E-Z-GO MPT 800, Owner'S Manual

Page 1: ...ELECTRIC POWERED UTILITY VEHICLES ISSUED APRIL 2005 OWNER S MANUAL AND SERVICE GUIDE 28803 G01...

Page 2: ...eeds encountered on a flat surface To pre vent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS...

Page 3: ...ed 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...

Page 4: ...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 win...

Page 5: ...n Tow Maintenance Switch 4 HORN 4 Fig 9 Horn Button 4 ELECTRIC LIFT SWITCH 5 STEEL LOADBED 5 MANUAL LIFT BED OPERATION 5 Fig 10 Manual Bed Latch 5 Fig 11 Bed Prop Rod 5 ELECTRIC LIFT BED OPERATION 5 F...

Page 6: ...3 Add Check and Drain Axle Lubricant 19 Fig 24 Lubrication Points 19 PDS SYSTEM TEST 19 HARDWARE 19 Fig 26 Torque Specifications and Bolt Grades 20 CAPACITIES AND REPLACEMENT PARTS 19 Fig 25 Capacitie...

Page 7: ...LE OF CONTENTS Owner s Manual and Service Guide INDUSTRIAL 1000 31 LIMITED WARRANTIES 35 DOMESTIC WARRANTY 36 INTERNATIONAL WARRANTY 37 DECLARATION OF CONFORMITY EUROPE ONLY 39 LABELS AND PICTOGRAMS A...

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

Page 9: ...into LSV s The Company in addition recommends that all E Z GO products sold as personal transportation vehicles BE OPER ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICA...

Page 10: ...ions or changes The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle Vehicles that are capa...

Page 11: ...aintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the ve...

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

Page 13: ...n 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...

Page 14: ...ious experience 5 2 3 The 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...

Page 15: ...brakes It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns re...

Page 16: ...uids 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...

Page 17: ...e 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 a...

Page 18: ...ot damaged and is inserted into a grounded receptacle The power AC cord is equipped with a grounded plug do not attempt to pull out cut or bend the ground post The charging DC cord is equipped with a...

Page 19: ...direction selector is shifted before the vehicle comes to a complete stop a warning beeper will activate Located on the seat support panel or the dash panel this lever or switch permits the selection...

Page 20: ...Tow Maintenance switch to the Tow Maintenance position Failure to do so will damage the controller or motor Before disconnecting or connecting a battery or any other wir ing move the Run Tow Maintena...

Page 21: ...e edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable surface could result in the vehicle falling backwards Before operating loadbed check to ensure no one is...

Page 22: ...to the edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable surface could result in the vehicle falling backwards Before operating check to ensure no one is beh...

Page 23: ...rrain 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 t...

Page 24: ...he above option numbers Regenerative Braking To prevent the possibili ty of loss of control that could cause severe inju ry or death use service brake to control speed The PDS system is not a substitu...

Page 25: ...m senses that the accelerator pedal is depressed power applied to motor b the brake is engaged so as to prevent vehicle motion the PDS system will sense a stalled motor condition and remove power from...

Page 26: ...oss of control is costly is consid ered abuse and will not be covered under warranty LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings Appe...

Page 27: ...se 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 clean...

Page 28: ...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...

Page 29: ...nting 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 recomm...

Page 30: ...s 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 no...

Page 31: ...un Tow Mainte nance switch must be left in the Tow Maintenance position for at least 30 seconds after the circuit is restored This vehicle will give years of satisfactory service provid ing it receive...

Page 32: ...ent rims missing or loose lug nuts MONTHLY 20 HOURS includes items listed in previous table the following BATTERIES Clean batteries terminals See BATTERY CLEANING Check charge condition and all connec...

Page 33: ...s installed and vehicle speed No specific braking distance can be reliably specified The test is conducted by latch ing the parking brake to eliminate different pedal pres sures and to include the aff...

Page 34: ...ith hydraulic front disc brakes check master cylinder fluid annually or if there is a decrease in braking effectiveness Inspect components for damage or wear It is unlikely that fluid will need to be...

Page 35: ...anual 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 identif...

Page 36: ...he possibility of a dropped wrench from shorting out a battery which could result in an explosion and severe personal injury or death BATTERY A battery is defined as two dissimilar metals immersed in...

Page 37: ...al importance is too much water which will result in electrolyte being forced out of the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle Do no...

Page 38: ...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 batteries with a solution of sodium bicarbo...

Page 39: ...osion Use care to connect the battery wires as shown Ref Fig 31 on page 23 Tighten the battery post hardware to 50 70 in lbs 6 8 Nm torque Protect the battery terminals and battery wire terminals with...

Page 40: ...n all cells must be at the rec ommended level and cover the plates The charging must take place in an area that is well ventilated and capable of removing the hydro gen gas that is generated by the ch...

Page 41: ...ing batteries Specific gravity is the measurement of a liquid that is compared to a baseline The baseline is water which is assigned a base number of 1 000 The concentration of sulfuric acid to water...

Page 42: ...y ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the battery providing all cells are within fifty points of each other Since the hydrometer t...

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

Page 44: ...ce park brake with automatic parking brake release accelerator kick off FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic s...

Page 45: ...th clipboard BRAKES Dual rear wheel mechanical self adjusting drum brakes Combination service park brake with automatic parking brake release accelerator kick off FRONT SUSPENSION Heavy duty leaf spri...

Page 46: ...adjusting drum brakes Combination service park brake with automatic parking brake release accelerator kick off FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION...

Page 47: ...BRAKES Dual rear wheel mechanical self adjusting drum brakes Combination service park brake with automatic parking brake release accelerator kick off FRONT SUSPENSION Heavy duty leaf springs with hyd...

Page 48: ...MPT 800 INDUSTRIAL 800 MPT 1000 INDUSTRIAL 1000 103 in 262 cm Rear 38 in 97 cm Front 38 in 97 cm 35 in 89 cm 10 in 25 cm 47 in 119 cm 47 in 119 cm 66 in 168 cm 111 in 282 cm 11 5 in 29 cm 18 in 46 cm...

Page 49: ...icle Dimensions Incline Specifications and Turning Clearance Diameter RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX TURNING CLEARANCE DIAMETER MPT 800 19 ft 5 8 m MP...

Page 50: ...Page 34 Owner s Manual and Service Guide GENERAL SPECIFICATIONS Notes...

Page 51: ...Page 35 Owner s Manual and Service Guide WARRANTY LIMITED WARRANTIES...

Page 52: ...WARRANTY 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...

Page 53: ...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...

Page 54: ...Page 38 Owner s Manual and Service Guide WARRANTY Notes...

Page 55: ...Page 39 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY...

Page 56: ...Page 40 Owner s Manual and Service Guide DECLARATION OF CONFORMITY...

Page 57: ...Page 41 DECLARATION OF CONFORMITY Owner s Manual and Service Guide NOT AVAILABLE AT TIME OF PUBLICATION...

Page 58: ...Page 42 Owner s Manual and Service Guide DECLARATION OF CONFORMITY Notes...

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

Page 60: ...tograms 20 1 21 22 Pb35493 G01 28203 G01 On Battery Under Seat WARNING Windshields do not provide protection from golf balls or other flying objects EGWHL14 See Following Pages For Explanation Of Pict...

Page 61: ...m LOAD CENTER OF GRAVITY MAXIMUM HEIGHT 14 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL MAX xxx lbs xxx kg SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY DO...

Page 62: ...NECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE DO NOT DISPOSE OF BATTERIES IN...

Page 63: ...OUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD P N TO LEAVE AN ELECTRIC POWER...

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

Page 65: ...omponents 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 c...

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