be used to change factory speed settings. For infor-
mation about diagnostics, troubleshooting, adjustments
and factory settings, see pages 27 - 30 of this manual.
EE UNITS
This vehicle is available in “EE” versions. “EE” Units
2 meet all the requirements of “E” Units and provide addi-
tional safeguards against inherent fire and electrical haz-
ards, as specified per U.L. 583.
Fig. 11 Battery Charger The additional components used on “EE” vehicles
include:
Fold Down Backrest • head light guard
The backrest is easily positioned to provide seating for a • rear light guard
passenger or, in a raised position, for cargo. • terminal boots for the circuit breaker, motor, and
To lower the backrest, lift it upward and toward the front forward, reverse and main solenoids
of the vehicle. When the pins on either side have cleared • a static strap
the slots, slowly lower the backrest into position. Reverse • a safety hasp to keep the battery compartment
the procedure when raising the backrest. (Ref Fig. 12 on securely closed
page 6).
“EE” Units function identically to “E” Units.
COMBINATION BEFORE ENTERING VEHICLE

BACKREST
AND SEAT 1. Check for correct tire inflation.
2. Inspect for fluid leaks.
3. Be sure everything is properly stored and secured.
PIN
If vehicle has built-in charger, unplug power cord from
electrical outlet and properly store cord under instrument
SLOT panel prior to moving vehicle. If vehicle has a portable
charger, remove charger plug from vehicle receptacle
and properly store cable prior to moving vehicle.
OPERATING THE VEHICLE

Improper use of the vehicle or the lack
Fig. 12 Fold Down Backrest of proper maintenance may result in
decreased performance or damage to the vehicle.
To prevent possible inju-
! !
ry, make sure the seat is Read and understand the following warnings before
in the lowered position attempting to operate the vehicle:
when carrying a passenger. Raise the seat if no pas- To reduce the possibility
senger will be carried. DO NOT allow a passenger to ! !
of severe injury or death
stand on the rear step. resulting from loss of
vehicle control, the following warnings must be
observed:

Drive the vehicle only as fast as terrain and safety the direction desired, release park brake and press the
considerations allow. Consider the terrain, traffic accelerator pedal to start the vehicle.
conditions and the environmental factors which When the direction selector is in the reverse
effect the terrain and the ability to control the position, a warning signal will sound. This is a
vehicle. device to indicate the vehicle is ready to run in reverse.
Use extra care and reduced speed when driving Releasing the accelerator slows the vehicle. To stop the
on poor surfaces, such as loose dirt, wet grass, vehicle more quickly, depress the brake pedal.
gravel, etc.
To avoid component damage, the vehi-
Avoid extremely rough terrain. cle must be brought to a complete stop
Avoid driving fast down hill. A sudden stop or before shifting the direction selector switch.
change of direction may result in loss of control. Do not hold vehicle on hill by using accelerator and motor. Leav-
Use service brake to control speed when traveling ing motor in a stalled condition for more than 3-4 seconds will
down an incline. cause permanent damage to motor.
Slow down before and during turns. All turns
should be executed at reduced speed. COASTING
All travel should be directly up or down hills. To prevent injury or
Use extra care when driving the vehicle across ! !
death resulting from
any incline. coasting at above recom-
Stay in designated areas and avoid steep slopes. To mended speeds, limit speed with service brake.
reduce the possibility of severe injury or death result- On steep hills/ramps, it is possible for vehicles to coast at
ing from improper vehicle operation, the following faster than normal speeds that may be encountered on a
warnings must be observed: flat surface. To prevent loss of vehicle control, speeds
should be limited to no more than the maximum speed
Refer to GENERAL SPECIFICATIONS for capacity. on level ground (see GENERAL SPECIFICATIONS).
Make sure that the direction selector is in correct Limit speed by releasing the accelerator pedal and apply-
position before attempting to start the vehicle. ing pressure to the heel of the pedal. Severe damage to
the drive train components due to excessive speed may
Do not take vehicle out of ‘gear’ while in motion result from driving the vehicle above specified speed.
(coast). Damage caused by excessive speed may cause a loss
Always bring the vehicle to a complete stop of control, is costly, is considered abuse and will not be
before shifting the direction selector. covered under warranty.
Check the area behind the vehicle before operat-
ing in reverse. OPERATION
Always hold on while the vehicle is in motion. The SAFETY WARNING decal shown is located on the
Keep feet, legs, hands and arms inside the vehicle upper portion of the right kick panel. All information on
at all times. the decal is of the utmost importance. This decal and all
To prevent inadvertent movement when the vehi- others must remain on the vehicle.
cle is to be left unattended, set parking brake ped- Failure to heed these
al completely, move direction selector switch to ! !
warnings may result in
neutral position, turn key to ‘OFF’ position and personal or fatal injury to
remove key. you or others and may also result in equipment and
or property damages.
STARTING THE VEHICLE Before operating vehicle:
To start the vehicle: Place the key in the key switch and Read and understand operator’s manual (located
turn to the ‘ON’ position. Move the direction selector to under seat).

All occupants must be seated in factory approved Passengers MUST NOT stand on rear footrest.
seats, switches spark-do not operate in explosive Keep both hands on steering mechanism when
or commuatible atmosphere. ever possible and keep arms and legs inside vehi-
While operating vehicle: cle while moving. Passenger must use the hand
Keep body inside vehicle passenger must be holds provided with the rear seat.
seated and use hand holds provided. Be aware of object haz-
Sudden sharp turns unbalanced or top heavy ! ! ards that can impact the
loads can cause upset. operator or passenger
within the confines of the vehicle; for example, low
Cargo must be secured to platform. hanging tree branches or laterally protruding objects.
Avoid sudden starts and stops to avoid unseating Make sure the operating area is clear of debris.
of passengers.
Use extreme care when backing up. Make sure no
Adjust speed to conditions. one is behind you. Back the vehicle carefully at a
Before leaving vehicle: reasonable speed.
Set direction selector to ‘OFF’ position. NEVER use the vehicle in or near an area where
there is explosive dust or fumes. The electrical
Turn key to vertical ‘OFF’ position and remove. system of the unit creates sparks which can ignite
If malfunction occurs, or adjustment is needed, explosive materials.
do not use, have all work performed by authorized Adjust your speed to current driving conditions.
personnel.
Travel directly up or down inclines. DO NOT travel
Apply hand or foot brake-not automatically across the face of any incline, ramp, grade or
applied. slope.
It is your responsibility to keep all labels (decals) Avoid driving fast down hill. A sudden stop or
and instructional literature legible and intact. change of direction can result in loss of control.
Replacement labels (decals) and literature are Use the service brake to control speed when trav-
available from the factory. eling down an incline.
Your safety and the safety of others around you depends NEVER overload the vehicle. See identification
on your conscientious operation of this vehicle. Read the decal on kick panel for rated capacity.
following section carefully and thoroughly to become
Position loads carefully so they cannot shift or tip
familiar with proper operating procedures. Be sure to
over suddenly. Distribute loads evenly over the
read and understand the following warnings before
rear area. Keep loads low to avoid top heaviness.
attempting to operate the vehicle.
DO NOT operate this DRIVING THE VEHICLE
! ! vehicle until this own-
er’s manual is read and • Make sure you are properly seated in the opera-
understood. tor’s seat.
DO NOT allow untrained or unauthorized persons • Make sure the direction selector switch is in the
NEUTRAL position.
to operate this vehicle. NEVER allow children to
operate the vehicle. • Apply the parking brake, if it isn’t already applied,
by depressing the front portion of the service/park-
Before using the equipment, check all parts and ing brake pedal.
any attachments. If a malfunction is found, do not • Insert the key in the key switch and turn it to the
use the vehicle until the problem is corrected. ON position.
NEVER carry more than one passenger or a pas- • Move the direction selector switch to the desired
senger along with a cargo load. Passenger must direction.
remain seated in rear at all times during transport.

