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Greenlee 28809-G01 User's Manual

1. 1 MOUNT VENDING UNIT REFRESHMENT VEHICLE 1 FRONT STRUT INSTALLATION 251 WINDSHIELD AND MIRROR INSTALLATION i Fig 1 Mounting the Refreshment Unit x2 CANOPY FRAME INSTALLATION 2 CANOPY INSTALLATION wes wes DRAIN VALVE INSTALLATION seen nennen nennen 2 REFRESHMENT UNIT REMOVAL esent trennen rrr 2 Fig 2 Front Strut Windshield and Mirror Installation es REFRESHMENT UNIT OPERATION MAINTENANCE AND 3 Operation vd Hoe veste dr ves ee doce b P d Hd Ere i td tc Ege 3 Cleaning eene 49 Fig 3 Canopy Installation 2 4 Fig 4 Emptying Water from Bins Maintenance 2 HM DS REFRESHMENT UNIT REPLACEMENT PARTS 5 5 Frame rade e 5 Fig 5 Initial ServiceChart uui ierit rr teet ie enr o ada eene rie rto chanter rin indeed 5 CONTROLS AND INDICATORS cereos concent ea te seen ta tea HYPER 5 KEY EIGHT SWLEBQEL ciet ere eq tr rere rn VE Ip e n Ee avn cn EHE NOE 6 Fig 6 Key Light Switch Low Oil Pressure Light and Fuel Gauge Heus DIRECTION SELECTOR x et et e ern nas ere e RAT
2. 45 HEADLIGHTS ON POSITION UNLOCKED 46 LOCKED DIFFERENTIAL LOCKED WARNING KEEP ENTIRE BODY INSIDE CAR Wy T WARNING Wa POSSIBILE ELECTRIC ARC OR BATTERY EXPLOSION WEAR EYE PROTECTION Service Guide Appendix A 5 LABELS AND PICTOGRAMS MAXIMUM TAILGATE 100 Ibs LOAD 45 kg Ref Pic 1 4 Appendix A 6 Owner s Manual and Service Guide Read and understand the following warnings before attempting to operate the vehicle To prevent personal injury or death observe the following When vehicle is to be left unattended engage parking brake move direction selector to F forward position turn key to OFF position and remove key Drive vehicle only as fast as terrain and safety considerations allow Consider the terrain and traffic conditions Consider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of direction may result in a loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel elc NOTE All travel should be directly up or down hills Use extra care when driving the vehicle across an incline Stay in designated areas and avoid steep slopes Use the parking brake whenever the vehicle is parked
3. BRE epe 6 CHOKE need itin is ber ei udine ee Ree eis 6 Fig 7 Direction Selector 2s 6 Fig 8 Choke 2 6 FUEL 0 1 2 6 LOW OIL PRESSURE INDICATOR LIGHT 22 2 6 ACCELERATOR 2 2477 Fig 9 Accelerator and Brake Controls bia COMBINATION SERVICE AND PARK BRAKE PEDAL ui FRONT DISC BRAKES OPTIONAL s EA M 7 Fig 10 Horn Button 7 OPERATING THE VEHICLE 7 RUN IN 8 Fig 11 Check Oil Level on Dipstick 8 COLD STARTING 4 22026 carta nm tee dde ee td ee Ce pe tee Ri e dete 8 STARTING AND DRIVING 2 8 STARTING THE VEHICLE ON A HILL 29 COASTING 4 549 2 9 Fig 12 Fueling 2 2 29 Wd bee LABELS AND PIGCTOGRAMS tpi tree tie nt ted t ineo A aer goce edge ce cp dva SUN TOP AND WINDSHIELD des 12 VOLT POWER OUTLET M Fig 13 12 Volt Power Outlet 10 TOWING TRAILER 10 VEHICLE CLEANING AND CARE 5 1 i sania 10 a 10
4. Fig 34 Cleaning the Cooling Fins REAR AXLE The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing Ref Fig 35 on page 23 Unless leakage of rear axle lubricant is evident an annual lubricant check is sufficient Owner s Manual and Service Guide Ref Raf 2 Drain Plug Fig 35 Add Check and Drain Rear Axle Lubricant Checking the Lubricant Level Tool List Qty Required Socket 13 mm 3 8 drive 1 Ratchet 3 8 2 1 FUN Sl 1 Clean the area around the check and fill plugs Remove the check plug The correct lubricant level is just below the bottom of the threaded hole Ref Fig 39 on page 26 If lubricant is to be added remove the fill plug and add lubricant using a funnel Add lubricant slowly until lubricant starts to seep from the check plug hole Install the check plug and the fill plug In the event that the lubri cant is to be replaced a drain plug is provided at the bot tom of the differential housing AIR CLEANER INSPECTION AND REPLACE MENT Canister Type Air Cleaner The air cleaner element is accessible by unsnapping the clips on the air canister and removing the cover and air filter element Ref Fig 36 on page 24 Clean inside of cover canister and dust collector Install the element and cover the same way they were removed Be sure the positioning a
5. neue E LIFTING THE VEHICLE Fig 14 Lifting the Vehicle Owner s Manual and Service Guide Page iii TABLE CONTENTS WHEELS AND TIRES bc ee ie e t re Dave c db o bate e dv b Cae 12 Tire Repair oinnes e RO Ferrer er recen Dr eT e ER 12 12 Fig 15 Wheel ect een 12 LIGHT BUEB REPLAGEMENT ERE Pie ERE HUMEUR 13 Fig 16 Headlight and Turn Signal Bulb Replacement seen 13 Fig 17 Tail and Brake Light Bulb Replacement sss 13 F SE HEPEAGEMENUE 35 2 3 i Mere e EH ee eov cR E EHE De RP HO EO 13 VEHICLE WITH DISCHARGED BATTERY ssseseessseeeeeeeeneeenennee nennen trennen nnne 13 TRANSPORTING VEHICLE eoo nap MUR E rER P S nn Koller Rx MD EP E NEUTRAL LOCK V Fig 18 Neutral Lock HAULING Eva ate ie ae ane need nevi ieee ena cane SERVICE AND MAINTENANCE 4 SERIAL NUMBER LABEL LOCATION PERIODIC SERVICE SCHEDULE Fig 19 Periodic Service Schedule nih eed et do 16 TIRE INSPECTION cor Na ete rab nerd te ar pU rer E
6. H PARTS COVERED UNDER THE CALIFORNIA EMISSIONS WARRANTY 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system il Air fuel ratio feedback and control system if applicable iil Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable 1 Air filter 3 Ignition System i Spark plugs il Magneto or electronic ignition system Page 38 Owner s Manual and Service Guide VEHICLE WARRANTIES CALIFORNIA 2004 iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable il Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable I MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2004 and later Owner s Manual and to retain proof that inspection and maintenance Services are performed at the times when recommended will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim if your failure to per form required maintenance resulted in the failure of warranted part The proof which you maintain should be given to each subsequent owner of the engine You are responsible for perform
7. NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions BEFORE USE Check service brake general operation Check park brake function Check warning device function in reverse Check tire condition Check overall vehicle condition WEEKLY TIRES ae for cuts excessive wear and pressure See GENERAL SPECIFICA TIONS WHEELS Check for bent rims missing or loose lug nuts FUEL GAUGE Check for proper operation at fueling and fuel cap vent is free of dirt ENGINE OIL Check and add if required DO NOT OVERFILL STARTER GENERATOR BELT V Check for tension wear cracks MONTHLY 20 HOURS includes items listed in previous table amp the following WIRING Check all wiring for loose connections and broken missing insulation ACCELERATOR V Check for smooth movement DO NOT LUBRICATE CABLE SERVICE BRAKE MECHANICAL BRAKES Conduct brake performance test PARK BRAKE Check brake performance and adjust if required CHOKE CABLE Check for smooth movement and adjustment DO NOT LUBRICATE CABLE CARBURETOR LINKAGE Check attachment adjust as required DIRECTION SELECTOR Check attachment adjust as required ENGINE V Check for unusual noise vibration acceleration oil leaks COOLING FAN v Check for build up of foreign matter inside blower housing an
8. Remem ber that the overall capacity of the vehicle operator pas senger contents of load bed and accessories must be reduced to compensate for the trailer and load The range of motion of the trailer is limited by the ball and hitch The trailer should not be used on rough trails or over objects such as logs large rocks holes etc Never install baskets or extensions using the hitch receivers front or rear Such items will change the per formance characteristics of vehicle and result in unsafe handling possible roll over or vehicle damage VEHICLE CLEANING AND CARE VEHICLE CLEANING To reduce the possibility of severe injury or vehi cle damage read and understand all instructions supplied by manufacturer of pressure washer CAUTION When pressure washing exterior of vehicle do not use pressure in excess of 700 psi To reduce the possibility of 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 Using excessive water pressure may cause severe injury to operator or bystander damage to seals plastics seat material body finish or electrical sys tem Do not use pressure in excess of 700 psi to wash exterior of vehicle Clean windshield with lots of water and a clean cloth Minor scratches may be removed using a commercial Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read a
9. 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 VENTILATION Always store gasoline vehicles in a well ventilated area Ventilation prevents gasoline fumes from accumulating Never fuel a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane water heaters and furnaces Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal 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 The following text is provided as recommended by part II of American Society of Mechanical Engineers American National Standards Institute ASME ANSI B56 8 1988 The manufacturer strongly endorses the contents of this specification PART Il FOR THE USER 4 GENERAL SAFETY PRACTICES 4 1 Introduction 4 1 1 Like o
10. tighten the upper jam nut against it Ref Fig 30 on page 21 Ref Abt 1 Fig 30 Adjusting Belt Tension Tighten the starter generator pivot bolt BATTERY CLEANING To reduce the possibility of damage to CAUTION vehicle or floor neutralize acid before rinsing battery To reduce the possibility of damage to electrical components while cleaning do not use a pressure washer Cleaning should take place per the Periodic Service Schedule Ref Fig 19 on page 16 When cleaning the outside of the battery and terminals first spray with a solution of sodium bicarbonate baking soda and water to neutralize any acid deposits before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from the top of the battery to another area of the vehicle or storage facility where it will attack the metal structure or the concrete asphalt floor Additionally a residue will be left on the battery which is conductive and will contribute to the discharge of the battery To reduce the possibility AWARNINGA of battery explosion that could result in severe Owner s Manual and Service Guide injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame or sparks away from the battery The correct cleaning technique is to spray the top and sides of the battery with a solution of sodium bicarbonate baking soda and water This solution is best applied w
11. Ca ve e UE eee deve ceils 18 GHECKING THE OIL BEVEL re tot ere ee ei eee eee dian e 18 Fig 20 Clean Entire Dipstick 18 Fig 21 Check Oil Level on 2 18 GHANGING THEIOIL rhet ence DR cedendo n o ERE RC Dg 18 Eig 22 Oil Viscosity Chart sities tices dette Re aset e t ppt e aret 19 Fig 23 Glean Top of Engine p OE ene E m 19 Li9 24 REMOVE OIL Filler s REPRHNERT 19 Eig 25 Clean OIL Filler riget A eA e RR n e CA Regg 19 Fig 26 Blowing Qut Oil Filler ete Petri RE eer 19 9 27 Add Engine Oll s cto epe rave e Or RO Tode n A da 20 STARTER GENERATOR BELT TENSION sees nennen nnne nre nnnnr 20 Fig 28 Checking Belt Tension with Gauge sse 20 Fig 29 Checking Belt Tension Manually esses 20 Adjusting the Belt 1 1 1 4 41 24 4 4 enne nnne tnnt tnis Fig 30 Adjusting Belt Tension BART ERY CLEANING peer Fig 31 Preparing Acid Neutralizing Solution 21 BRAKES Fig 32 Typical Brake Performance Test sss ener 22 Periodic Brake Test for Mechanical Brakes 2 22 Hy
12. Do not make repairs or adjustments unless specifically authorized to do so 5 7 4 The engine shall be stopped and the operator shall leave the carrier while refueling 5 7 5 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before starting engine 5 7 6 Do not operate a carrier with a leak in the fuel System or battery s 5 7 7 not use open flames for checking electro lyte level in storage battery s or liquid level in fuel tanks 6 MAINTENANCE PRACTICES 6 1 Introduction Page xiii SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 6 1 1 Carriers may become hazardous if mainte nance is neglected Therefore maintenance facilities trained personnel and procedures shall be provided Such facilities may be on or off the premises 6 2 Maintenance Procedures 6 2 1 Maintenance and inspection of all carriers shall be performed in conformance with the manufac turer s recommendations and the following practices a A scheduled preventive maintenance lubrication and inspection system shall be followed b Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers c Before undertaking maintenance or repair follow the manufacturer s recommendations for immobilizing the carrier d Block chassis before wo
13. GROUND 29 DRIVE ON FUEL PUMP HIGHWAY 19 a LOW OIL PRESSURE 2 PROVIDE 20 T2 NEGATIVE GROUND FLYING OBJECTS DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND p SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION N 1 i m NO 23 TAMPERING a KEEP HANDS OUT WARNING CORROSIVE P WARNING EXPLOSIVE WARNING LETHAL VOLTAGE d Ref Pic 1 2 BATTERIES ARE HEAVY USE CARE LIFTING USE INSULATED TOOLS WEAR EYE PROTECTION NO SMOKING HOT SURFACE Appendix A 4 Owner s Manual and Service Guide LABELS AND PICTOGRAMS Ref Pic 1 3 OPERATE FROM DRIVERS SIDE ONLY KEEP ARMS AND LEGS WITHIN VEHICLE TO OPERATE VEHICLE IN FORWARD TURN KEY TO ON MOVE DIRECTION SELECTOR TO FORWARD DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE TURN KEY TO ON MOVE DIRECTION SELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO NEUTRAL Owner s Manual and FINGERS BE TRAPPED 42 o 44
