Bad Boy 644582, Owner'S Manual

Page 1: ...OWNER S GUIDE 644582 HD ELECTRIC REVISED AUGUST 2015 ISSUED MAY 2015...

Page 2: ...ive hand tools If necessary contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule Repair or replacement parts are available fro...

Page 3: ...BILITY FOR INCIDENTAL AND CONSE QUENTIAL DAMAGES resulting from the use of the information and materials in this Manual These are the original instructions as defined by 2006 42 EC CONTACT US E Z GO D...

Page 4: ...drain The battery charger can stay connected to the vehicle to keep a full charge on the batteries while the charger is connected to an active electrical supply If the power to the electrical supply i...

Page 5: ...and Light Switch 11 State of Charge Meter 11 Direction Selector 12 Accelerator Pedal 12 Brake and Parking Brake Pedal 12 Charger Receptacle if equipped 12 CE Charger Receptacle if equipped 12 AC Outl...

Page 6: ...23 Tailgate Operation 23 PERFORMANCE 23 Pedal Up Braking 24 Terrain 24 Walk Away Feature 24 Anti Roll Back Feature 25 Anti Stall Feature 25 High Pedal Disable Feature 25 Diagnostic Mode Feature 25 STA...

Page 7: ...ICATION 37 CAPACITIES AND REPLACEMENT PARTS 37 HARDWARE 38 BATTERY CHARGING AND MAINTENANCE 39 Safety 39 Battery Disposal 39 Battery 40 Battery Maintenance 40 At Each Charging Cycle 40 Monthly 40 Elec...

Page 8: ...B vi TABLE OF CONTENTS Owner s Guide...

Page 9: ...caused by excessive speed is abusive and will not be covered under the warranty Use caution when you tow the vehicle Towing the vehicle at above the recommended speed can cause personal injury or dama...

Page 10: ...SAFE USE AND OPERATION of the product All customers must obey this SAFETY RULE Information on FMVSS 571 500 is found at Title 49 of the Code of Federal Regulations section 571 500 For information onl...

Page 11: ...tion make sure the area behind the vehicle is clear Make sure the direction selector is in the correct position before you press the accelerator pedal Decrease speed before and during turns Make sure...

Page 12: ...liar with Be careful when you drive on loose terrain Be careful when you operate the vehicle around people MAINTENANCE ALWAYS Replace damaged or missing warning caution or information labels Service t...

Page 13: ...G01 EGWHL14 740499G01 634229 75696G01 MAX 14o 25 MAX 400 lbs 180 kg MAX 5 in 12 cm P P MAX 100 lbs 45 kg 74821G06 634229 14 25 14 25 cm MIN 150 R F I O I O F R F I O I O R N I O I O R F N FOR INFORMAT...

Page 14: ...6 Owner s Guide SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 15: ...d Capacity 500 lb 227 kg Wheel Base 78 0 in 198 cm Vehicle Load Capacity 900 lb 408 kg Front Wheel Track 38 0 in 97 cm Outside Clearance Circle 24 0 ft 7 3 m Rear Wheel Track 38 8 in 99 cm Intersectin...

Page 16: ...y procedure Pay particular attention to Notices Cautions Warnings and Dangers VEHICLE DIMENSIONS RECOMMENDED MAX SIDE TILT 25 or 14o RECOMMENDED MAX RAMP GRADE 25 or 14 MAX o MAX 78 in 198 cm 111 in 2...

Page 17: ...ad all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 9 Owner s Guide TURNING DIAMETER AND INCLINE INFORMATION TURNING CLE...

Page 18: ...10 Owner s Guide GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 19: ...to the DC to DC con verter 1 Key and Light Switch To decrease the risk of component damage stop the vehicle before you move the key switch or the direction selector The key and light switch is found...

Page 20: ...s released the motor will stop To stop the vehicle immediately press the brake pedal 5 Brake and Parking Brake Pedal The foot operated parking brake is the top part of the brake pedal To engage the pa...

Page 21: ...unlocked by maintenance personnel only Unlock the seat lock with a 4 hex bit Turn the two screws 1 4 turn to the left to unlock or 1 4 turn to the right to lock 10 Seat The seat is for two people one...

Page 22: ...o raise and lower the truck bed 18 12 Volt Outlet if equipped The 12 volt outlet is on the instrument panel to the right of the cup holder The outlet has a protective cover The 12 volt outlet supplies...

Page 23: ...15 Owner s Guide Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers INTRODUCTION...

Page 24: ...16 Owner s Guide INTRODUCTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 25: ...erstand and follow the safety label on the instrument panel Make sure you understand how to safely operate the vehicle and its equipment Reckless use of this vehicle can cause severe injury or death T...

Page 26: ...electrical ground according to all codes and regulations A grounded outlet is necessary to decrease the risk of electric shock do not use ground adapters or replace the plug Do not touch parts of out...

Page 27: ...areas and do not drive on steep slopes Do not drive fast downhill Sudden stops or change of direction can cause a loss of control Use the brake to control the speed of the vehicle when you drive down...

Page 28: ...aded vehicle is more than the necessary distance to stop a vehi cle without a load In wet weather conditions apply light pressure to the brakes to supply enough friction to dry the brake unit Wet brak...