If the selector is moved to the REVERSE posi- LIFTING THE VEHICLE

tion, a backup warning alarm will sound until
the vehicle is again placed in NEAUTRAL or FORWARD. Tool List Qty. Required
Floor jack..................................................................... 1
SERVICING THE ELECTRIC VEHICLE Jack stands ................................................................. 4
Chocks ........................................................................ 4
To prevent severe injury
! !
or death, resulting from Chain hoist .................................................................. 1
improper servicing tech- Some servicing operations may require the vehicle be
niques, observe the following Warnings: raised.
Do not attempt any type of servicing operations To prevent possible inju-
before reading and understanding all notes, cau- ! !
ry or death resulting
tions and warnings in this manual. from a vehicle falling
Any servicing requiring adjustments to be made from a jack, be sure the vehicle is on a firm and level
to the powertrain while the motor is running must surface. Never get under a vehicle while it is support-
be made with the entire vehicle raised. ed by a jack. Use jack stands and test the stability of
the vehicle on the stands. Always place chocks in
Wear eye protection when working on front and behind the wheels not being raised. Use
the vehicle. In particular, use care extreme care since the vehicle is extremely unstable
when working around batteries, or during the lifting process.
using solvents or compressed air.
Never attempt to raise the rear wheels of a three
To reduce the possibility of causing an electrical wheel vehicle without first raising the front of the
arc, which could result in a battery explosion, turn vehicle and supporting on jack stands.
off all electrical loads from the batteries before
removing any heavy gauge battery wires. When lifting vehicle, position jacks and
To prevent the possibility of motor disintegration, jack stands only on the areas indicated.
never operate vehicle at full throttle for more than Due to the low ground clearance and short wheel base,
4 - 5 seconds while vehicle is in a “no load” condi- the vehicle should only be raised enough to remove the
tion. front axle or the rear wheels. Servicing that requires
access to the underside of the vehicle should be accom-
Battery posts, terminals and related accessories
plished by raising the front of the vehicle with a chain
contain lead and lead compounds. Wash hands
hoist attached to the front frame members. Always use
after handling.
an additional safety chain to prevent injury should the
It is in the best interest of both vehicle owner and servic- hoist malfunction.
ing dealer to carefully follow the procedures recom-
mended in this manual. Adequate preventative To remove a wheel or the front axle, loosen the hard-
maintenance, applied at regular intervals, is the best ware. Position a jack in the location indicated and care-
guarantee for keeping the vehicle both dependable and fully raise the front of the vehicle. Position the jack stands
economical. as shown. Use care not to place the jack or stands where
they could interfere with wiring or linkages. Slowly lower
the jack and test the stability of the vehicle.
TOWING To raise the rear of the vehicle, first raise the front of the
This vehicle is not vehicle as previously described and support on jack
! ! designed to be towed. stands. Then position the jack in the position shown at
the rear of the vehicle. Carefully raise the rear of the
It is recommended that this vehicle be moved by placing vehicle with the jack and place two jack stands in the
the entire vehicle on a trailer, flatbed truck or other suit- position shown. Slowly lower the jack and check that the
able transport. vehicle is securely supported by the jack stands before
proceeding.
Lower the vehicle by reversing the lifting sequence.

If the circuit breaker

! !
should open while driv-
Turn wheel as shown
ing on an incline, imme-
to permit jack placement diately apply the service and parking brakes to
prevent loss of vehicle control.
Detail
Parking The Vehicle
To park the vehicle, complete the following steps before
leaving the operator’s seat:
2 1 2 1. Stop the vehicle and move the direction selector
switch to the NEUTRAL position.
Place jack along
the flat edge of 2. Apply the parking brake.
footrest
3. Turn the key switch to the vertical OFF position and
remove the key.
When parking the vehicle on an incline, the
front wheel should be curbed whenever possi-
(See detail) ble. (Ref Fig. 14 on page 10).
4 4
View from underside of vehicle
Fig. 13 Lifting the Vehicle
SAFETY COMPONENTS
Fig. 14 Parking The Vehicle
The vehicle electrical circuit includes two protective com-
ponents: a seat switch and a thermal circuit breaker.
ROUTINE MAINTENANCE
Seat Switch
This vehicle will give years of satisfactory service, provid-
Removing body weight from the vehicle seat will cause ing it receives regular maintenance. Refer to the Periodic
the seat switch to interrupt electrical power to the control- Service Schedule for appropriate service intervals (Ref
ler. You must remain seated during vehicle operation. Fig. 22 on page 16). Refer to Lubrication Points for
appropriate lubrication locations (Ref Fig. 15 on page
Thermal Circuit Breaker 11).
The thermal circuit breaker prevents overloading of the Some maintenance items must be serviced
drive motor. Should the vehicle be stopped by the open- more frequently on vehicles used under severe
ing of the circuit breaker, turn the vehicle off to avoid an driving conditions.
accidental start when the breaker resets. The breaker Use maximum of three pumps of grease
automatically resets after approximately 20 seconds. An for each grease fitting - Overgreasing
audible click will sound when the breaker resets. may damage grease seals.
If the circuit breaker continues to open, a problem exists Putting more than three pumps of grease in a grease fit-
within the circuit or the vehicle is overloaded. Do not ting could damage grease seals and cause premature
operate the vehicle until the problem is resolved. bearing failure.

Wheel bearings
and fork pivot
Check/Fill Plug
Fig. 16 Rear Axle Lubricant Check and Fill
Rear axle BRAKES

check and
fill Service brakes in accordance with the Periodic Service
Schedule (Ref Fig. 22 on page 16). After the vehicle has
been put into service, it is recommended that the brakes
be checked by performing the following test:
Test Method
To prevent severe injury
! !
or death resulting from
View from underside of vehicle operating a vehicle with
improperly operating brake system, the braking sys-
Fig. 15 Lubrication Points tem must be properly maintained. All driving brake
tests must be done in a safe location with regard for
the safety of all personnel.
REAR AXLE
Over time, a subtle loss of performance may
The only maintenance required for the first five years is take place. Therefore, it is important to estab-
the periodic inspection of the lubricant level. The rear lish the normal braking distance with a new vehicle.
axle is provided with a lubricant level check/fill plug
Determine the braking performance of the vehicle by
located on the bottom of the differential. Unless leakage
engaging the parking brake at a common point on a flat,
is evident, the lubricant need only be replaced after five
dry, clean paved surface while traveling at maximum
years.
speed (Ref Fig. 17 on page 12). Observe the vehicle
Checking the Lubricant Level stopping location. If the vehicle stops in a significantly
greater distance than normal or pulls to one side, it
With the vehicle on level ground, clean the area around
should be tested again.
the check/fill plug and remove plug (Ref Fig. 16 on page
11). The correct lubricant level is just below the bottom of If the vehicle fails the second test, it should immediately
the threaded hole. If lubricant is low, add as required. be removed from service. The vehicle needs to be
Add lubricant slowly until lubricant starts to seep from the inspected by a qualified mechanic.
hole. Install the check/fill plug. In the event that the lubri-
cant is to be replaced, the vehicle must be elevated and
the oil pan removed or the oil siphoned out through the
check/fill hole.