14. Reinstall the wires REPAIR LIFTING THE VEHICLE Tool List Qty Required Floor nae o ieee 1 JACK SLANGS 4 pec 4 Some servicing operations may require the front wheels the rear wheels or the entire vehicle be raised To reduce the possibility NE of severe injury or death from a vehicle falling from a jack Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported by jack Use jack stands and test the stability of the vehi cle on the stands Owner s Manual and Service Guide Always place chocks in front and behind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process CAUTION When lifting vehicle position jacks and jack stands at the areas indicated only To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 14 on page 11 Cen ter the jack under the rear frame crossmember Raise the vehicle enough to place a jack stand under the outer ends of the rear axle Lower the jack and test the stability of the vehicle on the two jack stands Place the jack at the center of the front axle Raise the vehicle enough to place jack stands under the frame crossmember as indicated Lower the jack and test the stability of the vehicle on all four jack stands If only the front or rear of the vehicl
15. THAT IT HAS BEEN ALTERED OR MODIFIED IN ANY WAY FROM E Z GO SPECIFICATIONS INCLUDING BUT NOT LIMITED TO ALTERATIONS TO THE SPEED BRAKING SYSTEM ELECTRICAL SYSTEM STEERING OR OTH ER OPERATING SYSTEMS OF THE VEHICLE OR SHOWS INDICATIONS THAT ROUTINE MAINTENANCE WAS NOT PERFORMED WHEN AND IN THE MANNER SPECIFIED IN THE E Z GO MAINTENANCE MANUAL THIS WARRANTY SHALL BE VOID WITH RESPECT TO ANY DEFECT OR DAMAGE CAUSED BY OR AS A RE SULT OF OR RELATED TO PARTS OR ACCESSORIES WHICH ARE NOT MANUFACTURED OR AUTHO RIZED BY E Z GO OR WERE NOT INSTALLED PER E Z GO S INSTRUCTIONS OR FOR GASOLINE VEHI CLES THE USE OF NON RECOMMENDED FUELS AND LUBRICANTS FOR FURTHER INFORMATION CALL 1 706 798 4311 OR WRITE TO E Z GO Division of Textron Inc ATTEN TION WARRANTY DEPARTMENT P O BOX 388 AUGUSTA GEORGIA 30903 0388 Owner s Manual and Service Guide Page 33 VEHICLE WARRANTIES Notes Page 34 Owner s Manual and Service Guide VEHICLE WARRANTIES FEDERAL 2004 FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all States except the State of California Fuji Heavy Industries Ltd and E Z GO Division of Textron Augusta Georgia herein E Z GO warrant s to the initial retail purchaser and each subsequent owner that this Non road engine herein engine h
16. and four 1 4 20 lock nuts item 24 Tighten hardware firmly Thread mirrors item 25 onto mirror brackets and tighten securely Page 1 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Available Refreshment Unit Accessories Include Sign Boards Condiment Tray Bottle Caddy Mini Bottle Carrier Humidor Credit Card Machine Mount Cash Drawer Ref Rfi 1 Fig 1 Mounting the Refreshment Unit CANOPY FRAME INSTALLATION Orient the two canopy frame sections end to end aligning five existing mounting holes as shown Ref Fig 3 on page 4 and fasten together with five 1 4 20 X 2 bolts item 26 ten 1 4 flat washers item 27 and five 1 4 20 lock nuts item 28 Orient the assembled canopy frame as shown and rest front of frame on top mounting plate and rear of frame on refreshment unit struts Secure can frame to refreshment unit struts with two 1 4 20 X 1 1 4 bolts item 29 four 1 4 flat washers item 30 and two 1 4 20 lock nuts item 31 as shown Secure canopy frame to front strut with two 1 4 20 X 2 bolts item 32 four 1 4 flat washers item 33 and two 1 4 20 lock nuts item 34 as shown Tighten hardware firmly CANOPY INSTALLATION Wipe canopy frame with a clean cloth Unfold canopy and locate clearance openings in the mounting flap Drape canopy over frame and orient
17. any responsibility to modify previously manufactured vehicles or battery chargers DISCLAIMER THIS WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES IMPLIED OR EXPRESSED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TGTSP WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISING FROM ANY DEFECT IN THE VEHICLE BATTERY CHARGER No agent employee or representative of E Z GO or any person has any authority to bind E Z GO to any other agreement representation or warranty concerning the goods sold under this warranty WARNING ANY MODIFICATION OR CHANGE TO THE VEHICLE OR BATTERY CHARGER WHICH ALTERS THE WEIGHT DISTRIBUTION OF THE VEHICLE ITS STABILITY INCREASES THE SPEED OR ALTERS THE OUTPUT OF THE BATTERY CHARGER BEYOND THE FACTORY SPECIFICATION CAN CAUSE PERSONAL INJURY DO NOT MAKE ANY SUCH MODIFICATION OR CHANGE E Z GO PROHIBITS AND DISCLAIMS RE SPONSIBILITY FOR ANY SUCH MODIFICATIONS OR ANY OTHER ALTERATION WHICH WOULD ADVERSE LY AFFECT THE SAFETY OF VEHICLE OR BATTERY CHARGER VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR BAT TERY CHARGER IS ABUSED OR OTHERWISE NOT USED IN ITS INTENDED MANNER IS IN AN ACCIDENT OR COLLISION SHOWS INDICATIONS THAT THE SPEED GOVERNOR WAS ADJUSTED OR MODIFIED AL LOWING THE VEHICLE TO OPERATE BEYOND E Z GO S SPECIFICATIONS SHOWS INDICATIONS
18. are supplied by the manufacturer 4 3 2 user shall not perform any modification or Owner s Manual and Service Guide addition which affects capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 4 3 3 As required under paras 4 3 1 or 4 3 2 the manufacturer shall be contacted to secure new name plates warnings or instructions which shall then be affixed in their proper place on the carrier 4 4 Fuel Handling and Storage 4 4 4 The user shall supervise the storage and han dling of liquid fuels when used to be certain that it is in accordance with appropriate paragraphs of American National Standards Institute National Fire Protection Association ANSI NFPA 505 and ANSI NFPA 30 4 4 2 Storage and handling of liquefied petroleum gas fuels shall be in accordance with appropriate para graphs of ANSI NFPA 505 and ANSI NFPA 58 If such storage or handling is not in compliance with these stan dards the user shall prevent the carrier from being used until such storage and handling is in compliance with these standards 4 5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 4 5 1 user shall require battery cha
19. canopy on frame so that clearance openings match strut attachment points and canopy frame juncture Ref Fig 3 on page 4 With the aid of assistants pull canopy taut over canopy frame Fold mounting flap up inside canopy frame as shown Page 2 Secure each mounting flap to inner surface of canopy frame with 10 X 1 2 self tapping screws item 35 evenly spaced approximately 9 apart as shown To pre vent gathering of canopy material during installation use the aid of assistants to hold the canopy taut while securing to canopy frame For best results begin secur ing the canopy at the middle of each side and proceed to each end of frame DRAIN VALVE INSTALLATION Locate the drain hose ends and drain valve mounting holes under the rear of unit Orient each drain valve assembly with spigot facing rearward Attach each valve assembly to unit with two 1 4 20 X 3 4 screws Slide the hose clamps onto the end of each drain hose Push the hose ends onto the drain valves and tighten clamps REFRESHMENT UNIT REMOVAL The vending unit is AWARNINGA heavy Care and proper lifting equipment and procedures must be used when removing unit to reduce the possibility of severe injury and or damage Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Fig 2 Front Strut Windshield and Mi
20. fill cap will result in oil becoming contaminated and or oil being discharged into the engine compartment The oil should be checked with the engine warm The vehicle must be on a level surface with the park brake engaged Allow adequate time for oil to drain into the crankcase before checking Remove the dipstick and wipe off the entire area indi cated with a lint free cloth Ref Fig 20 on page 18 Ref Ced 1 Fig 20 Clean Entire Dipstick Insert the dipstick fully into the dipstick hole and remove Examine the level of oil on the dipstick The engine can be operated safely as long as oil is within the safe operating range as indicated on the dipstick Do not operate vehicle if oil level is below the safe area indicated on the dipstick Ref Fig 21 on page 18 Maximum oil level DO NOT OVERFILL Full operating range Ref Dsk 1 Fig 21 Check Oil Level on Dipstick Oil should be added to bring the level into the safe oper ating range Do not overfill Check that the oil fill cap and dipstick are firmly in place CHANGING THE OIL Tool List Qty Required Socket 10 mm 3 8 1 Ratchet 3 8 1 Extension 8 3 8 drive 1 Oll drain pali deo erri rhetor Rr ades 1 For maximum performance and longevity the engine oil should be replaced every 125 hours of operation or semi annually whichever comes first The
21. is low Check oil level If oil level is between ADD and FULL mark on dipstick a mechanical problem exists within the engine and the vehicle must not be driven Contact a local distributor or authorized branch CAUTION To prevent engine damage do not oper ate engine until oil pressure is correct ed Do not overfill engine Too much oil may cause smoking or allow oil to enter the air filter enclosure Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings If oil level is below ADD mark on dipstick add oil to bring level to FULL mark Drive vehicle a short distance and check oil pressure If oil light does not come on continue to use vehicle ACCELERATOR PEDAL Unintentional movement IW of the accelerator pedal will release the park brake and may cause the vehicle to move which could result in severe injury or death With the key switch ON depressing the accelerator pedal starts the engine When the pedal is released the engine will stop Ref Fig 9 on page 7 To stop the vehi cle more quickly depress the service brake Park Service Brake Brake Fig 9 Accelerator and Brake Controls If key switch is ON and park brake is set depressing the accelerator inadvertently will release the park brake and will cause the vehicle to move which could cause
22. left unattended engage the park brake move direction selector to forward posi tion turn key to OFF position and remove key Make sure that the direction selector is in correct position before attempting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operat ing in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehicle is in motion RUN IN Check for oil or fuel leaks that could have developed in shipment from the factory Avoid full throttle starts and rapid acceleration until the engine has achieved operat ing temperature All engines consume more oil than normal during the first hours of operation As internal moving parts are run in oil consumption should gradually decrease until the rate of consumption stabilizes Check the oil level per the Periodic Service Schedule Add oil if the level on the dipstick indicates that oil is in the add oil range Ref Fig 19 on page 16 Page 8 Do not overfill engine Too much oil CAUTION may cause smoking or allow oil to enter the air filter enclosure NOTE Both the oil dipstick and fill cap must be in place before operating the engine Failure to install the dipstick and fill cap will result in oil becoming contam inated and or being discharged into the engine co
23. on a flat sur face To reduce the possible loss of vehicle control and severe drivetrain damage speeds should be limited to no more than the maximum governed speed on level ground see GENERAL SPECIFICATIONS Limit speed by applying service brake FUEL To reduce the possibility FINENESS Ey of severe injury or death from improper fuel han dling Owner s Manual and Service Guide Do not smoke near the fuel tank Do not refuel near open flame or electrical items which could produce a spark Always handle gasoline in a well ventilated area Always wear eye protection to protect against splashed fuel and fuel vapors Always allow adequate space for the expansion of gasoline Leave at least 1 2 5 cm space below bottom of filler neck Inspect fuel cap tank and other components for leaks or deterioration that could cause a hazard ous condition The fuel tank is located under the seat on the passenger side of the vehicle Ref Fig 12 on page 9 Fill the tank with fresh clean automotive grade gasoline Ref Fig 39 on page 26 High altitude or heavy use load applications may benefit from higher octane gasoline Do not use gasoline which contains Methanol CAUTION Some fuels called oxygenated or reformu lated gasoline are gasoline blended with alcohols or ethers Excessive amounts of these blends can damage the fuel system or cause performance problems If any undesirable operat ing symptoms occur use gasoline
24. result from modifications or tampering with the engine fuel ignition or air intake systems Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling This spark ignition system meets all require NOTE ments of the Canadian Interference Causing Equipment Regulations AWARNINGA syst me d allumage par tincelle de v hicule respecte toutes les exigences R glement sur le mat riel brouilleur du Canada NOTES CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER 5 MANUAL AND SERVICE GUIDE GASOLINE POWERED REFRESHMENT VEHICLE REFRESHER 1200 Starting Model Year 2004 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 infor mation 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 TO CONTACT US NORTH AMERICA TECHNICAL ASSISTANCE amp 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 E Z GO DIVISION OF TEXTRON INC 1451 MARVIN GRIFFIN ROAD AUGUSTA GEORGIA USA 30906 3852 Owner s Manual and Service Guide Page i GE
25. severe injury or death Depressing the accelerator pedal will release the park brake if it is engaged This is a feature to assure the vehi cle is not driven with the park brake engaged Depress ing the accelerator pedal is not the preferred method of releasing the park brake Depressing the lower section of the brake NOTE pedal is the preferred method of releasing the park brake to assure the longest service life of brake compo nents COMBINATION SERVICE AND PARK BRAKE PEDAL The brake pedal incorporates a park brake feature Ref Fig 9 on page 7 To engage push down on the upper section of the pedal until it locks in place The park brake will release when the service brake pedal is depressed Owner s Manual and Service Guide Use the lower section of the brake pedal to operate the service brake system OPTIONAL FRONT DISC BRAKES The front disc brakes activate as the brake pedal reaches the park or latch position Depressing the brake pedal further will increase the effectiveness of the front brakes HORN The horn is operated by pushing the horn button located on the floor to the left of the brake pedal Ref Fig 10 on page 7 Fig 10 Horn Button OPERATING THE VEHICLE Improper use of the vehicle or the lack CAUTION of proper maintenance may result in damage or decreased performance Read and understand the following warnings before attempting to operate the vehicle To redu