Page 29: ...enly move and cause severe injury or death An engaged parking brake will release when the accelerator pedal is pressed and cause the vehi cle to move suddenly When the vehicle is parked make sure the...

Page 30: ...Understand and obey the warnings on this label for safe operation of the vehicle See the load bed warning label for maximum load Position the load in the truck bed as far forward as possible Make sur...

Page 31: ...ands are not trapped by the truck bed Electric Lift Operation Make sure your clothing can not be caught while you oper ate the electric lift Make sure your fingers and other body parts can not be caug...

Page 32: ...t occurs when the accelerator pedal is released and the vehicle in motion between 8 mph 13 kph and the vehicle top speed Example If all of the following events occur a the vehicle being driven down a...

Page 33: ...he brake pedal is released the vehicle will move backward slightly before power is returned to the motor High Pedal Disable Feature High pedal disable prevents acceleration of the vehicle if the direc...

Page 34: ...al and release the parking brake Press the accelerator with right foot and release the brake pedal Coasting Do not allow the vehicle to coast at above recommended speeds Control vehicle speed with the...

Page 35: ...27 Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers OPERATING PROCEDURES Owner s Guide...

Page 36: ...28 OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide...

Page 37: ...nd plastic or rubber trim Dry with a cloth Use a commercially available vinyl and rubber cleaner to remove oil tar asphalt shoe polish etc Wash the vehicle frequently with cool water and mild detergen...

Page 38: ...u lift the vehicle put the jacks and jack stands at the areas indicated only Tool List Quantity Tool List Quantity Floor Jack 1 Jack Stands 4 Wheel Chocks 4 Remove payload from vehicle before lifting...

Page 39: ...ion pressure rating on the tire sidewall when seating a bead Protect the face and eyes when you remove a valve core When you remove the wheels use only sockets made for impact wrenches to decrease the...

Page 40: ...inflate the tires The vehicle has low pressure tubeless tires installed on one piece rims Use a tire plug to repair small holes in the tread part of the tire For large holes and cuts replace the tire...

Page 41: ...from a local Distribu tor an authorized Branch or the Service Parts Depart ment Taillight To replace the taillight and brake light bulb lift the rubber bezel from around the edge of the taillight and...

Page 42: ...trailer at highway speeds the sun top must be removed and the seat bottom secured When you move the vehicle on a trailer below highway speeds check for tight hardware and cracks in sun top at the moun...

Page 43: ...Use a metal container that has insulation to prevent an explosion The vehicle owner and service technician must carefully follow the procedures recommended in this manual The pre ventative maintenanc...

Page 44: ...recording the stopping location or stopping distance Several vehicles should be tested when new and the range of stopping locations or dis tances recorded Over time a subtle loss of performance may oc...

Page 45: ...as required Add lubricant 30 WT engine oil slowly until lubricant starts to seep from the hole Install the check fill plug In the event that the lubricant is to be replaced the oil pan must be removed...

Page 46: ...r and Service Manual ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten all hardware in accordance with this chart Th...

Page 47: ...and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately Always wear a safety shield or approved safety goggles when you add...

Page 48: ...itions that can reduce the life of the battery Battery Maintenance Tool List Quantity Tool List Quantity Insulated Wrench 9 16 1 Battery Carrier 1 Hydrometer 1 Battery Maintenance Kit P N 25587 G01 1...

Page 49: ...ion Use distilled water or filtered water only Test water that is not distilled water and filter if needed Refer to the water purity table for requirements Hand held watering devices available at an a...

Page 50: ...cid deposits first The water hose moves the acid from the top of the batteries to another area of the vehicle or storage facility where it can cause damage After spraying the batteries a conductive re...

Page 51: ...o 45 55 in lbs 5 6 Nm torque The hold downs must be tight enough to prevent movement of the battery but not tight enough to cause distortion of the battery cases Inspect all wires and terminals Clean...

Page 52: ...n discharge the battery The controller must be disconnected from the batteries For portable chargers disconnect the charger plug from the vehicle receptacle For on board chargers disconnect the chargi...

Page 53: ...discharge machine manufacturer instructions A hydrometer is used to identify a poorly performing battery in a set with a low specific gravity When the particular cell or cells that are the problem are...

Page 54: ...rature was 70 F 21 C subtract four points 004 from the 1 250 to give a corrected reading of 1 246 5 Test each cell and note the readings corrected to 80 F or 27 C A variation of fifty points between a...

Page 55: ...47 Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers MAINTENANCE Owner s Guide...

Page 56: ...48 MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide...

Page 57: ...er Check controller braking force for correct operation Wiring Inspect for loose connections broken or missing insulation Direction Selector Inspect attachment and mechanism C A C A C A C A Steering A...

Page 58: ...50 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide...

Page 59: ...rop erly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible component failures or the manner in which they may fail A vehicle requiring repair indicate...

Page 60: ...0 E mail info badboybuggies com For parts and repair contact local dealer Dealers can be located at www BADBOYBUGGIES com Copyrighted Material This manual may not be reproduced in whole or in part wit...