TIRES
Tools List Qty. Required
Impact wrench, 1/2" drive ............................................1
Impact socket, 3/4", 1/2" drive .....................................1
Torque wrench, 1/2" drive, ft. lbs. ................................1
Wrench, 1 1/8" .............................................................2
To prevent injury caused
! !
by a broken socket, use
only sockets designed
Dry, Level, Clean, Paved Surface for impact wrench use. Never use a conventional
socket.
Tire condition should be inspected per the Periodic Ser-
vice Schedule (Ref. Fig. 22 on page 16). Inflation pres-
sures should be checked when the tires are cool. When
removing wheels with an impact wrench, use only impact
sockets. Regular sockets are not designed for impact
Accelerate To pressures exerted by power tools.
Maximum Speed
A tire explosion can
! !
cause severe injury or
death. Never exceed
inflation pressure rating on tire sidewall.
To prevent tire explosion, pressurize tire with
small amount of air applied intermittently to seat
beads. Never exceed the tire manufacturer’s rec-
Engage Line or Marker
Parking Brake
ommendation when seating a bead. Protect face
and eyes from escaping air when removing valve
core.
Use caution when inflating tires. Due to the low
volume of these small tires, overinflation can
occur in a matter of seconds. Overinflation could
Acceptable Line or Marker
cause the tire to separate from the wheel or cause
Stopping the tire to explode, either of which could cause
Distance Normal Range of personal injury.
Stopping Distance
Use caution when inflating tires. Due to the low volume of
Any vehicles that stop
these small tires, overinflation can occur in a matter of
beyond the Acceptable
Stopping Distance or seconds. Overinflation could cause the tire to separate
pulls to one side should from the rim or cause the tire to explode, either of which
be removed from service could cause personal injury.
and inspected by a
qualified mechanic See GENERAL SPECIFICATIONS section for recom-
mended tire inflation pressure. Under no condition
should inflation pressure be higher than recommended
on tire sidewall. All three tires should have the same
pressure for optimum handling characteristics. Be careful
not to overinflate. Due to the low volume of these small
tires, overinflation can occur in a matter of seconds. Be
Fig. 17 Periodic Brake Performance Test sure to install the valve dust cap after checking or inflat-
ing.

Tire Repair
'Cross Sequence'
The vehicle is fitted with tubeless tires mounted on one 1 3
piece rims.
Generally, the most cost effective way to repair a flat tire
resulting from a puncture in the tread portion of the tire is
to use a commercial tire plug.
Tire style 4 2
Tire plug tools and plugs are available at most
may vary
automotive parts outlets and have the advan-
tage of not requiring the tire be removed from the rim.
Fig. 18 Wheel Installation
If the tire is flat, remove the wheel and inflate the tire to
Removing and Reinstalling Front Tire
the maximum recommended pressure for the tire.
Immerse the tire in water to locate the leak and mark with To remove and reinstall the front tire, complete the fol-
chalk. Insert tire plug in accordance with manufacturer’s lowing steps and (Ref. Fig. 19 on page 13).
specifications.
If tire is to be removed from or mounted on rim, the tire
2
changing machine manufacturer’s recommendations
must be followed to reduce possibility of personal injury.
To prevent injury, be
! !
sure mounting/demount-
ing machine is anchored 3
to floor. Wear OSHA approved safety equipment when
mounting/demounting tires. 1
4
Follow all instructions and safety warnings provided by
the mounting/demounting machine manufacturer.
Wheel Installation 5
Do not tighten lug nuts to more than

85 ft. lbs. (115 Nm) torque.
Fig. 19 Wheel Installation
It is important to follow the ‘cross sequence’ 1. Front Axle Lock
pattern when installing lug nuts. This will
assure even seating of the wheel against the hub. 2. Axle Nut
With the valve stem to the outside, mount the wheel onto 3. Retaining Washer
the hub with lug nuts. Finger tighten lug nuts in a ‘cross 4. Wheel Retaining Nut
sequence’ pattern (Ref Fig. 18 on page 13). Then,
5. Valve Stem
tighten lug nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in
20 ft. lbs. (30 Nm) increments following the same ‘cross 1. Loosen the axle nuts and lower entire wheel, hub and
sequence’ pattern. axle assembly from front fork. Remove the four wheel
retaining nuts.
2. Completely deflate the tire, then remove from wheel.
3. Reinstall tire and wheel by reversing the above
sequence and tighten wheel retaining nuts. Tighten to
70 to 80 ft. lbs. (95 to 108.5 Nm) torque.
4. Position the large flat washer located on the ends of
the axle above the front axle locks.
5. Tighten axle nuts to 100 to 120 ft. lbs. (130 to 156
Nm) torque.

Install the wheel assembly with the valve stem with lukewarm or cold water is the best method of pre-
on the same side as the wheel retaining nuts. serving the painted surfaces.
To prevent possible inju- Do not use hot water, strong soap or harsh chemical
! ! ry, always deflate the tire detergents.
completely before Rubber parts should be cleaned with nonabrasive house-
removing from the wheel. hold cleaner.
When reinstalling the front wheel assembly, always Occasional cleaning and waxing with nonabrasive prod-
place the axle and retaining washer over the axle ucts designed for ‘clear coat’ automotive finishes will
locks (as shown) and tighten the axle nuts. Tighten enhance the appearance and durability of the painted
axle nuts to 100 to 120 ft. lbs. (130 to 156 Nm) torque. surfaces.
Failure to follow the procedure may allow the axle to Corrosive materials used for dust control can collect on
drop, resulting in loss of vehicle control. the underbody of the vehicle. These materials will accel-
Removing and Reinstalling Rear Tire erate corrosion of underbody parts. It is recommended
that the underbody be flushed occasionally with plain
1. Remove the wheel retaining nuts and remove the
water. Thoroughly clean any areas where mud or other
wheel assembly from the hub.
debris can collect. Sediment packed in closed areas
2. Completely deflate the tire, then remove from wheel. should be loosened to ease its removal, taking care not
3. Reinstall the tire and wheel by reversing above to chip or otherwise damage paint.
sequence and tighten wheel retaining nuts. Tighten to
70 to 80 ft. lbs. (95 to 108.5 Nm) torque. TRAILERING
4. Make sure the valve stem is located toward the out-
side. To prevent personal inju-
! !
ry to occupants of other
highway vehicles, be
LIGHT BULB REPLACEMENT sure that the vehicle and contents are adequately
To replace the headlight bulb, pivot the headlight forward
secured to trailer.
and remove the two Phillips head screws from back side Do not ride on vehicle being trailered.
and separate light assembly. Place new light bulb in
place and secure with screws previously removed. Always check that the vehicle and contents are ade-
quately secured before trailering the vehicle. The rated
To replace the taillight bulb, remove hardware securing
capacity of the trailer must exceed the weight of the vehi-
lens and remove lens. Install replacement bulb.
cle and load plus 400 pounds (180 kg) (see GENERAL
SPECIFICATIONS section for vehicle weight). Secure
CARE AND CLEANING OF THE VEHICLE the vehicle to the trailer using ratchet tie downs.
To prevent cosmetic damage, do not

use any abrasive or reactive solvents to
clean plastic parts.
It is important that proper techniques and cleaning mate-
rials be used.
Normal cleaning of the vinyl backrest and plastic or rub-
ber 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 vehicle provide attractive
appearance and durable protection. Frequent washing

HARDWARE
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref Fig. 21 on page Grade 2 Grade 5
15). Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
Fig. 20 Bolt Grades
torque values.
Generally, two grades of hardware are used in the vehi-
cle. Grade 5 hardware can be identified by the three
TORQUE SPECIFICATIONS
marks on the hexagonal head. Unmarked hardware is
ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)

Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
BOLT SIZE 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"
4 8 15 24 35 55 75 130 125 190
Grade 2
(5) (11) (20) (33) (47) (75) (102) (176) (169) (258)
Grade 5 6 13 23 35 55 80 110 200 320 480

(8) (18) (31) (47) (75) (108) (149) (271) (434) (651)
6 18 35 55 80 110 170 280 460 680
Grade 8
(8) (24) (47) (75) (108) (149) (230) (380) (624) (922)
BOLT SIZE M4 M5 M6 M8 M10 M12 M14

Class 5.8 1 2 4 10 20 35 55
(Grade 2) 5.8 (2) (3) (6) (14) (27) (47) (76.4)
Class 8.8 2 4 7 18 35 61 97
(Grade 5) 8.8 (3) (6) (10) (24) (47) (83) (131)
Class 10.9 3 6 10 25 49 86 136

(Grade 8) 10.9 (4) (8) (14) (34) (66) (117) (184)
Ref Tsp 1
Fig. 21 Torque Specifications

PERIODIC SERVICE SCHEDULE
✓ Check ♦ Clean, Adjust, etc. ▲ Replace

NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions
DAILY
BODY ♦ Clean body components as required
REVERSE WARNING DEVICE ✓ Check operation when direction selector is in reverse
✓ Examine for cuts, excessive wear and pressure

TIRES (See GENERAL SPECIFICATIONS)
WHEELS ✓ Check for bent rims, missing or loose lug nuts
BATTERIES ♦ Recharge to full state of charge after each day’s use
MONTHLY - 20 HOURS (includes items listed in previous table & the following)
♦ Clean batteries & terminals with 1/4 cup (60 ml) baking soda to 1 1/2 gallons (6 liters)
BATTERIES water solution, rinse with clear water
✓ Check charge condition and all connections
✓ Check brake performance, smooth operation

SERVICE/ PARK BRAKE
♦ Adjust if required
WIRING ✓ Check all wiring for loose connections and broken/missing insulation
ACCELERATOR ✓ Check for smooth movement
STEERING ✓ Check for excessive play, tightness of all hardware and bent or loose components
REAR AXLE ✓ Check for oil leakage, add lubricant (SAE 80-90 oil) as required 10 Oz (.3L) Capacity.
QUARTERLY - 50 HOURS (includes items listed in previous tables & the following)
FRONT FORK ✓ Check for damage to axle and loose or missing hardware
FRONT WHEEL ALIGNMENT ✓ Check for unusual tire wear, align if required
✓ Check for bent/binding linkage rods

SERVICE / PARK BRAKE
✓ Check for damage or wear
Fig. 22 Periodic Service Schedule

Notes:
SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)
♦ Clean and adjust, see Technician’s Repair and Service Manual
SERVICE / PARK BRAKES
✓ Check brake shoe linings, see Technician’s Repair and Service Manual
BODY ♦ Clean body components and wax all painted surfaces
STEERING ♦ Lubricate, use wheel bearing grease
ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)
♦ Adjust, see Technician’s Repair and Service Manual
FRONT WHEEL BEARINGS
♦ Pack, use lithium based wheel bearing grease
✓ Check lubricant, add lubricant (SAE 80-90 oil) as required

REAR AXLE
▲ Replace lubricant after 5 years
Fig. 22 Periodic Service Schedule

BATTERIES AND CHARGING Wrap wrenches with

vinyl tape to prevent the
Safety possibility of a dropped
Always observe the following warnings when wrench from ‘shorting
working on or near batteries: out’ a battery, which could result in an explosion
and severe personal injury or death.
To prevent burns or bat-
! !
tery explosion that could Aerosol containers of battery terminal protectant
result in severe personal must be used with extreme care. Insulate metal
injury or death, keep all smoking materials, open container to prevent can from contacting battery
flame or sparks away from the batteries. terminals which could result in an explosion.
Hydrogen gas is formed when charging batteries.
Do not charge batteries without adequate ventila- BATTERY
tion. A 4% concentration of hydrogen gas is A battery is defined as two dissimilar metals immersed in
explosive. an acid. If the acid is absent or if the metals are not dis-
Be sure that the key switch is off and all electrical similar, a battery has not been created. The batteries
accessories are turned off before starting work on most commonly used in these vehicles are lead acid.
vehicle. A battery does not store electricity, but is able to produce
Never disconnect a circuit under load at a battery electricity as the result of a chemical reaction which
terminal. releases stored chemical energy in the form of electrical
energy. The chemical reaction takes place faster in warm
Batteries are heavy. Use proper lift- conditions and slower in cold conditions. Temperature is
ing techniques when moving them. important when conducting tests on a battery and test
Always lift the battery with a com- results must be corrected to compensate for temperature
mercially available battery lifting differences.
device. Use care not to tip batteries
when removing or installing them; As a battery ages, it still performs adequately except that
spilled electrolyte can cause burns its capacity is diminished. Capacity describes the time
and damage. that a battery can continue to provide its design amperes
from a full charge.
The electrolyte in a storage battery is an acid
A battery has a maximum life, therefore good mainte-
solution which can cause severe burns to the skin
nance is designed to maximize the available life and
and eyes. Treat all electrolyte spills to the body
reduce the factors that can reduce the life of the battery.
and eyes with extended flushing with clear water.
Contact a physician immediately.
Always wear a safety shield or approved BATTERY MAINTENANCE
safety goggles when adding water or charg- Tool List Qty. Required
ing batteries.
Insulated wrench, 9/16" ...............................................1
Battery carrier ..............................................................1
Any electrolyte spills should be neutralized with a Hydrometer P/N 50900-G1..........................................1
solution of 1/4 cup (60 ml) sodium bicarbonate
(baking soda) dissolved in 1 1/2 gallons (6 liters) Battery maintenance kit P/N 25587-G01 .....................1
of water and flushed with water.
Overfilling batteries may result in electrolyte
being expelled from the battery during the charge
cycle. Expelled electrolyte may cause personal
injury and damage to the vehicle and storage
facility.
At Each Charging Cycle