26. slightly less than 1 1 2 quarts 1 4 liters to allow for possible residual oil left in engine Ref Fig 27 on page 20 The oil must be high quality oil that meets or exceeds API SF SG CC standards Ref Fig 39 on page 26 Check oil level on dipstick If necessary continue to add oil slowly and allow time for oil to flow down into engine Check oil level on dipstick Do not overfill CAUTION Do not overfill engine Too much oil may cause smoking or allow oil to enter the air filter enclosure NOTE Both the oil dipstick and fill cap must be in place before operating the engine Failure to install the dipstick and fill cap will result in oil being discharged into the engine compartment Ref Aeo 1 Fig 27 Add Engine Oil Inspect oil fill cap O ring and replace if necessary Install the oil fill cap Run the vehicle for one or two minutes and check the filter for oil leaks Check the oil level again with the vehicle on level ground Oil should be added to bring the level into the safe oper ating range Do not overfill The engine can be operated safely as long as the oil is within the safe operating range as indicated on the dipstick Do not operate vehicle if oil level is below the safe area indicated on the dip stick STARTER GENERATOR BELT TENSION Tool List Qty Required Belt tension 1 Wrench 3 4 kao aa 1 Page 20 Wrench 9 1
27. the unit is put back into service Consumable Ice Compartment The consumable ice compartment located in the rear driver side of the bever age container is to be used for consumable ice only Ref Fig 1 on page 2 This compartment is equipped with it s own drain per FDA requirements and should not be used for canned goods or other products Trash Compartment The trash compartment is located in the rear of the vehicle The aluminum trash bin should be lined with a disposable plastic bag to maintain cleanli ness The trash bin is removable from the rear door only Drains The two spigot valves located under the rear of the beverage container drain the compartments To open the valves simply turn the valve handles away from the vehicle Ref Fig 4 on page 5 To close the valves turn the valve handles to a position parallel with the vehicle It is recommended that the valves be left in an open posi tion while the vehicle is in service Cup Dispensers The cup dispensers are designed to carry cups ranging from 14 to 20 ounces To adjust the cup dispenser for your size and type of cup remove the outer collar insert a sleeve of cups into the dispenser and turn the adjusting screw until the cups are securely held in the cup dispenser Re install the outer collar Shelves are to be used for any type of dry good such as chips peanuts hats golf balls etc Air Pot The three one gallon Air Pots are for serving hot or cold be
28. vinyl Qu tape to reduce the possibility of a dropped wrench short ing out a battery which could result in an explo sion Reduce the possibility of accidental starting by removing and grounding spark plug wires and disconnecting battery at negative terminal before servicing The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately Any electrolyte spills should be neutralized with a solution of 2 teaspoons 10 ml sodium bicarbon ate baking soda dissolved 1 quart 1 liters of water and flushed with water Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to reduce the possibility of can contact ing battery terminals which could result in an explosion Owner s Manual Service Guide It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recom mended in this manual Preventative maintenance applied at recommended intervals is the best guarantee for keeping the vehicle both dependable and economical This vehicle will give years of satisfactory service provid ing it receives regular maintenance Refer to the Periodic Service Schedule for appropriate service intervals Ref Fig 19 on page 16 Refer to Lubrication Points
29. 28809 G01 A Textron Company 5 MANUAL AND SERVICE GUIDE GASOLINE POWERED REFRESHMENT VEHICLE ISSUED APRIL 2005 SAFETY For any questions on material contained in this manual contact an authorized representative for clarification Read and understand all labels located on the vehicle 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 soeeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS Limit speed by applying the service brake Catastrophic damage to the drivetrain 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 For towing transporting vehicle refer to TRANSPORTING VEHICLE Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition BATTERIES ND RELATED PARTS CONTAIN LEA BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm WASH HANDS AFTER HANDLING WARNING Battery posts terminals and
30. 5 Class 10 9 4 Grade 8 Ref Tsp 1 Fig 38 Torque Specifications Owner s Manual and Service Guide Page 25 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings CAPACITIES AND REPLACEMENT PARTS Fuel Tank Fuel 6 0 gal 22 5 L 87 Octane 020 030 71 76 mm Gap Starter Generator P N 26414 01 Fig 39 Capacities and Replacement Parts Ref Cap 10 Page 26 Owner s Manual and Service Guide GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner s Manual and Service Guide Page 27 GENERAL SPECIFICATIONS STANDARD EQUIPMENT WEIGHT dry fuel tank TIRES TIRE PRESSURE LOAD CAPACITY REFRESHMENT UNIT LOAD CAPACITY GROUND CLEARANCE CHASSIS BODY amp FINISH SAFETY LIGHTING PACKAGE STEERING WHEEL BRAKES FRONT SUSPENSION REAR SUSPENSION STEERING DASH PANEL SEATING ENGINE VALVE TRAIN LUBRICATION BALANCER IGNITION CARBURETOR AIR CLEANER DRIVE TRAIN ELECTRICAL SYSTEM TRANSAXLE FUEL TANK SPEED REFRESHER 1200 1 054 lbs 478 kg fuel capacity 36 lbs 16 kg Front 18 x 8 50 x 8 4 ply rated 18 x 9 50 x 8 6 ply rated 18 22 psi 124 152 kPa 1200 Ibs 544 kg including operator passenger cargo and accessories 500 Ibs 227 kg 5 in 12 7 cm at differential Welded high yield strength tubular steel with powder coat paint Front
31. 5 GOVERNOR FAILURE TO COMPLY COULD RESULT IN SERIOUS On Governor Cover At For Explanation Of These j alg See to Top Of Rear Axle Pictograms 23 27 18 20 2 3 22 17 15 a 74093901 Appendix 2 Owner s Manual and Service Guide LABELS AND PICTOGRAMS WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL WARNING READ MANUAL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE IF USING ALCOHOL OR DRUGS MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED 1 2 DANGER OF EXPLOSION DO NOT FILL GAS CAN 14 25 IN LOAD BED WARNING MAXIMUM CROSS HILL RAMP WARNING ANGLE AS MAXIMUM LOAD SPECIFIED 2 GRAVITY KEEP LOAD LOAD WITH AS FAR HIGH CENTER FORWARD AS OF GRAVITY POSSIBLE COULD RESULT DO NOT RIDE IN TIP OVER IN LOAD BED LOAD KEEP HANDS amp CENTER FINGERS AWAY FROM DUMP BED DO NOT STAND BEHIND DUMP BED OF GRAVITY 14 MAXIMUM HEIGHT Ref Pic 1 1 Owner s Manual and Service Guide Appendix A 3 LABELS AND PICTOGRAMS 1 3 CLEAN UP GASOLINE re DO NOT 15 ge SPILLS WITHWATER 27 EXPOSE _ e BEFORE STARTING TO FLAME zzz ENGINE 16 UNLEADED GASOLINE 28 DISPOSE OF BATTERIES DO NOT 17 2 SPILL FUEL IN LANDFILL 19 ON A HOT ENGINE PONO 18
32. 6 iisseiitess 2 Ratchet 3 8 drive 2 1 Socket 3 4 3 8 1 The starter generator belt tension should be checked after the first 15 20 hours and set to 75 80 lbs 34 36 kg NOTE A loose belt can cause audible vibration and squeal Tighten a new starter generator belt Ref Fig 39 on page 26 to 90 110 lbs 41 50 kg tension when a gauge is applied half way between the two pulleys Ref Fig 28 on page 20 Ref Cbg 1 Fig 28 Checking Belt Tension with Gauge A new belt may be checked manually A maximum deflection of 3 8 10 mm is acceptable Ref Fig 29 on page 20 28 8 1 cm Max Deflection for New Belt 1 2 1 3 cm Max Deflection for Existing Belt Ref Cbm 1 Fig 29 Checking Belt Tension Manually Tighten an existing belt to 75 80 Ibs 34 36 kg ten sion using the same technique and inspect for cracking or wear A maximum deflection of 1 2 13 mm is accept able Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Adjusting the Belt Loosen the starter generator pivot bolt While holding the lower adjusting nut with a wrench loosen the upper jam nut with another wrench Move the lower nut up or down the adjustment bolt until proper belt tension is achieved Hold the lower nut in place and
33. A Replace SPARK PLUGS A Replace gap new plugs Ref Capacities and Replacement Parts on page 26 MUFFLER EXHAUST Y Check mounting hardware check for leaks at head and muffler gaskets VALVES V Check cold intake exhaust per Technician s Repair and Service Manual Fig 19 Periodic Service Schedule Owner s Manual and Service Guide Page 17 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 500 HOURS includes items listed in previous tables amp the following TIMING BELT v Check tension and for signs of wear damage replace if worn or damaged CARBURETOR Clean CYLINDER HEAD AND PISTONS Remove carbon from cylinder head and pistons Check valve seats for carbon buildup and clean as required Fig 19 Periodic Service Schedule TIRE INSPECTION Tire condition should be inspected per the Periodic Ser vice Schedule Ref Fig 19 on page 16 Inflation pres sures should be checked when the tires are cool Be sure to install the valve dust cap after checking or inflating CHECKING THE OIL LEVEL CAUTION Do not overfill engine Too much oil may cause engine to smoke or spark plug fouling When adding oil between oil changes do not NOTE mix brands and viscosity grades of oil Both the oil dipstick and fill cap must be in place before operating the engine Failure to install the dipstick and
34. Flexible impact resistant panels Color coat clear coat finish Rear Lightweight replaceable steel panels Dash mounted key switch reverse warning indicator deadman accelerator control integral handgrip on hip restraints manual forward reverse selector electric horn poly carbonate windshield Dual halogen headlights optional taillights brake lights turn signals Dual handgrips Dual rear wheel mechanical self adjusting drum brakes Combination service park brake with automatic parking brake release accelerator kick off Optional hydraulic front disc brakes Heavy duty leaf springs with hydraulic shock absorbers Heavy duty leaf springs with hydraulic shock absorbers Self compensating single reduction rack and pinion Scuff resistant with four drink holders fuel gauge low oil pressure indicator light Formed fabric backed vinyl covers over cushion foam Seating for operator and one passenger 11 hp 8 2 kW rated 4 cycle 350cc twin cylinder air cooled Overhead valve overhead cam belt drive Pressurized oil system washable permanent filter Internal counter rotating balance shaft Solid State electronic timing advance and RPM limiter Fixed jet remote pulse fuel pump Replaceable dry cartridge element Automatic continuously variable transmission CVT External starter generator Solid State regulator 12 volt maintenance free battery 425 CCA 60 minute reserve High efficiency differential with helical gears 13 32 1 ratio
35. IVERS 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 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 all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein If you have any questions regarding this vehicle contact your closest representative or write to the
36. Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Make sure the direction selector is in correct position before attempting to start the vehicle Slow down before and during turns All turns should be executed at reduced speed Always bring vehicle to a complete stop before shifting the direction selector See GENERAL SPECIFICATIONS for vehicle load and seating capacity Read and understand the following text and NOTE 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 It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating correctly take time to consider the safety of yourself and others around you should the component move unexpectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in serious bodily
37. MATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Thank you for purchasing this vehicle Before driving the vehicle we ask you to spend some time reading this Owner s Manual and Service Guide This guide contains the information that will assist you in maintaining this highly reliable vehicle Some illustrations may show items that are optional for your vehicle This guide covers the operation of several vehicles therefore some picto rial views may not represent your vehicle Physical differ ences in controls will be illustrated This vehicle has been designed and manufactured as a World Vehicle Some countries have individual require ments to comply with their specifications therefore some sections may not apply in your country Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in accordance with the Periodic Service Sched ule Service Parts Manuals and Technician s Repair and Ser vice Manuals are available from a local Distributor an authorized Branch or the Service Parts Department When ordering parts or requesting information for your vehicle provide vehicle model serial number and manu facture code REFRESHMENT UNIT The vending unit is equipped with two beverage compart ments a cold storage compartment a con
38. NERAL INFORMATION This vehicle has been designed and manufactured in the United States of America USA as a World Vehicle The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated The use of non Original Equipment Manufacturer OEM approved parts may void the warranty Overfilling battery may void the warranty Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture 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 Page ii Owner s Manual and Service Guide TABLE CONTENTS SARE dex x inside covers GENERAL INFORMATION nnns sn nenne nnn nn nnns ii SAFETY
39. RMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings LIGHT BULB REPLACEMENT To reduce the possibility of premature CAUTION bulb failure do not touch new bulbs with bare fingers Use clean dry tissue or paper towel to handle the glass portion of the bulb For vehicles with headlights mounted in cowl locate the two screws on backside of cowl that secure headlight Ref Fig 16 on page 13 Remove screws pull headlight out and disconnect wires Connect wires to new head light install in cowl and secure with screws previously removed Headlight Bulb Turn Signal 1 Housing Ref Hdr 2 Fig 16 Headlight and Turn Signal Bulb Replacement To replace the turn signal light bulb support turn signal housing from backside of cowl while removing two screws securing lens Install new bulb and replace lens To replace the tail and brake light bulb roll the rubber bezel from around the edge of the taillight and remove lens Install replacement bulb and replace lens FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new auto motive type fuse Headlight and taillight bulos and fuses are available from a local Distributor an authorized Branch or the Service Parts Department VEHICLE WITH A DISCHARGED BATTERY To reduce the possibility IW of severe injury or deat
40. RRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual E Z GO recommends that you retain all receipts covering maintenance on your engine but E Z GO cannot Owner s Manual and Service Guide Page 35 VEHICLE WARRANTIES FEDERAL 2004 deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte nance As the engine owner you should however be aware that E Z GO may deny warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to the nearest distributor dealer or service provider authorized by E Z GO when a problem exists If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 for the information THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise These receipts and mainte nance records should be transferred to each subsequent owner of the engine E Z GO reserves the right to deny warranty coverage if the engine has not been properly maintained Warranty clai
41. Y RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd herein FUJI are pleased to explain the emis sion control system warranty your 2004 and later small off road engine herein engine In California new gine must be designed built and equipped to meet the State s stringent anti smog standards FUJI must warrant the emission control system on your engine for the period of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor and the ignition system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists FUJI will repair your engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2004 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by FUJI OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual FUJI recommends that you retain all receipts covering maintenance on your engine but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that FUJI may de
42. address on the back cover of this publication Attention Product Service Department The manufacturer reserves the right to make design changes without obligation to make these changes on units previ ously sold and the information contained in this manual is subject to change without notice The manufacturer 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 This vehicle conforms to the current applicable standard s for safety and performance requirements Owner s Manual and Service Guide Page vii SAFETY INFORMATION These vehicles are designed and manufactured for off road use They do not conform to Federal Motor Vehicle Safety Standards of the United States of America USA and are not equipped for operation on public streets Some commu nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi nances 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 manu
43. al injury or property damage the following must be carefully observed CAUTION 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 DR
44. ard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest authorized E Z GO distributor dealer or service provid er Bring your sales receipts indicating date of purchase for this engine The distributor dealer or service provider authorized by E Z GO will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order All parts and accessories replaced under this warranty become the prop erty of E Z GO WHAT IS NOT COVERED Conditions resulting from tampering misuse improper adjustment unless they were made by the distributor dealer or service provider authorized by E Z GO during a warranty repair alteration accident failure to use the recommended fuel and oil or not performing required maintenance services The replacement parts used for required maintenance services Consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc Diagnosis and inspection charges that do not result in warranty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts OWNER S WA
45. as been designed built and equipped to conform at the time of initial sale to all applicable regulations of the U S Environmental Pro tection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period For the components listed under PARTS COVERED the distributor dealer or service provider authorized by E Z GO will at no cost to you make the necessary diagnosis repair or replacement necessary to ensure that the engine complies with applicable U S EPA regulations EMISSISON COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of 2 years PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system ii XAir fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance ret
46. ation shall be Page xiv 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 prevent the use of the carrier until the leak has been eliminated The carrier manufacturer s capacity operation and maintenance instruction plates tags or decals shall be maintained in legible condition p Batteries motors speed and directional control lers limit switches protective devices electrical conduc tors and connections shall be inspected and maintained in conformance with manufacturers recommended pro cedures q Carriers shall be kept in a clean condition to mini mize fire hazards and facilitate detection of loose or defective parts r Modifications and additions which affect capacity and safe machine operation shall not be performed by the customer or user without manufacturer s prior written authorization where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly s Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment END OF ASME ANSI B56 8 1988 TEXT Owner s Manual and Service Guide OPERATION AND SERVICE INFOR
47. cap for leaks or breaks that could result in fuel spillage Always wear safety glasses while refueling to pre vent possible eye injury from gasoline or gasoline vapor Keep hands clothing and jewelry away from mov ing parts Use care not to contact hot objects Raise the rear of the vehicle and support on jack stands before attempting to run the engine Preparing the engine for a prolonged storage period 30 days or more calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corro sion in the engine Raise the rear of the vehicle and support on jack stands Refer to Lifting the Vehicle for proper lift ing procedure and safety information e Disconnect the fuel hose at the fuel tank and plug hose With proper ventilation depress the accelerator pedal and allow engine to run until it stops due to lack of fuel Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Remove spark plugs Refer to SPARK PLUGS on page 24 and pour about 1 2 30 ml of engine oil into each cylinder Replace spark plugs ground spark plug wires and use starter to turn engine over a few seconds to distribute oil Add a gasoline additive to the tank in accordance with the manufacturer s recommendations e fuel line to tank and drive the veh
48. ce the possibility INI of severe injury or death resulting from loss of vehicle control the following warnings must be observed When driving vehicle consider the terrain traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc Stay in designated areas and avoid extremely rough terrain Maintain a safe speed when driving down hill Use Page 7 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings service brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control Slow down before and during turns All turns should be made at reduced speed Never drive vehicle up down or across an incline that exceeds 14 25 grade To reduce the possibility FMW NANT severe injury or death resulting from improper vehicle operation the following warnings must be observed Refer to GENERAL SPECIFICATIONS for seating capacity Depressing accelerator pedal will release foot operated park brake and may cause inadvertent vehicle movement Turn the key to the OFF posi tion whenever the vehicle is parked To prevent inadvertent movement when the vehi cle is to be
49. claiming previous experience Page xii 5 2 3 user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads carrier operator and other employees c general safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were for mulated d introduction of equipment control locations and functions and explanation of how they work when used properly and when used improperly and surface condi tions grade and other conditions of the environment in which the carrier is to be operated e operational performance tests and evaluations during and at completion of the program 5 3 Personnel and Burden Carrier Operator Responsibility 5 3 1 Operators shall abide by the following safety rules and practices in paras 5 4 5 5 5 6 and 5 7 5 4 General 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 operator is authorized only on personnel seat s provided by the manufacturer All parts of the body shall remain within the plan view outline of the carrier 5 4 3 When a carrier is to be left unattended stop carrier apply the parking brake stop the engine or turn off power turn off the control
50. d fins clean if required STEERING ASSEMBLY Check for abnormal play tightness of all hardware TIE ROD LINKAGES Check for excessive play bent components or loose connections REAR AXLE Check for leakage add SAE 30 oil as required QUARTERLY 50 HOURS includes items listed in previous tables amp the following FRONT AXLE Check for damage to axle and loose or missing hardware Page 16 Fig 19 Periodic Service Schedule Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings FRONT SHOCK ABSORBERS Check for oil leakage and loose fasteners FRONT SPRINGS Check for loose hardware cracks at attachments FRONT WHEEL ALIGNMENT Check for unusual tire wear align if required Check for bent binding linkage rod PARK BRAKE Check for damage or wear to latch arm or catch bracket Lubricate as required use light oil DO NOT LUBRICATE CABLES OR BRAKE LATCH REAR SHOCK ABSORBERS Check for oil leakage loose mounting hardware ENGINE ELECTRICAL SYSTEM Check coil spark plug wires for cracks loose connections Check for leaks at tank cap system lines filters pump carburetor Check system lines for cracks deterioration THROTTLE GOVERNOR LINKAGE Check operation and governed speed FUEL SYSTEM v Check for loose or miss
51. draulic Front Disc Brakes AIR INTAKE AND COOLING FINGS ottenere tenet trn trant d d t dna a Pei i da ten ied Fig 33 Gleaning Air Intake o tn ph ere ERE e REEL E Fig 34 Cleaning the Cooling Fins hide Fig 35 Add Check and Drain Rear Axle Lubricant 2299 99 23 Checking the Lubricant Level AIR CLEANER INSPECTION AND REPLACEMENT c ccecceceeseeereeeeeeeeeeeeeeeeseeaeeeeeseeeaesaeeeeesaeeeaeeaeeeeeeeeaees 23 Canister Type Air RR ae ae Cleaning the Air Filter Element Fig 36 Canister Type Air 24 LUBRICATION 24 FAQS 37 LUDNCAUOM 24 SPARK PLUGS aii Raia eee cane a a oe 24 PROEONGED STORAQGE 1 4 REB RARE Dn fene detecte te 24 HARDWARE receta necne re os ce Pete A te dee de Cod eec ve t de deed eod aed se Ua de 25 Fig 38 Torque 5 9 25 CAPACITIES AND REPLACEMENT PARTS ceceeseesceeeeeeeeeseeaeeeeesaeeeeecaeseeeeaeseesaeseeesaesaeeeaesaeseaeeeeeeaeeneeeees 26 Fig 39 Capacities and Replac
52. e only sockets designed for impact wrench use Use caution when inflating tires Overinflation could cause the tire to separate from the wheel or cause the tire to explode either of which could cause severe injury Use caution when inflating tires Due to the low volume of the small tires overinflation can occur in seconds Over inflation could cause the tire to separate from the wheel or cause the tire to explode Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor appli cations with major use on grassy areas the following should be considered On hard turf it is desirable to have a slightly higher inflation pressure On very soft turf a lower pressure reduces the possibility of tires cutting into the turf For vehicles being used on paved or hard sur faces tire inflation pressure should be in the higher allowable range but under no condition should inflation pressure be higher than recommended on tire sidewall All four tires should have the same pressure for opti mum handling characteristics Be sure to install the valve dust cap after checking or inflating Page 12 The vehicle is fitted with low pressure tubeless tires mounted on one piece rims therefore the most cost effective way to repair a puncture in the tread is to use a commercial tire plug NOTE Tire plug tools and plugs are available at most automotive par
53. e four mounting holes on refreshment unit with corresponding holes on vehicle mounting frame Secure unit to frame with four 5 16 18 X 1 1 4 bolts item 1 eight 5 16 flat washers item 2 and four 5 16 18 lock nuts item 3 Tighten hardware firmly FRONT STRUT INSTALLATION Position front strut item 4 and braces item 5 as shown Ref Fig 2 on page 3 and secure to vehicle at each side of the cowl with four 5 16 18 X 2 1 2 bolts item 6 four 5 16 lock washers item 7 two spacers item 8 and six 3 8 flat washers item 9 Secure top of braces with two 5 16 18 X 2 1 4 bolts item 10 four 5 16 lock washers item 11 and two 5 16 18 lock nuts item 12 Attach canopy frame mounting plate item 13 to front strut using two 1 4 20 X 1 1 2 bolts item 14 four 1 4 flat washers item 15 and two 1 4 20 lock nuts item 16 as shown Tighten hardware firmly WINDSHIELD AND MIRROR INSTALLATION Typical operation of a P AnA NIESE Refresher vehicle on a golf course may expose operator to possibility of being struck by a golf ball Always operate vehicle with windshield in place Insert two bumpers item 17 and four grommets item 18 into holes in windshield item 19 as shown Ref Fig 2 on page 3 Position windshield and mirror brackets item 20 as shown Secure windshield and mirror brack ets to front strut with four 1 4 20 X 1 3 4 bolts item 21 four spacers item 22 four 1 4 washers item 23
