Ezgo 28806-G01, Owner'S Manual And Service Manual

Page 1: ...GASOLINE POWERED UTILITY VEHICLES ISSUED APRIL 2005 OWNER S MANUAL AND SERVICE GUIDE 28806 G01...

Page 2: ...le mat riel brouilleur du Canada For any questions on material contained in this manual contact an authorized representative for clarification Read and understand all labels located on the vehicle Alw...

Page 3: ...tained 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...

Page 4: ...e 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 sp...

Page 5: ...4 Fig 8 Bed Prop Rod 4 ELECTRIC LIFT BED OPERATION 4 Fig 9 Electric Lift Switch 4 PLASTIC LOAD BED 4 MANUAL LIFT BED OPERATION 5 Fig 10 Manual Bed Latch 5 Fig 11 Gas Strut 5 ELECTRIC LIFT BED OPERATIO...

Page 6: ...g 32 Adjusting Belt Tension 19 BATTERY CLEANING 19 Fig 33 Preparing Acid Neutralizing Solution 19 BRAKES 19 Fig 34 Typical Brake Performance Test 20 AIR INTAKE AND COOLING FINS 21 Fig 35 Cleaning Air...

Page 7: ...Page v TABLE OF CONTENTS Owner s Manual and Service Guide DECLARATION OF CONFORMITY EUROPE ONLY 45 LABELS AND PICTOGRAMS Appendix A...

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

Page 9: ...OPER ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the product On behalf of E Z G...

Page 10: ...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 t...

Page 11: ...s 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...

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

Page 13: ...user shall not perform any modification or 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 autho...

Page 14: ...l be presented in its entirety to all new operators and not condensed for those claiming previous experience 5 2 3 The user should include in the operators train ing program the following a instructio...

Page 15: ...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...

Page 16: ...kage 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...

Page 17: ...lace 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 ba...

Page 18: ...stributor or authorized branch 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 filt...

Page 19: ...ual lift bed is the standard bed for the vehicle The bed may be equipped with an optional electric lift switch A load bed warning label is affixed to the front of the bed See Appendix A For safe opera...

Page 20: ...d may be equipped with an optional electric lift switch Failure to follow these instructions may result in personal injury dam age the vehicle and or cause the vehicle to tip over Operate the vehicle...

Page 21: ...st in raising the empty loadbed and will keep the bed raised Ref Fig 11 on page 5 Over time the gas strut may allow the load bed to slowly lower If this condition is evident replacement of gas strut i...

Page 22: ...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...

Page 23: ...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 s...

Page 24: ...t provide protection from tree limbs or flying objects To prevent damage to the vehicle do not hold on to sun top struts and stand on body panels The sun top and windshield provide some protection fro...

Page 25: ...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 as...

Page 26: ...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...

Page 27: ...equiring 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...

Page 28: ...r that is rated at 10 amps or less Read and understand all instructions provided by the manufacturer of the charger TRANSPORTING VEHICLE TOWING This vehicle is not designed to be towed It is recommend...

Page 29: ...erminal 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 wit...

Page 30: ...UMBER 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 th...

Page 31: ...OIL Check and add if required DO NOT OVERFILL STARTER GENERATOR BELT Check for tension wear cracks MONTHLY 20 HOURS includes items listed in previous table the following WIRING Check all wiring for lo...

Page 32: ...d 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 lea...

Page 33: ...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 23 on page 17 Oil should be added to b...

Page 34: ...engine damage 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...

Page 35: ...r 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 lo...

Page 36: ...attery explosion that could result in severe 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 clean...

Page 37: ...dry clean paved surface Ref Fig 34 on page 21 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 aggre...

Page 38: ...readed hole Ref Fig 42 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...

Page 39: ...ssed 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 ligh...

Page 40: ...ear 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...

Page 41: ...cifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners 4 5 8 11 15 20 24 33 35...

Page 42: ...6 0 gal 22 5 L 87 Octane 1 1 2 qt 1 4 L 40 oz 1 2 L 15 amp P N 35212 G01 P N 20209 G3 912 P N 74005 G01 1157 P N 21759 G1 P N 26591 G01 P N 72368 G01 Panel Filter P N 28463 G01 Canister Filter NGK BPR...

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

Page 44: ...draulic front disc brakes FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers STEERING Self compensating sing...

Page 45: ...ional hydraulic front disc brakes FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers STEERING Self compensat...

Page 46: ...l hydraulic front disc brakes FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers STEERING Self compensating...

Page 47: ...Optional hydraulic front disc brakes FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers STEERING Self compe...

Page 48: ...PT 800 INDUSTRIAL 800 MPT 1200 INDUSTRIAL 1200 103 in 262 cm Rear 38 in 97 cm Front 37 5 in 95 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 VEHICLE WARRANTIES VEHICLE WARRANTIES...

Page 52: ...LE 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 ve...

Page 53: ...TY 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 FRO...

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

Page 55: ...or 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 retar...

Page 56: ...s not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF...

Page 57: ...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 ce...

Page 58: ...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 appropriate warranty service fac...

Page 59: ...mes 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 FUJI will not deny a warranty claim solely...

Page 60: ...Page 44 Owner s Manual and Service Guide VEHICLE WARRANTIES CALIFORNIA 2004...

Page 61: ...Page 45 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY...

Page 62: ...Page 46 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION...

Page 63: ...Appendix A 1 LABELS AND PICTOGRAMS Owner s Manual and Service Guide LABELS AND PICTOGRAMS...

Page 64: ...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 65: ...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 66: ...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 67: ...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 68: ...Appendix A 6 Owner s Manual and Service Guide LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD 51 Ref Pic 1 4...

Page 69: ...ere 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 con...

Page 70: ...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...