To reduce the possibility Do not overfill batteries. The charging

! !
of fire, never attach a cycle will expel electrolyte and result in
battery charger to a vehi- component damage.
cle that is to be unattended beyond the normal charg- A battery being charged will ‘gas’ with the majority of the
ing cycle. Overcharging could cause damage to the gassing taking place at the end of the charging cycle.
vehicle batteries and result in extreme overheating. This gas is hydrogen which is lighter than air. Water and
The charger should be checked after 24 hours and sulfuric acid droplets will be carried out of the battery
unplugged after the charge cycle is complete. vents by the hydrogen gas; however, this loss is minimal.
Before charging the batteries, inspect all plugs/recepta- If the battery electrolyte level is too high, the electrolyte
cles of the battery charging system for dirt or debris. will block the vent tube and the gas will force it out of the
vent tube and battery cap. The water will evaporate but
Charge the batteries after each days use. the sulfuric acid will remain where it can damage vehicle
Monthly components and the storage facility floor. Sulfuric acid
loss will weaken the concentration of acid within the elec-
• Inspect all wiring for fraying, loose terminations, trolyte and reduce the life of the battery.
corrosion or deterioration of insulation.
• Check that the electrolyte level is correct and add Over the life of the battery, a considerable amount of
suitable water as required. water is consumed. It is important that the water used be
pure and free of contaminants that could reduce the life
• Clean the batteries and wire terminations.
of the battery by reducing the chemical reaction. The
Electrolyte Level and Water water must be distilled or purified by an efficient filtration
The correct level of the electrolyte is 1/2" (13 mm) above system. Water that is not distilled should be analyzed
the plates in each cell (Ref Fig. 23 on page 19). and if required, filtration installed to permit the water to
meet the requirements of the water purity table (Ref Fig.
24 on page 19).
Vent Cap
Impurity Parts Per
Expansion Million
Space
Color ............................................................................... Clear
Gas Vent
1/4" to 3/8" Suspended...................................................................... Trace
(6 to 10 mm) Vent
Total Solids .......................................................................100
Calcium & Magnesium Oxides...........................................40
Iron......................................................................................5
1/2" (13 mm)
Electrolyte level should Ammonia.............................................................................8
be at least 1/2" (13 mm) Organic & Volatile Matter...................................................50
above the plates and
1/4" to 3/8" (6 to 10 mm) Nitrites.................................................................................5
Plates
below vent Nitrates ..............................................................................10
Chloride ..............................................................................5
Fig. 23 Correct Electrolyte Level
Fig. 24 Water Purity Table
This level will leave approximately 1/4" - 3/8" (6 - 10 mm)
of space between the electrolyte and the vent tube. The Even if the water is colorless, odorless, tasteless and fit
electrolyte level is important since any portion of the for drinking, the water should be analyzed to see that it
plates exposed to air will be ruined beyond repair. Of does not exceed the impurity levels specified in the table.
equal importance is too much water which will result in Automatic watering devices such as the one included in
electrolyte being forced out of the battery due to gassing the Battery Maintenance Kit can be used with an
and the increase in volume of the electrolyte that results approved water source (Ref Fig. 25 on page 20). These
from the charging cycle. watering devices are fast and accurate to use and

maintain the correct electrolyte level within the battery In addition to the batteries, special attention should be
cells. paid to metallic components adjacent to the batteries
which should also be sprayed with the sodium bicarbon-
ate (baking soda) solution.
Watering gun similar to the type included in the
E-Z-GO Battery Maintenance Kit
1 1/2 gallons
(6 liters)
Clear Water
1/4 Cup (60 ml)

Sodium Bicarbonate
Valve consistently (Baking Soda)
fills to a
predetermined
level Non Metalic
Wand
Electrolyte
Level 2 gallon (7.5 liter)
Garden Sprayer
Pure Water Single Battery Cell
Fig. 25 Automatic Watering Gun

The watering device should only be used if the Fig. 26 Preparing Acid Neutralizing Solution
electrolyte level is less than 1/2" (13 mm)
above top of plates.
Allow the solution to sit for at least three minutes; use a
soft bristle brush or cloth to wipe the tops of the batteries
Cleaning Batteries in order to remove any residue that could cause the self
When cleaning the outside of the batteries and terminals, discharge of the battery. Rinse the entire area with low
do not use a water hose without first spraying with a solu- pressure clear water. All of the items required for com-
tion of sodium bicarbonate (baking soda) and water to plete battery cleaning and watering are contained in the
neutralize any acid deposits. Battery Maintenance Kit.
Use of a water hose without first neutralizing any acid, Cleaning should take place once a month or more often
will move acid from the top of the batteries to another under extreme conditions.
area of the vehicle or storage facility where it will attack
the metal structure or the concrete/asphalt floor. After Battery Replacement
hosing down the batteries, a residue will be left on the Remove battery hold downs and cables. Lift out batteries
batteries which is conductive and will contribute to the with a commercially available lifting device.
discharge of the batteries.
If the batteries have been cleaned and any acid in the
To prevent battery damage, be sure that battery rack area neutralized as recommended, no corro-
all battery caps are tightly installed. sion to the battery racks or surrounding area should be
present. Any corrosion found should be immediately
The correct cleaning technique is to spray the top and
removed with a putty knife and a wire brush. The area
sides of the batteries with a solution of sodium bicarbon-
should be washed with a solution of sodium bicarbonate
ate (baking soda) and water. This solution is best applied
(baking soda) and water and thoroughly dried before
with a garden type sprayer equipped with a non metallic
priming and painting with a corrosion resistant paint.
spray wand. The solution should consist of 1/4 cup (60
ml) of sodium bicarbonate (baking soda) mixed with 1 1/2 The batteries should be placed into the battery racks and
gallons (6 liters) of clear water (Ref Fig. 26 on page 20). the battery hold downs tightened to 45 - 55 in. lbs. (5 - 6

Nm) torque, to prevent movement but not tight enough to allowed to sit unused, it will become partially discharged.
cause distortion of the battery cases. When it reaches 1.240, which it will do in less than
Inspect all wires and terminals. Clean any corrosion from twenty days, it should be recharged. If a battery is left in
the battery terminals or the wire terminals with a solution a discharged state, sulfating takes place on and within
of sodium bicarbonate (baking soda) and brush clean if the plates. This condition is not reversible and will cause
required. permanent damage to the battery. In order to prevent
damage, the battery should be recharged. A hydrometer
To prevent battery explo- can be used to determine the specific gravity and there-
! !
sion that could result in fore the state of charge of a battery.
severe personal injury or
death, extreme care must be used with aerosol con-
tainers of battery terminal protectant. Insulate the
metal container to prevent the metal can from con- E
O
F OC
tacting battery terminals which could result in an L
E +15 -9
explosion. C +5 -15
T
Use care to connect the battery wires as shown (Ref. Fig. R -5 -21
O
27 on page 21) . Tighten the battery post hardware to 50 L -15 -26
- 70 in. lbs. (6 - 8 Nm) torque. Protect the battery termi- Y
T -25 -32
nals and battery wire terminals with a commercially avail- E
-35 -37
able protective coating.
T
E -45 -43
M -55 -48
P
Front of Vehicle E -65 -54
RED to Fuse inside Console R
A -75 -60
T
+ - U -85 -65
R
-95 -71
E
- + 1.100 1.140 1.180 1.220 1.260 1.300
1.120 1.160 1.200 1.240 1.280
+ - SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT
+
-
Fig. 28 Freezing Point of Electrolyte
BLK to BL- to WHT to BL+ to
Charger ESC Charger Solenoid In winter conditions, the battery must be fully charged to
prevent the possibility of freezing (Ref Fig. 28 on page
Fig. 27 Battery Connections 21). A fully charged battery will not freeze in tempera-
tures above -75° F (-60° C). Although the chemical reac-
Prolonged Storage tion is slowed in cold temperatures, the battery must be
stored fully charged, and disconnected from any circuit
Battery charger and controller must be
that could discharge the battery. For portable chargers,
disconnected since they will contribute
disconnect the charging plug from the vehicle receptacle.
to the premature discharge of batteries. Other electronic devices
may need to be disconnected. For on-board chargers, disconnect the charging harness
from the batteries. The batteries must be cleaned and all
During periods of storage, the batteries will need atten- deposits neutralized and removed from the battery case
tion to keep them maintained and prevent discharge. to prevent self discharge. The batteries should be tested
In high temperatures the chemical reaction is faster, or recharged at thirty day minimum intervals.
while low temperatures cause the chemical reaction to
slow down. A vehicle that is stored at 90° F (32° C) will
Battery Charging
lose .002 of specific gravity each day. If a fully charged The battery charger is designed to fully charge the bat-
battery has a specific gravity of 1.275, and the battery is tery set. If the batteries are severely deep cycled, some