54. e is to be raised place the chocks in front and behind each wheel not being raised to stabilize the vehicle Lower the vehicle by reversing the lifting sequence Center of E Pd Front Axle a Flat Portion of Frame Outside End of Rear Axle Ref Liv 1 View from Underside of Vehicle Fig 14 Lifting the Vehicle Page 11 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings WHEELS AND TIRES Tire Repair Tool List Qty Required LUG wrench 3 4 tiec enn neri on 1 Impact socket 3 4 1 2 1 Impact wrench 1 2 1 Torque wrench 1 2 0421222 1 A tire explosion can cause severe injury or death Never exceed inflation pressure rating on tire sidewall To reduce the possibility of tire explosion pres surize tire with small amount of air applied inter mittently to seat beads Due to the low volume of the small tires overinflation can occur in sec onds Never exceed the tire manufacturer s rec ommendation when seating a bead Protect face and eyes from escaping air when removing valve core To reduce the possibility of severe injury caused by a broken socket when removing wheels us
55. e warranty service facilities where the warranty repair is per formed F WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealers distributors and service providers anywhere in the United States When warranty repair is needed the engine must be brought to an autho rized dealer distributorship or service provider s place of business during normal business hours In all cas es areasonable time not to exceed 30 days must be allowed for the warranty repair to be completed after the engine is received by the authorized dealer distributor or service station G MAINTENANCE REPLACEMENT AND REPAIR OF EMISSION RELATED PARTS Only warranted engine replacement parts approved by FUJI should be used in the performance of any war ranty maintenance or repairs on emission related parts If other than authorized parts are used for mainte nance replacement or repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability however assumes no liability under this warranty with respect to parts other than autho rized parts The use of non authorized replacement parts does not invalidate the warranty on other com ponents unless the non authorized parts cause damage to warranted parts
56. els during service operations a neutral lock is located on the direction selector To operate Turn key switch to OFF and lift seat Pull out and rotate the neutral lock pin handle so that the pointed portion of the handle is to the side of the direction selector cam Ref Fig 18 on page 14 Move direction selector towards the area between F and R During that motion the pin will snap into the hole in the direction selector mounting bracket preventing any movement When in this position the direction selector remains locked in the neutral position To unlock the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction selector cam Hole in Direction Selector Cam Hole in Direction Selector Mounting Bracket Neutral Lock Pin Handle Ref Nik 2 Fig 18 Neutral Lock Page 14 HAULING To reduce the possibility VNDC IW of severe injury or death while transporting vehi cle Secure the vehicle and contents Never ride on vehicle being transported Always remove windshield before transporting Maximum speed with sun top installed is 50 mph 80 kph If the vehicle is to be transported at highway speeds the sun top must be removed and the seat bottom secured When transporting vehicle below highway speeds check for tightness of hardware and cracks in sun top at mount ing points Always remove windshield wh
57. ement Parts 20001 2 2 0000000 000000000000 26 GENERAL SPECIFICATIONS eoo rcu reor lence eusunceccvececcscctinssnceccyeusuuteecbueesecccsaeveeteccse 27 Page iv Owner s Manual and Service Guide TABLE CONTENTS 2 erstes DEAN LUE ne neater haan LUC E 28 Fig 40 Vehicle Dimensions 29 Fig 41 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter 30 6 222202 DOMESTIC WARRANTY mE INTERNATIONAL WARRANTY 2004 FEDERAL EMISSION COMPONENT DEFECT WARRANTY cescesceeceeseeeseceeeeeeeeeeaeeeaeeaeeeaeeaeeneeeaeenneeaeeaees 35 CALIFORNIA EMISSION CONTROL WARRANTY 5 37 DECLARATION OF CONFORMITY EUROPE 41 LABELS AND 6 4 422 Appendix A Owner s Manual and Service Guide Page v TABLE CONTENTS Page vi Owner s Manual and Service Guide SAFETY INFORMATION This manual has been designed to assist 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 person
58. en transporting Always check that the vehicle and contents are ade quately secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehi cle see GENERAL SPECIFICATIONS for vehicle weight and load Lock the park brake and secure the vehicle using ratchet tie downs Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings SERVICE AND MAINTENANCE To reduce the possibility of severe injury or death from improper servicing techniques Do not attempt any type of servicing operations before reading and understanding all notes cau tions and warnings in this manual Any servicing requiring adjustments to be made to the powertrain while the engine is running must be made with both drive wheels raised and vehicle properly supported on jack stands To reduce the possibility of engine damage never operate vehicle at full throttle for more than 4 5 seconds while vehicle is in a load condition Wear eye protection when working on the vehicle Use extra care when work ing around batteries or using sol vents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads from the battery before removing battery wires Wrap wrenches with
59. epair and Service Manual Hydraulic Front Disc Brakes For vehicles equipped with hydraulic front disc brakes check master cylinder fluid per PERIODIC SERVICE SCHEDULE or if there is a decrease in braking effective ness Inspect components for damage or wear It is unlikely that fluid will need to be added unless there is a leak in the system Raise the front of the vehicle See raising the vehicle Remove passenger side wheel tire Carefully wipe off dirt and debris from master cylinder and cap before opening Remove the cap Using a mechanics mirror check to see that fluid is no more than Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 1 4 below top of reservoir Add DOT 3 or 4 fluid as required AIR INTAKE AND COOLING FINS To prevent possible burns engine parts should be kept clean to reduce risk of overheating and ignition of accumulat ed debris Ref Cai 1 Fig 33 Cleaning Air Intake After every off road use allow to cool and then check for a build up of dirt and debris in the air intake and cooling fins Dirt and debris may clog the engine s air cooling system Clean areas shown to prevent engine damage Ref Fig 33 on page 23 Ref Fig 34 on page 23 Keep linkages springs and controls clean Keep area around muffler free of any combustible material
60. er formed Ref Fig 5 on page 5 Vehicle battery must be fully charged before initial use Check for correct tire inflation See GENERAL SPECIFI CATIONS Check for oil or fuel leaks that could have developed in shipment from the factory Determine and record braking distance required to stop vehicle for future brake performance tests Remove the protective clear plastic that protect the seat bottom and back rest during shipping before placing the vehicle in service SERVICE OPERATION Battery Charge battery Seats Remove protective plastic covering Brakes Check operation and adjust if necessary Check hydraulic brake fluid level if equipped Establish acceptable stopping distance Tires Check air pressure see SPECIFICATIONS Fuel Fill tank with correct fuel Engine Check oil level Ref Isc 6 Fig 5 Initial Service Chart CONTROLS AND INDICATORS Vehicle controls and indicators consist of key light switch direction selector choke Page 5 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings fuel gauge low oil pressure indicator light accelerator pedal combination service and park brake pedal with front disc brakes optional horn KEY LIGHT SWITCH Located on the dash panel this switch enables the basic electrical system of the vehicle t
61. facturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment Additionally speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition Read and observe all warnings and operation instruction labels affixed to the vehicle Follow all safety rules established in the area where the vehicle is being operated Reduce speed to compensate for poor terrain or conditions Apply service brake to control speed on steep grades Maintain adequate distance between vehicles Reduce speed in wet areas Use extreme caution when approaching sharp or blind turns Use extreme caution when driving over loose terrain Use extreme caution in areas where pedestrians are present MAINTENANCE Always Maintain the vehicle in accordance with the manufacturer s periodic service schedule Ensure that repairs are performed by those that are trained and qualified to do so Follow the manufacturer s maintenance procedures for the vehicle Be sure to disable the vehicle before performing any maintenance Disabling includes removing the key from the key switc
62. for appropriate lubrication locations Ref Fig 37 on page 24 CAUTION To prolong vehicle life some mainte nance items must be serviced more fre quently on vehicles used under severe driving conditions such as extreme temperatures extreme dust debris conditions fre quent use with maximum load To access powertrain for routine maintenance lift or remove seat For major repair refer to appropriate Tech nician s Repair and Service Manual Some service procedures may require the vehicle to be lifted Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information SERIAL NUMBER LABEL LOCATION Two serial number and manufacture date code label are on the vehicle One is placed on the body below the front driver side of the seat The other is located on the chassis under the seat Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manu facture date code serial number and vehicle model must be provided when ordering service parts Page 15 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings PERIODIC SERVICE SCHEDULE vy Check Clean Adjust etc A Replace To perform service that is listed in this schedule but not described in this manual contact a local Service Representa tive or see the Repair and Service Manual for this vehicle
63. ground speed governor forward and reverse with neutral lock 6 gal 23 L 13 mph 5 mph 21 kph 8 kph Specifications subject to change without notice Page 28 Owner s Manual and Service Guide GENERAL SPECIFICATIONS Front 5 37 5 in 95 cm 7 77 in 196 cm 114 290 38 in 97 REFRESHER 1200 Fig 40 Vehicle Dimensions Owner s Manual and Service Guide Page 29 GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP GRADE RECOMMENDED SIDE TILT 2595 or 14 MAX i 25 or 149 MAX TURNING CLEARANCE DIAMETER 22 ft 6 7 m Fig 41 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter Page 30 Owner s Manual and Service Guide VEHICLE WARRANTIES VEHICLE WARRANTIES Owner s Manual and Service Guide Page 31 VEHICLE WARRANTIES DOMESTIC WARRANTY U S AND CANADA To obtain a copy of the limited warranty applicable to the vehicle call or write a local distributor authorized Branch or the Warranty Department with vehicle serial number and manufacturer date code Page 32 Owner s Manual and Service Guide VEHICLE WARRANTIES 2004 INTERNATIONAL WARRANTY ALL COUNTRIES OUTSIDE THE U S AND CANADA E Z GO Division of Textron Inc E Z GO warran
64. h from inadvertent motion do not attempt to jump start a vehicle The vehicle is equipped with a starter generator and does not idle When starting the engine the starter gen Owner s Manual and Service Guide Roll Rubber Bezel Away From Body Tail Brake Light Rear Fender Ref Tir 2 Fig 17 Tail and Brake Light Bulb Replacement erator functions as a starter and with the engine running it functions as a generator With the short running times associated with this kind of vehicle the generator is more than adequate to maintain the battery charge level The generator is not designed to charge a discharged battery When engine starts the clutches engage and cause vehicle to move making jump starting both dangerous and impractical If the vehicle battery has become discharged it must be charged using a 12 volt charger that is rated at 10 amps or less Read and understand all instructions provided by the manufacturer of the charger Page 13 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings TRANSPORTING VEHICLE TOWING This vehicle is not IW designed to be towed It is recommended that the vehicle be moved by placing the entire vehicle on a trailer flatbed truck or other suit able transport NEUTRAL LOCK To prevent the driven clutch from turning the rear whe
65. h and removal of a battery wire Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Remove the battery or cover exposed terminals with an insulating material Page viii Owner s Manual and Service Guide SAFETY INFORMATION Use specified replacement parts Never use replacement parts of lesser quality Use recommended tools 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 Support the vehicle using wheel chocks and jack stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Empty the fuel tank or plug fuel hoses to prevent fuel leakage Maintain the vehicle in an area away from exposed flame or persons who are smoking Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated 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 Replace damaged or missing warning caution or information labels Keep complete records of the maintenance history of the vehicle The manufacturer cannot anticipate all situations therefore people attempting to maintain or repair the vehicle must
66. he first oil change metal chips and lint may be found This is normal resulting from engine run in At subsequent oil changes the presence of metal chips may indicate possible engine damage Owner s Manual and Service Guide Ref Rof 1 End Of Oil Filter Fig 24 Remove Oil Filter Wear eye protection to reduce the possi bility of splashed solvent contacting the eyes when cleaning oil filter Clean the filter by washing in any shop degreaser and brushing the metal screen clean with a soft brush Ref Fig 25 on page 19 Ref Cof 1 Fig 25 Clean Oil Filter Blow out the filter with low pressure air 30 psi 210 kPa or less from no closer than 3 8 cm and allow to air dry Ref Fig 26 on page 19 dor 80 psi 210 kPa Maximum Fig 26 Blowing Out Oil Filter Wipe the area around the filter mount with a clean lint free cloth and inspect both filter O rings for damage replace if necessary Install the filter into the engine The filter engages over a short nipple in the engine The filter should slide easily onto the nipple and seat against the engine using light hand pressure only Align the holes in Page 19 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings the filter mounting plate with the holes in the engine Install and hand tighten the bolts before tightening them firmly Add
67. icle for several minutes to circulate the additive through the carburetor While engine is still warm change oil Refer to CHANGING THE OIL on page 18 Clean body chassis and engine of debris mud chaff or grass Refer to AIR INTAKE AND COOL ING FINS on page 23 HARDWARE Periodically the vehicle should be inspected for loose fasteners Fasteners should be tightened in accordance with the Torque Specifications table Ref Fig 38 on page 25 Use care when tightening fasteners and refer to the Technician s Repair and Service Manual for specific torque values Generally three grades of hardware are used in the vehi cle Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head Unmarked hardware is Grade 2 Ref Fig 38 on page 25 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 fasteners BOLT SIZE 1 4 5 16 3 8 7 16 1 2 9 16 5 8 8 15 24 Gde2 7 1 2000 33 35 55 75 47 75 102 13 23 35 18 31 47 55 80 110 75 108 149 18 35 55 24 47 75 80 110 170 230 BOLT SIZE Class 5 8 Grade 2 Class 8 8 Grade
68. ing hardware and components HARDWARE AND FASTENERS WA Tighten or replace missing hardware SEMI ANNUAL 125 HOURS includes items listed in previous tables amp the following BATTERY Clean battery amp terminals DIRECTION SELECTOR Check for wear and smooth movement lubricate shaft with light oil if required KING PINS Check for excessive play and tightness of retaining nuts STEERING ASSEMBLY Check bellows and pinion seal for damage or grease leakage RACK END BALL JOINT Lubricate use wheel bearing grease REAR AXLE Check for unusual noise and loose or missing mounting hardware AIR FILTER ELEMENT Check filter element clean replace as required OIL FILTER Clean in solvent at oil change replace O rings if required A Replace with SAE 10W 30 or 10W 40 that meets or exceeds SF SG CC oil ENGINE OIL DO NOT OVERFILL DRIVE BELT Check for cracks fraying and excessive wear ANNUAL 250 300 HOURS includes items listed in previous tables amp the following FRONT WHEEL BEARINGS Check and adjust as required see Technician s Repair and Service Manual REAR AXLE Check lubricant add lubricant Ref Fig 39 on page 26 as required Clean and adjust see Technician s Repair and Service Manual SERVICE BRAKES Check brake shoe linings see Technician s Repair and Service Manual Check level add if required DOT 3 and check for leakage FUEL FILTER
69. ing the scheduled main tenance described in the Periodic Service Schedule of this manual The scheduled maintenance is based on the normal engine operating schedule Owner s Manual and Service Guide Page 39 VEHICLE WARRANTIES CALIFORNIA 2004 Page 40 Owner s Manual and Service Guide DECLARATION CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY Owner s Manual and Service Guide Page 41 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION Page 42 Owner s Manual and Service Guide LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner s Manual and Service Guide Appendix A 1 LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms 2 3 4 6 9 36 37 38 39 40 29 35962G01 35964G01 See Following Pages For Explanation Of These Pictograms 19 43 44 45 See Following Pages For Explanation Of These Pictograms 1 2 71489 On Battery Under Seat See Following Pages fs For Explanation Of This Pictogram 28 35493G01 28203001 See Following Pages For Explanation Of These Pictograms 20 1 21 22 28203 G01 See Following Pages For Explanation Of Pictogram 49 A WARNING A Keep entire body inside car 27653G01 71419601 24 71417G01 25 71415601 26 DO NOT TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE Th Is La b el ls Locate d See Following Pages
70. injury to the technician mechanic and bystanders if not treated with the utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment Before working on the vehicle remove all jewelry rings watches necklaces etc Be sure that no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise rear of vehicle and support on jack stands before attempting to run or adjust powertrain Wear eye protection when working on or around vehicle In particular use care when working around batteries using solvents or compressed air Hydrogen gas is formed when charging batteries Do not charge batteries without adequate ventilation Do not permit open flame or anyone to smoke in an area that is being used for charging batteries A concentration of 4 hydrogen gas or more is explosive Engine exhaust gas carbon monoxide is deadly Carbon monoxide is an odorless colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels Carbon monoxide is a dangerous gas that can cause unconsciousness is potentially lethal The following are symptoms of carbon monoxide inhalation e Dizziness Vomiting Intense headache Muscular twitching e Weakness and sleepiness Throbbing i
71. iod of two 2 years after the date of delivery to the first retail purchaser C WHAT IS COVERED 1 REPAIR OR REPLACEMENT PARTS Repairs and replacement of any warranted part will be performed at no charge to you by an au thorized dealer distributor or a service provider You may contact the E Z GO Warranty Depart ment at 1 800 241 5855 to get the nearest appropriate location where your warranty repairs are performed 2 WARRANTY PERIOD This warranty continues for a period of two 2 years and shall apply only to the repair replace ment or adjustment of the component parts which are not scheduled for replacement as required maintenance Further component parts which are scheduled only for regular inspection to the ef fect of repair or replace as necessary shall be warranted for the warranty period Any warranted Owner s Manual and Service Guide Page 37 VEHICLE WARRANTIES CALIFORNIA 2004 part which is scheduled for replacement as required maintenance shall be warranted for the pe riod of time up to the first scheduled replacement point for that part 3 DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective if the diagnostic work is performed at an authorized dealer distributor or service provider 4 CONSEQUENTIAL DAMAGES If a warranted part failed causing damages to other engine components consult a service provid er D WHAT IS NOT COVERED 1 This limited wa
72. is vehicle Pay particular attention to all Notes Cautions and Warnings Dry Level Clean Paved Surface Accelerate To Maximum Speed Latch Line or Marker Parking Brake and Take Foot Off Pedal Acceptable MA Stopping 4 ft 1 2 m Line or Marker Distance Normal Range of Stopping Distance Any vehicles that stop more than 4 ft 1 2 m beyond the Acceptable Stopping Distance or pulls to one side should be removed from service and inspected by a Ref Bpt 1 qualified mechanic Fig 32 Typical Brake Performance Test Over time a subtle loss of performance may NOTE take place therefore it is important to establish the standard with a new vehicle The Periodic Brake Performance Test should be per formed regularly Ref Fig 19 on page 16 as an evalua tion of braking system performance or if there is a decrease in braking effectiveness It is useful as a method of identifying subtle loss of performance over time Page 22 Periodic Brake Test for Mechanical Brakes The purpose of this test is to compare the braking perfor mance of the vehicle to the braking performance of new or known to be good vehicles or to an established acceptable stopping distance Actual stopping distances will be influenced by weather conditions terrain road surface condition actual vehicle weight accessories installed and vehicle speed No specific braking distance can be reliab
73. ith a garden type sprayer equipped with a non metallic spray wand or a plastic spray bottle The solution should consist of the amounts of sodium bicarbonate baking soda and clear water shown below Ref Fig 31 on page 21 In addition to the battery special attention should be paid to metal components adjacent to the bat tery which should also be sprayed with the sodium bicar bonate baking soda solution 1 1 2 gallons 6 liters Clear Water 1 quart 1 liter Clear Water 1 4 Cup 60 ml 2Teaspoos Sodium Bicarbonate Baking Soda lt gt 10 Sodium e Bicarbonate Baking Soda Non Metallic Wand Plastic 2 Gallon Spray 7 5 liter Bottle Garden Sprayer Ref Pns 1 Fig 31 Preparing Acid Neutralizing Solution Allow the solution to sit for at least three minutes use a soft bristle brush or cloth to wipe the tops of the battery to remove any residue that could contribute to the self dis charge of the battery Rinse the entire area with low pres sure clear water Do not use a pressure washer BRAKES To reduce the possibility injury or death always evaluate pedal travel before operating a vehicle to verify some brak ing function is present All driving brake tests must be done in a safe location with regard for the safety of all personnel Page 21 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with th
74. ll of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings plastic polish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use of a commercially available vinyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces Occasional cleaning and waxing with non abrasive prod ucts designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle These mate rials will cause corrosion of underbody parts unless flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sedi ment packed in closed areas should be loosened to ease it s removal taking care not to chip or otherwise damage paint NOTE If the engine does not start or runs improperly after washing remove the spark plug wires by pulling the spark plug boots never the wires Dry all connec tions with forced air
75. ly specified The test is conducted by latch ing the parking brake to eliminate different pedal pres sures and to include the affects of linkage mis adjustment Establish the acceptable stopping distance by testing a new or known to be good vehicle and recording the stopping location or stopping distance For fleets of vehi cles several vehicles should be tested when new and the range of stopping locations or distances recorded Over time a subtle loss of performance may NOTE take place therefore it is important to establish the standard with a new vehicle Drive the vehicle at maximum speed on a flat dry clean paved surface Ref Fig 32 on page 22 Quickly depress the brake pedal to latch the parking brake at the line or marker in the test area and remove foot from pedal The vehicle should stop aggressively The wheel brakes may or may not lock Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched The vehicle should stop within the normal range of stopping distances If the vehicle stops more than 4 ft 1 2 m beyond the accept able stopping distance or pulls to one side the vehicle has failed the test and should be tested again If the vehicle fails the second test it should immediately be removed from service The vehicle must be inspected by a qualified mechanic who should refer to the TROU BLESHOOTING section in the Technicain s R
76. mpartment The oil should be changed in accordance with the Peri odic Service Schedule while the engine is warm See SERVICE AND MAINTENANCE for checking oil level and changing oil procedures Maximum oil level DO NOT OVERFILL Full operating range Ref Dsk 1 Fig 11 Check Oil Level on Dipstick COLD STARTING Starting a cold engine may require use of the choke Depress the accelerator approximately 1 2 5 cm or until the starter just begins to operate Pull the choke out if required Accelerate slowly and push the choke in com pletely when the engine runs smoothly Do not allow the starter to operate con CAUTION tinuously for more than 10 seconds Allow 30 seconds between starting attempts If the vehicle does not start on the third attempt turn the key switch off set the park brake and determine the cause of the problem If the vehicle had been running and the engine does not start within 10 seconds use the choke STARTING AND DRIVING To reduce the possibility I ot roll back which could result in severe injury or vehicle damage do not release service brake until engine has started To operate vehicle Apply the service brake place the key in the key switch and turn it to the ON position Move the direction selector to the direction desired Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay par
77. ms will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALER OR SERVICE PROVIDER AUTHO RIZED BY E Z GO THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DU RABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CON TROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM If other than the parts authorized by E Z GO are used for maintenance replacements or for the repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by E Z GO in their performance and durability HOW TO MAKE A CLAIM repair qualifying under this limited warranty must be performed by a distributor dealer or service provider autho rized by E Z GO In the event that any emission related part is found to be defective during the warranty period you shall notify E Z GO Warranty Department at 1 800 241 5855 and you will be advised of the appropriate warranty Service providers where the warranty repair can be performed Page 36 Owner s Manual and Service Guide VEHICLE WARRANTIES CALIFORNIA 2004 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANT
78. n temples If any of these symptoms are experienced get fresh air immediately Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area Textron Company E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US North America Technical Assistance amp 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
79. nging and charging facilities and procedures to be in accordance with appropriate paragraphs of ANSI NFPA 505 4 5 2 The user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs of ANSI NFPA 505 are strictly complied with and shall familiarize carrier operators with it 4 6 Hazardous Locations 4 6 1 The user shall determine the hazard classifi cation of the particular atmosphere or location in which the carrier is to be used in accordance with ANSI NFPA 505 4 6 2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI NFPA 505 4 7 Lighting for Operating Areas 4 7 1 user in accordance with his responsibility to survey the environment and operating conditions shall determine if the carrier requires lights and if so shall Page xi SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings equip the carrier with appropriate lights in accordance with the manufacturer s recommendations 4 8 Control of Noxious Gases and Fumes 4 8 1 When equipment powered by internal com bustion engines is used in enclosed areas the atmo sphere shall be maintained within limits specified in the American Conference of Governmental Industrial Hygienists publication Threshold Limit Values for Chemical Substances and Physical Agents in the Work
80. ny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a dealer distributor or service provider authorized by E Z GO Division of Textron Augusta Georgia herein E Z GO to which FUJI supplies the engine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to ex ceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the E Z GO War ranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control Systems California Only FUJI Tokyo Japan warrants to the owner of the 2004 and later engine that the engine 1 has been designed built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Re sources Board and 2 is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below A WARRANTY COMMENCEMENT DATE The warranty period begins on the date the engine is delivered to a first retail purchaser B LENGTH OF COVERAGE FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which could cause the failure of a warranted emission related part for a pe r
81. o be turned on and off by turning the key To prevent inadvertent operation of the vehicle when left unattended the key should be turned to the OFF position and removed Ref Fig 6 on page 6 Key Light Switch _ Fuel Low Oil Pressure Ref Kes 2 Indicator Light Fig 6 Key Light Switch Low Oil Pressure Light and Fuel Gauge If the vehicle is equipped with lights the key switch has a position to operate them indicated by the light icon NOTE If the vehicle is equipped with factory installed custom accessories some accessories remain operational with the key switch in the OFF position DIRECTION SELECTOR CAUTION To reduce the possibility of component damage the vehicle must be complete ly stopped before moving the direction selector Located on the seat support panel this lever permits the selection of either F forward or R reverse Ref Fig 7 on page 6 Vehicle should be left in F when unat tended CHOKE The choke is used to aid cold starting Ref Fig 8 on page 6 See COLD STARTING section for operating instructions Page 6 Ref Chk 1 Fig 8 Choke FUEL GAUGE The fuel gauge if equipped will either be located on the dash panel electric Ref Fig 6 on page 6 or directly on the fuel tank mechanical LOW OIL PRESSURE INDICATOR LIGHT A low oil pressure indicator light is located on the dash panel Ref Fig 6 on page 6 The light illuminates when the oil pressure
82. on Canopy Cover Periodically hose off the fabric with fresh water and allow to dry on the canopy frame Maintenance The door latches and locks will require periodic tighten ing adjusting and lubricating with a silicone spray lubri cant We recommend that this be done every two weeks Tightening of all screws nuts and bolts should be accom plished on a regular basis REFRESHMENT UNIT REPLACEMENT PARTS When ordering refreshment unit replacement parts refer ence manufacturer s D plate located in trash bin com partment BEFORE INITIAL USE Read understand and follow the safety label on the instrument panel Be sure you understand how to oper ate the vehicle its equipment and how to use it safely Maintaining good performance depends to a large extent on the operator Owner s Manual and Service Guide Hydrogen gas is generat TWENEY INI edas 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 are Before a new vehicle is put into operation the items shown in the INITIAL SERVICE CHART must be p
83. or before a carrier is allowed to enter or exit Owner s Manual and Service Guide 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a smooth sweeping motion 5 6 Loading 5 6 1 Handle only stable and safely arranged loads When handling off center loads which cannot be cen tered operate with extra caution 5 6 2 Handle only loads within the capacity of the carrier as specified on the nameplate 5 6 3 Handle loads exceeding the dimensions used to establish carrier capacity with extra caution Stability and maneuverability may be adversely affected 5 7 Operator Care of Personnel and Burden Carriers 5 7 1 At the beginning of each shift during which the carrier will be used the operator shall check the carrier condition and inspect the tires warning devices lights battery s speed and directional controllers brakes and steering mechanism If the carrier is found to be in need of repair or in any way unsafe the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating condition 5 7 2 f during operation the carrier becomes unsafe in any way the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating con dition 5 7 3
84. or ignition circuit and remove the key if provided Block the wheels if machine is on an incline 5 4 4 A carrier is considered unattended when the operator is 25 ft 7 6 m or more from the carrier which remains in his view or whenever the operator leaves the carrier and it is not within his view When the operator is dismounted and within 25 ft 7 6 m of the carrier still in his view he still must have controls neutralized and the parking brake s set to prevent movement 5 4 5 Maintain a safe distance from the edge of ramps and platforms 5 4 6 Use only approved carriers in hazardous loca tions as defined in the appropriate safety standards 5 4 7 Report all accidents involving personnel 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 building structures and equipment 5 4 8 Operators shall not add to or modify the car rier 5 4 9 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles access to stairways or fire equipment 5 5 Traveling 5 5 1 Observe all traffic regulations including autho rized speed limits Under normal traffic conditions keep to the right Maintain a safe distance based on speed of travel from a carrier or vehicle ahead and keep the car rier under control at all times 5 5 2 Yield the right of way to pedest
85. related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm WASH HANDS AFTER HANDLING WARNING WARNING WARNING SHARP TURN SHARP TURN STEEP HILL APPLY BRAKE TO LIMIT SPEED lt 14 25 DO NOT DRIVE ACROSS SLOPES IN EXCESS OF 14 APPLY BRAKE TO LIMIT SPEED APPLY BRAKE TO LIMIT SPEED Be sure that this manual remains as part of the permanent service record should the vehicle be sold NOTES CAUTIONS AND WARNINGS Throughout this guide NOTE CAUTION and WARNING will be used NOTE A NOTE indicates a condition that should be observed CAUTION A CAUTION indicates a condition that may result in damage to the vehicle A WARNING indicates a hazardous condition that could result in severe injury or death Observe these NOTES CAUTIONS and WARNINGS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe Engine exhaust from this NE product contains chemi cals known in certain quantities to cause cancer birth defects or other reproductive harm NOTE The exhaust emissions of this vehicles engine complies with regulations set forth by the Envi ronmental Protection Agency EPA of the United States of America USA at time of manufacture Significant fines could
86. rians ambu lances fire trucks or other carriers or vehicles in emer gency situations 5 5 3 Do not pass another carrier or vehicle travel ing in the same direction at intersections blind spots or at other dangerous locations 5 5 4 Keep a clear view of the path of travel observe other traffic and personnel and maintain a safe clearance 5 5 5 Slow down or stop as conditions dictate and activate the sound producing warning device at cross aisles and when visibility is obstructed at other locations 5 5 6 Ascend or descend grades slowly 5 5 7 Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up and down 5 5 8 Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop in a safe manner 5 5 9 Make starts stops turns or direction rever sals in a smooth manner so as not to shift the load endanger passengers or overturn the carrier 5 5 10 Do not indulge in dangerous activities such as stunt driving or horseplay 5 5 11 Slow down when approaching or on wet or slippery surfaces 5 5 12 Do not drive carrier onto any elevator unless specifically authorized to do so Approach elevators 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 advisable that all other personnel leave the elevat
87. rking underneath it e Before disconnecting any part of the engine fuel system of a gasoline or diesel powered carrier with grav ity feed fuel systems be sure shutoff valve is closed and run engine until fuel system is depleted and engine stops running f Before disconnecting any part of the engine fuel system of LP gas powered carriers close the LP gas inder valve and run the engine until fuel in the system is depleted and the engine stops running g Operation to check performance of the carrier shall be conducted in an authorized area where safe clear 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 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 oper
88. room Environment This shall be accomplished by venti lation provided by the user and or the installation use and proper maintenance of emission control equipment recommended or provided by the manufacturer of the equipment 4 9 Warning Device s 4 9 1 The user shall make periodic inspections of the carrier to be certain that the sound producing and or visual device s are maintained in good operating condi tion 4 9 2 user shall determine if operating condi tions require the carrier to be equipped with additional sound producing and or visual devices and be responsi ble for providing and maintaining such devices in accor dance with the manufacturer s recommendations 5 OPERATING SAFETY RULES AND PRACTICES 5 1 Personnel and Burden Carrier Operator Qualifications 5 1 1 Only persons who are trained in the proper operation of the carrier shall be authorized to operate the carrier Operators shall be qualified as to visual auditory physical and mental ability to safely operate the equip ment according to Section 5 and all other applicable parts of this Standard 5 2 Personnel and Burden Carrier Operators Training 5 2 1 user shall conduct an operators training program 5 2 2 Successful completion of the operators train ing program shall be required by the user before opera tion of the carrier The program shall be presented in its entirety to all new operators and not condensed for those
89. rranty does not cover any part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions set forth in the 2004 and later Owner s Manual in cluding 1 improper scheduled engine inspection and maintenance 2 improper maintenance of any warranted parts 3 improper installation adjustment or repair of the engine or of any warranted part unless per formed by an authorized dealer 4 failure to follow recommendations on fuel use contained in the 2004 and later Owner s Manual 5 repairs performed outside of the authorized warranty service facilities 6 use of parts which are not authorized by FUJI 2 Add on or modified parts This warranty does not cover any part which malfunctions fails or is damaged due to alterations by changing adding to or removing parts from the engine 3 Expenses incurred by processing warranty claims FUJI any authorized dealer distributors and service providers shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconve nience E HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or service providers authorized by E Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriat
90. rror Installation to the unit Be sure hands and fingers are clear of unit while lowering The drain valves protrude below the CAUTION frame of the unit and can be damaged if the unit is removed from pallet and placed directly onto a flat surface Remove drain valves from refreshment unit before removing unit Refreshment unit removal is the reverse order of installa tion The unit should be lifted onto a pallet being careful not to damage drains and then handled with a forklift If a forklift is not available be sure an adequate number of assistants are available to safely lift the vending unit and pallet REFRESHMENT UNIT OPERATION MAIN TENANCE AND CLEANING Operation Consumable ice must be NI stored in the rear driver side compartment only Clean this compartment and the driver side drain valve before and after each use to reduce the possible contamination of consumable ice Owner s Manual and Service Guide Canned Beverage Compartments The canned bever age compartments are designed to carry canned bever ages and cooling ice Cold snacks sandwiches fruit candy etc can also be served from these compartments by inserting the product into a plastic food container Pre cooling the canned beverages will minimize the amount of ice required to keep the product cool Maintaining ice in the canned beverage compartment when the container is not in service will help to maintain a colder temperature when