automatic battery chargers contain an electronic module may result in a vehicle that runs slowly or in a vehicle that
that may not activate and the battery charger will not is unable to operate for the time required.
function. Automatic chargers will determine the correct A new battery must mature before it will develop its max-
duration of charge to the battery set and will shut off imum capacity. Maturing may take up to 100 charge/dis-
when the battery set is fully charged. Always refer to the charge cycles. After the maturing phase, the older a
instructions of the specific charger used. battery gets, the lower the capacity. The only way to
Before charging, the following should be observed: determine the capacity of a battery is to perform a load
test using a discharge machine following manufacturer’s
Do not overfill batteries. The charging
recommendations.
cycle will expel electrolyte and result in
component damage. A cost effective way to identify a poorly performing bat-
tery is to use a hydrometer to identify a battery in a set
• The electrolyte level in all cells must be at the rec- with a lower than normal specific gravity. Once the partic-
ommended level and cover the plates. ular cell or cells that are the problem are identified, the
• The charging must take place in an area that is suspect battery can be removed and replaced. At this
well ventilated and capable of removing the hydro- point there is nothing that can be done to salvage the
gen gas that is generated by the charging pro- battery; however, the individual battery should be
cess. A minimum of five air exchanges per hour replaced with a good battery of the same brand, type and
is recommended. approximate age.
• The charging connector components are in good
condition and free from dirt or debris. Hydrometer
• The charger connector is fully inserted into the A hydrometer (P/N 50900-G1) is used to test the state of
vehicle receptacle. charge of a battery cell (Ref Fig. 29 on page 23). This is
• The charger connector/cord set is protected from performed by measuring the density of the electrolyte,
damage and is located in an area to prevent injury which is accomplished by measuring the specific gravity
that may result from personnel running over or of the electrolyte. The greater the concentration of sulfu-
tripping over the cord set. ric acid, the more dense the electrolyte becomes. The
• The charger is automatically turned off during the higher the density, the higher the state of charge.
connect/disconnect cycle and therefore no electri-
To prevent battery explo-
cal arc is generated at the DC plug/receptacle
contacts.
! !
sion that could result in
severe personal injury or
AC Voltage death, never insert a metal thermometer into a bat-
Battery charger output is directly related to the input volt-
tery. Use a hydrometer with a built in thermometer
age. If multiple vehicles are receiving an incomplete
that is designed for testing batteries.
charge in a normally adequate time period, low AC volt- Specific gravity is the measurement of a liquid that is
age could be the cause and the power company should compared to a baseline. The baseline is water which is
be consulted. assigned a base number of 1.000. The concentration of
sulfuric acid to water in a new golf car battery is 1.280
TROUBLESHOOTING which means that the electrolyte weighs 1.280 times the
weight of the same volume of water. A fully charged bat-
In general, troubleshooting will be done for two distinct tery will test at 1.275 - 1.280 while a discharged battery
reasons. First, a battery that performs poorly and is out- will read in the 1.140 range.
side of the manufacturers specification should be identi-
fied in order to replace it under the terms of the Do not perform a hydrometer test on a battery
manufacturer’s warranty. Different manufacturers have that has just been watered. The battery must
different requirements. Consult the battery manufacturer go through at least one charge and discharge cycle in order to
permit the water to adequately mix with the electrolyte.
or a service representative for specific requirements.
The temperature of the electrolyte is important since the
The second reason is to determine why a particular vehi-
hydrometer reading must be corrected to 80° F (27° C).
cle does not perform adequately. Performance problems
High quality hydrometers are equipped with an internal

conform with the electrolyte temperature, e.g., if the

Bulb
Cylinder reading indicates a specific gravity of 1.250 and the
Float electrolyte temperature is 90° F (32° C), add four
1100 points (.004) to the 1.250 which gives a corrected
1125 reading of 1.254. Similarly if the temperature was 70°
32
28
1150 F (21° C), subtract four points (.004) from the 1.250
Add to Float 24 1175 to give a corrected reading of 1.246 (Ref Fig. 30 on
Reading 20
16 1200 page 23).
12 1225
8 1250
4
0 1275 Electrolyte
4 1100
1125 1300 Temperature
8 1150
1200
1225 ˚F ˚C
12 1250
16
1275
1300 160 71 +.032
Subtract 20 +.030
from Float
24 150 66 +.028 Electrolyte Temperature
28 +.026
Reading 32 Above 80˚ F (27˚ C)
36
140 60 +.024
+.022
Electrolyte temperature
32
28
24
20
16
130 54 +.020
12
8
4
0
90˚ F (32˚ C)
4
8
12
16
20
+.018
24
28
32
36
120 49 +.016 Hydrometer reading 1.250

+.014 1.250 + .004 = 1.254
110 43 +.012 corrected specific gravity
+.010
Weight 100 38 +.008
+.006
90 32 +.004 EXAMPLE #1:
Thermometer +.002
80 27 0
Fig. 29 Hydrometer –.002
70 21 –.004 EXAMPLE #2:
thermometer that will measure the temperature of the –.006
electrolyte and will include a conversion scale to correct 60 16 –.008
the float reading. It is important to recognize that the –.010
electrolyte temperature is significantly different from the 50 10 –.012 Electrolyte Temperature
ambient temperature if the vehicle has been operated. –.014 Below 80˚ F (27˚ C)
40 4 –.016
Using A Hydrometer –.018
Electrolyte temperature
30 –1 –.020
–.022 70˚ F (21˚ C)
1. Draw electrolyte into the hydrometer several times to
2 –7 –.024 Hydrometer reading 1.250
permit the thermometer to adjust to the electrolyte 1.250 - .004 = 1.246
–.026
temperature and note the reading. Examine the color 10 –12 –.028 corrected specific gravity
of the electrolyte. A brown or gray coloration indicates
a problem with the battery and is a sign that the bat-
tery is nearing the end of its life.
2. Draw the minimum quantity of electrolyte into the
hydrometer to permit the float to float freely without
contacting the top or bottom of the cylinder.
3. Hold the hydrometer in a vertical position at eye level Fig. 30 Hydrometer Temperature Correction
and note the reading where the electrolyte meets the
scale on the float.
4. Add or subtract four points (.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

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) indicates a
problem with the low reading cell(s).
As a battery ages the specific gravity of the electrolyte
will decrease at full charge. This is not a reason to
replace the battery, providing all cells are within fifty
points of each other.
Since the hydrometer test is in response to a vehicle
exhibiting a performance problem, the vehicle should be
recharged and the test repeated. If the results indicate a
weak cell, the battery or batteries should be removed
and replaced with a good battery of the same brand, type
and approximate age.

E-Z-GO FACTORY SET CONTROLLER PARAMETERS

PARAMATER RANGE DEFAULT DESIRED UNITS DESCRIPTION
Current Limit, Main 20 - 250 250 250 Amps Maximum current forward speed
Current Limit, Low Speed

20 - 250 250 250 Amps Maximum current reverse speed
Main
Current Limit, Plug 20 - 250 70 70 Amps Max. plug current forward speed
Current Limit, Low Speed

20 - 250 70 70 Amps Max. plug current reverse speed
Plug
Current Limit, Emergency Max. plug current in emergency

20 - 250 140 250 Amps
Reverse reverse
Current Limit, Low Speed Max. plug current in low speed emer-
Emergency Reverse 20 - 250 140 250 Amps gency reverse
Current Limit, Ramp Start 20 - 250 140 250 Amps Max. plug current during ramp start
Current Limit, Low Speed Max. plug current during ramp start in
Ramp Start 20 - 250 140 250 Amps low speed
Time to reach full output from zero

Acceleration Rate 0-3 1 0.8 Sec.
output
Output will respond to rate of throttle

Quick Start 0-6 1.4 0.2
change
Ohm or Type of throttle input type 2 = 0-5V, 3-

Throttle type type 1, 2, 3 type 1 type 2 Volts wire pot
Adjust desired PWM output at 50%

Ramp Shape 20 - 70 50 50 % throttle to vary throttle sensitivity at
low speed
Creep Speed/Min. Duty

0 - 25 10 0 % Speed at min. throttle setting
Cycle
Low Speed 40 - 100 60 55 % Max. speed in reverse
High Speed 40 - 100 100 100 % Max. speed in forward
Emergence Reverse Speed 25 - 100 100 100 % Speed during emergency reverse
Sequencing Delay 0-3 0 0 Sec. Delays HPD and SRO from brake
after controller is enabled
On = plug current dependent upon

Variable Plug On/Off On On
throttle position. Off = fixed
Option to disable controller if throttle

High Pedal Disable (HPD) 0-2 0 1 is applied before brake or keyswitch
input (KSI)
type 1 type 0 No Sequencing of KSI or brake before

Static Return To Off (SRO) type 0, 1, 2
brake SRO direction is selected
Anti - tiedown On/Off On Off Prevents high speed mode if HSS in

not released after brake
Fig. 31 Factory Settings

W/BL 2
W/G 3
W/B 4 MAIN
BL 5 CONTACT
W 6 24V 841208
Y 7 840766 36V 841112 887855
OR 11 16--
CONNECT OR R R
G 12 887855 892458 891653 RESISTOR
BR 14 840765
TERMINAL W 893142
R 15 G
CONTROLLER R 886649 B
W/Y 16 G
892789 W/G W
FWD W/R R
W/Y BL 24V841248 R
R 36V841123
A1S2 A2 S1
W W/B
A2 891862 R
1 9 B+ R BL
BL
Y REV OR
R
8 16 M-- B-- B 24V841248
BR 36V841123 R 890495
MINUTE MISER 892671
OR W/B OR G TUG 884890
892999 B B B
G
Y
886649 891655
W/BL W/BL
W/G 892901
B
W/R
HOUR METER 886802 R

B
G
OR
BR
R
TAILLIGHT R
892676
Y
B
W R
W W
R
B
B
Y
Y
W/Y
Y R
BL W Y R
BR BR R BR
A--YELLOW
C
R
B--WHITE
C--BLUE
DIODE
R 884398
STOPLIGHT SWITCH
POT AY R 886182 (TUG)
892894
STOPLIGHT SWITCH
814005 (MINUTE MISER)
R B
SEAT SWITCH AY
ALL WIRES IN MAIN HARNESS 158135--01 CONTROLLER
897160 UNLESS NOTED. P16 P6 P14 P12 P2 M-- B-- B+ A2
W R P2-- REVERSE P5 P7 P11 P4 P3
WIRE COLOR CHART P3-- FORWARD
P4-- MAIN CONTACT
B BLACK P5-- POT HIGH
BL BLUE P6-- 0--5V INPUT
BR BROWN P7-- POT LOW
G GREEN P11-- REVERSE (INPUT)
OR ORANGE P12-- FORWARD (INPUT)
PK PINK P14-- HIGH (INPUT)
P16-- KEYSWITCH (INPUT)
CAUTION
R RED CHARGER
W WHITE 24V 892860 REAR
W/B WHITE/BLACK 36V 893090 LIGHT
W/BL WHITE/BLUE
W/BR WHITE/BROWN
W/R WHITE/RED
W/Y WHITE/YELLOW
Y YELLOW
W/G WHITE/GREEN
REAR LIGHT
(COM)
TL (+) BL (+)
Fig. 32 Wiring Diagram

CIRCUIT BRKR: MINUTE MISER 829164

TUG 824800 892833
W/B 893282
R 893383
W/B
884045
TUG LIFTOUT RACK 6V 6V 6V
R
891693
EC TUG MM 36V TUG
B
B FRONT
R 6V 6V 6V
B W/B
887204
TUG LIFTOUT RACK TO
891657 OPTIONAL CIRCUIT 883078
EC TUG MM QUICK BRKR
DISCONNECT FRONT BRIDGE
20 AMP
RECTIFIER
6V 6V 24V MINUTE CIRCUIT BREAKER
840679 892523
MISER 829780
HEADLIGHT
B
6V 6V
R
B
G
BB W/B
0R
BR B
W/B
R
R
Y BL B
B
Y
BR
BR
W/BL B OR
R OR
W/BL Y NOT USED ON STD.
BAT. COND. METER CONNECTION FOR WIRING
Y HORN WITH TUG STEERING
WIRE DESTINATIONS WHEEL MOD.
R Y Y 0R Y
BR SAME AS STD. METER W/BL BL
R G B
Y W/BL W/BL BR OR
BB R W BR B
BB R
OR
BATT
IGN
ACC
FORWARD
2 4 1
REVERSE
Y 2 4 1 3
OR G
RB
R BR B R
Y Y 36V BAT. COND.
METER 841851
HEADLIGHT
REVERSE SWITCH
HORN BUTTON HORN
KEY SWITCH BATTERY WARNING 830640 806791
DIRECTION MEMORY 886090
886311 SWITCH CONDITION BUZZER
MODULE METER: 890000
836354
841852 24V 840526
BATTERIES 36V 841111
B-- B+ LIFTOUT BATTERY
(24V MINUTE MISER RACK APPLICATION
BATTERY ARRANGEMENT
SHOWN IN SCHEMATIC)
CHARGER
MAIN CONTACT
HOUR
FORWARD AC RELAY
METER FOOT
SWITCH
+
REVERSE AC AC
S1S2 REV SEAT SW

A1 A2 ALARM DIRECTION KEY
SWITCH
BCI
TUG BRAKE
0V LIGHT SW
CCW
5V MINUTE MISER
BRAKE LIGHT SW HORN BUTTON
HORN
HEADLIGHT
SWITCH
HEADLIGHT
Fig. 33 Wiring Diagram

Notes:

GENERAL SPECIFICATIONS

ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE

BATTERY MONITORING.................................................. LED State of charge meter
BATTERIES....................................................................... Four 6 volt deep cycle (105 minute minimum, 225 amp-hour @ 20 hour discharge
rate)
SPEED CONTROLLER..................................................... Programmable Solid state, 250 amp capacity
MOTOR ............................................................................. 24 VDC, series wound 1.5 hp (1.1 kW) @ 2800 rpm & 4.3 hp (3.2 kW) @ 1200
rpm, brazed armature and solid copper windings
REAR AXLE ...................................................................... Bevel gear with spur and helical gearreduction with input pinion shaft directly
connected to motor shaft
BRAKES............................................................................ Dual rear wheel, self adjusting mechanical drum brakes
PARKING BRAKE ............................................................. Toe lock combined with service brake
FRONT SUSPENSION ..................................................... Rubber mounted torque arm
REAR SUSPENSION........................................................ Coil springs and hydraulic shock absorber
STEERING ........................................................................ Handlebar connected directly to front fork
SEATING ........................................................................... Driver and rear facing passenger
TOTAL LOAD CAPACITY.................................................. 550 lbs. (250 kg) including operator, accessories & cargo
SPEED .............................................................................. 10 1/2 mph (17 kph)
CHASSIS........................................................................... Welded tubular steel; powder coated (Durashield™)
VEHICLE PROTECTION .................................................. None
BODY ................................................................................ Diamond pattern body with Durashield™ Industrial Yellow powder coat paint
STANDARD COLOR ......................................................... Industrial Yellow
LOAD BED ........................................................................ 22 3/4" (58cm) x 28 1/2" (72cms) x 4" (10cms)
LOAD BED FEATURES .................................................... Removable panel for powertrain access
LIGHTING (Standard)........................................................ Rear brake light
TIRES (Standard) .............................................................. 4.80 x 8 Industrial Load Range B
TIRE PRESSURE ............................................................. 60 psi (415 kPa)
WEIGHT (with batteries) ................................................... 690 lbs. (315 kg)
OPERATING CONTROLS & INSTRUMENTATION .......... Removable key, ‘deadman’ accelerator control, direction selector, audible reverse
warning
BATTERY CHARGER ....................................................... Lestronic II built-in 24 V, 120 VAC, fully automatic, line compensating, 25 amp DC
output at 24 volts, 60 Hz, UL recognized, CSA certified
RANGE (Nominal) ............................................................. 35 miles (56kms) max
Specifications subject to change without notice