91. rrow on cover is pointing upward and all clips are fastened securely Cleaning the Air Filter Element CAUTION Do not use compressed air to clean the air filter doing so will damage the filter which may result in damage to the engine If the element is in acceptable condition loose dirt may be removed by tapping the filter lightly Do not use oil on the filter element or any part of the unit Install the ele Page 23 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Air Filter Element Air Cleaner Canister Air Cleaner Dust Cover Collector Ref Air 2 Fig 36 Canister Type Air Cleaner ment in the same way it was removed being sure that the clips are fastened securely LUBRICATION CAUTION Do not use more than three 3 pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Putting more than three pumps of grease in a grease fit ting could damage grease seals and cause premature bearing failure Ref Fig 37 on page 24 i Rack Ball Joint Ref Lub 1 View From Underside Of Vehicle Fig 37 Lubrication Points SPARK PLUGS Tool List Qty Required Spark plug socket 13 16 1 2 drive 1 Ratchet 1 2 drive iiis re
92. selection of oil is dependent upon the service that the vehicle will perform Most vehicles require 10W 30 oil whereas vehicles used at capacity or near capacity load applications will require 10W 40 oil after run in Ref Fig 22 on page 19 To reduce the possibility N of severe injury wear rubber gloves to protect skin from exposure to hot used oil and degreaser These fluids contain chemicals known to cause can Owner s Manual Service Guide Page 18 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings HEAVY DUTY WORK 10W 40 LIGHT DUTY WORK C 30 20 10 0 10 20 FE AIR TEMPERATURE Fig 22 Oil Viscosity Chart The oil should be changed with the engine warm Park the vehi cle on a level surface engage the park brake and remove the key Place a drain pan under the engine Wipe the top of the engine clean with a cloth Ref Fig 23 on page 19 Remove the oil fill cap Ref Cte 1 Fig 23 Clean Top of Engine Clean the area around the filter Oil drainage is accom plished by removing the three bolts securing the oil filter to the engine Remove the filter by pulling it from the engine and allow the oil to drain The O rings may remain on the engine or the filter Ref Fig 24 on page 19 At each oil change thoroughly inspect filter before clean ing At t
93. sumable ice compartment a food display cabinet two cup dispensers and a trash bin Available accessories are listed in illus tration Ref Fig 1 on page 2 Tool List Qty Required Ratchet 3 8 teet dateien 1 Socket 1 2 3 8 1 Mex 1 Phillips screwdriver 2 1 Wrench 716 1 1 Socket adapter 1 4 drive 1 Socket 5 16 1 4 drive a 1 MOUNT VENDING UNIT TO REFRESHMENT VEHICLE The vending unit is AWARNINGA heavy Care and proper lifting equipment and procedures must be used when installing unit to reduce the possibility of severe injury and or damage Owner s Manual and Service Guide to the unit Be sure hands and fingers are clear of unit while placing unit on frame The refreshment unit is shipped on a pallet While resting on pallet the unit should be handled with a forklift If a forklift is not available be sure an adequate number of assistants are available to safely lift the vending unit Orient vending unit so that door on unit will be facing the rear of the vehicle when unit is placed on the mounting frame Ref Fig 1 on page 2 Using a forklift lift the refreshment unit and pallet level with the bed of refresh ment vehicle Lift the refreshment unit off of the pallet and carefully place it onto the mounting frame on vehicle Align th
94. t rea 1 Plug gauge wire 1 Anti seize 1 AR Torque wrench 1 2 drive ft 165 1 CAUTION Use care not to over tighten the plug Over tightening can cause damage to the aluminum cylinder head threads Page 24 Remove and inspect the spark plugs at intervals indi cated in the Periodic Service Schedule Ref Fig 19 on page 16 All new spark plugs should be properly gapped before installation Ref Fig 39 on page 26 Apply a light coat of anti seize compound and tighten to 18 ft lbs 24 Nm torque Fouled spark plugs are indicated by a wet black appear ance This could be caused by a dirty air filter element or other restrictions in the air intake system Incorrectly adjusted valves spark plug wires which are in poor con dition or poor quality fuel could also contribute to the problem PROLONGED STORAGE To reduce the possibility AWARNING A of severe injury or death resulting from a possi ble explosion Do not handle fuel in an area that is not adequate ly ventilated Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark Store vehicle in a clean dry area Do not store in same area as a Stove furnace water heater or other appliance that uses a pilot light or has a device that can create a spark When refueling inspect the fuel
95. ther machines carriers can cause injury if improperly used or maintained Part Il contains broad safety practices applicable to carrier operations Before operation the user shall establish such additional spe cific safety practices as may reasonably be required for safe operation 4 2 Stability 4 2 1 Experience has shown that this vehicle which complies with this standard is stable when properly operated and when operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions However improper operation faulty maintenance or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard Some of the conditions which may affect stability are failure of the user to follow safety practices also ground and floor conditions grade speed loading the operation of the carrier with improper loads battery weight dynamic and static forces and the judgement exercised by the carrier operator a The user shall train carrier operators to adhere strictly to the operating instructions stated in this Stan dard b The user shall survey specific operating conditions and environment and establish and train carrier opera tors to comply with additional specific safety practices 4 3 Nameplates Markings Capacity and Modifica tions 4 3 4 user shall maintain in a legible condition all nameplates warnings and instructions which
96. ticular attention to all Notes Cautions and Warnings Release the park brake by depressing the service brake pedal until the park brake releases Slowly depress the accelerator pedal to start the engine Release service brake when engine starts When the accelerator pedal is released the igni tion circuit is de energized and the engine stops To stop the vehicle more quickly depress the ser vice brake pedal NOTE When the direction selector is in the reverse position a warning signal will sound to indicate that the vehicle is ready to run in reverse STARTING THE VEHICLE ON A HILL To reduce the possibility P NUES 4 or roll back which could result in severe injury or vehicle damage do not release service brake until engine has started Do not hold vehicle on hill by using CAUTION accelerator and engine This will cause premature and excessive wear to drive train components To reduce the possibility of permanent damage to the drive system it is important to prevent excessive roll back when starting the vehicle on a hill Place left foot on service brake and release the park brake Depress accelerator with right foot and release the service brake by lifting left foot COASTING To reduce the possibility severe injury or death from coasting at above recommended speeds limit speed with service brake On steep hills it is possible for the vehicle to coast at greater than normal speeds encountered
97. ts outlets and have the advan tage of not requiring the tire be removed from the wheel If the tire is flat remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in accordance with manufacturer s instructions To reduce the possibility of severe injury be sure mounting demounting machine is anchored to floor Wear OSHA approved safety equipment when mounting demounting tires If the tire is to be removed or mounted the tire changing machine manufacturer s recommendations must be fol lowed in order to reduce possibility of severe injury Wheel Installation To reduce the possibility of component CAUTION damage do not tighten lug nuts to more than 85 ft Ibs 115 Nm torque NOTE It is important to follow the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten lug nuts in a cross sequence pattern Ref Fig 15 on page 12 Tighten lug nuts to 50 85 ft Ibs 70 115 Nm torque in 20 ft Ibs 30 Nm increments following the cross sequence pat tern Cross Sequence 1 3 Tire style may vary Ref Whi 1 Fig 15 Wheel Installation Owner s Manual and Service Guide OPERATION AND SERVICE INFO
98. ts to the Original Retail Purchaser or the Original Retail Lessee that 2004 E Z GO vehicle and or Battery Charger shall be free from any defects in material or workmanship for one year from the date of installation at the customer s location with respect to parts and labor EXCLUSIONS Specifically excluded from any E Z GO warranty are adjustments repairs made due to normal wear beyond the first 180 days routine maintenance items cosmetic deterioration and electrical components which are susceptible to fluctuations in current beyond the control of E Z GO This warranty also does not apply to Acts of God or other events over which E Z GO has no control Transportation charges for warranty service as well as freight charges to receive warranty parts are excluded from this warranty and all replaced parts shall become the property of E Z GO This warranty also excludes batteries tires and Lester battery chargers which are warranted by their respective manufacturer REMEDY The sole remedy under this warranty and E Z GO s only obligation in the event of a defect in the vehicle battery charger is that E Z GO will at its sole option repair or replace any defective parts This remedy precludes all other remedies including any lawsuits claims or other proceedings alleging strict liability negligence of contract or any cause of action E Z GO reserves the right to improve or change the design of any E Z GO vehicle or battery charger without assuming
99. verages Cleaning Interior Aluminum Surfaces The interior surfaces should be cleaned on a daily basis using a soap and water solution Thoroughly rinse after cleaning Exterior Painted Surfaces The painted surfaces should be cleaned on a daily basis using a soap and water solution Exterior Aluminum Surfaces The aluminum surfaces should also be cleaned on a daily basis using a soap and water solution Periodic cleaning with an aluminum or Page 3 OPERATION AND SERVICE INFORMATION ughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warn Read all of manual to become thoro A ay ANE W Fig 3 Canopy Installation Owner s Manual and Service Guide Page 4 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Clear Hose Fig 4 Emptying Water from Bins stainless steel cleaner is recommended We recommend ZEP Stainless Steel Polish or equal Drains The drains should be flushed with a hose ona daily basis Periodically the drains should be cleaned and sanitized Acrylic The clear acrylic doors should be cleaned daily with a soap and water solution Dry with a clean damp chamois Do not use window cleaning sprays Polypropylene The polypropylene doors should be cleaned daily with a soap and water soluti
100. with a lower percentage of alcohol or ether Ref Fil 1 Fig 12 Fueling BATTERY Excessive use of accessories may drain CAUTION the battery and leave insufficient reserve to start the vehicle The vehicle uses a combination starter generator to both start the engine and charge the battery The engine will not idle therefore the battery cannot be charged while the vehicle is stopped Do not operate accessory items Page 9 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings such as accessory lights radios winch etc exces sively while the vehicle is stopped The generator is capable of supplying 35 amps there fore operation of all accessories could result in the dis charge of the battery even though the engine is running and the generator operating Discharging the battery is known as deep cycling The battery is not a deep cycle model but is a starting battery Multiple deep cycling will result in the premature failure of the battery If the vehicle battery has become discharged it must be charged using a 12 volt charger that is rated at 10 amps or less and in accordance with all instructions provided by the manufacturer of the charger LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings Appendix A illus trates and explains pictograms that ma
101. y appear on the vehicle Not all pictograms shown in Appendix A will be found on your vehicle SUN TOP AND WINDSHIELD The sun top does not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects To prevent damage to the vehicle do CAUTION not hold on to sun top struts and stand on body panels The sun top and windshield provide some protection from the elements however they will not keep the opera tor and passenger dry in a downpour This vehicle is not equipped with seat belts and the sun top has not been designed to provide roll over protection In addition the sun top does not protect against falling objects nor does the windshield protect against flying objects and tree limbs Keep arms and legs inside of vehicle while it is moving 12 VOLT POWER OUTLET Overuse of accessories may drain the CAUTION battery and leave insufficient reserve to start the vehicle A 12 volt power outlet rated at 15 amps is located to the left side of the key light switch Ref Fig 13 on page 10 It provides constant power for accessories equipped with Page 10 Ref Pow 1 Outlet Fig 13 12 Volt Power Outlet TOWING A TRAILER The vehicle is equipped with a receiver that can be fitted with a standard 1 7 8 ball The trailer and its load must not exceed 500 Ibs 227 kg and no more than 50 Ibs 23 kg tongue weight may be attached to the hitch

Greenlee 28809-G01 User's Manual

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