22.75 in
(58 cm)
28.5 in
(73 cm)
39 in
4 in (99 cm)
(10 cm)
25.8 in 53 in
(65 cm) (135 cm)
30 in
(76 cm) 85 in (216 cm)
RECOMMENDED MAXIMUM RAMP GRADE RECOMMENDED MAXIMUM SIDE TILT

25% or 14˚ MAXIMUM 25% or 14˚ MAXIMUM
Fig. 33 Vehicle Dimensions and Incline Specifications

TURNING CLEARANCE
DIAMETER
130 in (330 cm) (Handlebar)

154 in (391 cm)
54 in.
(137 cm)
INTERSECTING
AISLE CLEARANCE
54 in
(137 cm)
Fig. 34 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance

Read and understand the following warnings Read and understand the following text and
before attempting to operate the vehicle: warnings before attempting to service vehicle:
In any product, components will eventually fail to perform
properly as the result of normal use, age, wear or abuse.
To prevent personal
! ! injury or death, observe It is virtually impossible to anticipate all possible compo-
nent failures or the manner in which each component
the following: may fail.
When vehicle is to be left unattended, release ped- Be aware that a vehicle requiring repair indicates that the
al completely, move direction selector to neutral, vehicle is no longer functioning as designed and there-
turn key to ‘OFF’ position and remove key. fore should be considered potentially hazardous. Use
extreme care when working on any vehicle. When diag-
Drive vehicle only as fast as terrain and safety nosing, removing or replacing any components that are
considerations allow. Consider the terrain and not operating correctly, take time to consider the safety of
traffic conditions. Consider environmental factors yourself and others around you should the component
which effect the terrain and the ability to control move unexpectedly.
the vehicle. Some components are heavy, spring loaded, highly cor-
Avoid driving fast down hill. Sudden stops or rosive, explosive or may produce high amperage or
change of direction may result in a loss of control. reach high temperatures. Battery acid and hydrogen gas
Use service brake to control speed when traveling could result in serious bodily injury to the technician/
mechanic and bystanders if not treated with the utmost
down an incline. caution. Be careful not to place hands, face, feet or body
Use extra care and reduced speed when driving in a location that could expose them to injury should an
on poor surfaces, such as loose dirt, wet grass, unforeseen situation occur.
gravel, etc.
All travel should be directly up or down hills. To prevent personal
Use extra care when driving the vehicle across an ! ! injury or death, observe
incline. the following:
Stay in designated areas and avoid steep slopes. Before working on the vehicle, remove all jewelry
Use the parking brake whenever the vehicle is (rings, watch, necklaces, etc.).
parked. Be sure no loose clothing or hair can contact
Keep feet, legs, hands and arms inside vehicle at moving parts.
all times. Use care not to touch hot objects.
Avoid extremely rough terrain. Raise entire vehicle and support on jack stands
Check area behind the vehicle before operating in before attempting to run or adjust powertrain.
reverse. Wear eye protection when working on or around
Make sure the direction selector is in correct posi- the vehicle. In particular, use care when working
tion before attempting to start the vehicle. around batteries, using solvents or compressed
air.
Slow down before and during turns. All turns
should be executed at reduced speed. Hydrogen gas is formed when charging batteries.
Do not charge batteries without adequate ventila-
Always bring vehicle to a complete stop before tion.
shifting the direction selector.
Do not permit open flame or anyone to smoke in
See GENERAL SPECIFICATIONS for standard an area that is being used for charging batteries.
vehicle load and occupant capacity. A concentration of 4% hydrogen gas or more is
explosive.
1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852
TO CONTACT US
North America:
Technical Assistance & Warranty 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: 010-1-706-798-4311, FAX: 010-1-706-771-4609
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.
Technical Communications Department

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29175-G01

ELECTRIC POWERED THREE WHEEL

BATTERY WARNING BATTERIES

Battery posts, CONTAIN LEAD

NOTES, CAUTIONS AND WARNINGS

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

CUSHMAN MINUTE MISER™

Starting Model Year 2004

Owner’s Manual and Service Guide Page i

Overfilling of batteries may void the warranty.

BATTERY PROLONGED STORAGE

Page ii Owner’s Manual and Service Guide

BEFORE INITIAL USE ............................................................................................................... 2

CONTROLS, METERS AND SWITCHES .................................................................................. 2

ADDITIONAL FEATURES .......................................................................................................... 5

Owner’s Manual and Service Guide Page iii

LIFTING THE VEHICLE ............................................................................................................. 9

ROUTINE MAINTENANCE ...................................................................................................... 10

LIGHT BULB REPLACEMENT ................................................................................................. 14

TORQUE SPECIFICATIONS .................................................................................................. 15

PERIODIC SERVICE SCHEDULE .......................................................................................... 16

BATTERIES AND CHARGING ................................................................................................. 18

Page iv Owner’s Manual and Service Guide

Fig. 29 Hydrometer ..............................................................................................................................23

GENERAL SPECIFICATIONS ................................................................................................. 29

Owner’s Manual and Service Guide Page v

Page vi Owner’s Manual and Service Guide

Owner’s Manual and Service Guide Page vii

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

Always reduce speed to compensate for poor terrain or conditions.

Always apply service brake to control speed on steep grades.

Always maintain adequate distance between vehicles.

Always reduce speed in wet areas.

Always use extreme caution when approaching sharp or blind turns.

Always use extreme caution when driving over loose terrain.

Always use extreme caution in areas where pedestrians are present.

Page viii Owner’s Manual and Service Guide

Always use recommended tools.

Always replace damaged or missing warning, caution or information labels.

Always keep complete records of the maintenance history of the vehicle.

Owner’s Manual and Service Guide Page ix

Page x Owner’s Manual and Service Guide

GENERAL manual without the manufacturer’s prior written authori-

4 GENERAL SAFETY PRACTICES 4.4 Fuel Handling and Storage

Owner’s Manual and Service Guide Page xi

4.8 Control of Noxious Gases and Fumes turer;

Page xii Owner’s Manual and Service Guide

Owner’s Manual and Service Guide Page xiii

Page xiv Owner’s Manual and Service Guide

STANDARDS AND PUBLICATIONS • ANSI/UL 583; Electric Battery Powered Industrial

Most of the service procedures in this guide can be

To facilitate maintenance, a Service Parts Manual and a

Owner’s Manual and Service Guide Page 1

BEFORE INITIAL USE On Board Charger

Be sure you understand the vehicle, its equipment and

Page 2 Owner’s Manual and Service Guide

Fig. 5 Controls On Floorboard

Fig. 4 Controls On Dashboard

Owner’s Manual and Service Guide Page 3

ON POSITION: Supplies power Power ON/Battery Condition Meter

Fig. 7 Key Switch Headlight (Accessory)

Page 4 Owner’s Manual and Service Guide

ALWAYS apply the park-