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Summary of Contents for Bad Boy 644582
- Page 1 OWNER’S GUIDE HD ELECTRIC 644582 ISSUED MAY 2015 REVISED AUGUST 2015...
- Page 2 WELCOME Thank you for purchasing this vehicle. Before you drive the vehicle, read this Owner’s Guide. This guide contains mainte- nance and operation information. The illustrations can show items that are optional for your vehicle. You can do most of the service procedures in this guide with common, automotive hand tools. If necessary, contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule.
- Page 3 OWNER’S GUIDE 72V ELECTRIC POWERED VEHICLE HD ELECTRIC STARTING MODEL YEAR 2016 CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids con- tained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
- Page 4 FORWARD This vehicle was designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless other- wise indicated. Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective. If you do not correctly do maintenance on the batteries, you will cancel the warranty.
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Page 5: Table Of Contents
TABLE OF CONTENTS SAFETY GENERAL ......................... 1 NOTICES, CAUTIONS, WARNINGS AND DANGERS ............ 1 GENERAL OPERATION....................3 MAINTENANCE ........................ 4 LABELS AND PICTOGRAMS................... 5 GENERAL SPECIFICATIONS VEHICLE DIMENSIONS ....................8 TURNING DIAMETER AND INCLINE INFORMATION ............ 9 INTRODUCTION FEATURES ........................11 General Information .................. - Page 6 TABLE OF CONTENTS BEFORE INITIAL USE..................... 17 CHARGER ........................18 On-Board Charger ....................18 HOW TO OPERATE THE VEHICLE ................19 Key and Light Switch Operation ................20 Direction Selector Operation ................21 Accelerator Pedal Operation ................21 Brake and Parking Brake Operation ..............21 Truck Bed Operation ...................22 Truck Bed Handle/Latch Operation ..............23 Electric Lift Operation ..................23...
- Page 7 TABLE OF CONTENTS Taillight ....................... 33 FUSE REPLACEMENT....................33 TRANSPORTING VEHICLE ................... 34 Towing ........................ 34 Hauling ....................... 34 SERVICE AND MAINTENANCE..................34 ROUTINE MAINTENANCE..................... 35 TIRE INSPECTION ......................35 BRAKES ......................... 36 Periodic Brake Test .................... 36 REAR AXLE ........................37 Checking the Lubricant Level ................
- Page 8 TABLE OF CONTENTS Owner’s Guide...
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Page 9: Safety
SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY GENERAL For any questions about material in this manual, contact an authorized representative. Read and understand all labels on the vehicle. Always replace any damaged or missing labels. Steep hills allow the vehicle to move at faster speeds than on a flat surface. - Page 10 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This manual contains recommended maintenance procedures from the manufacturer. Follow these procedures and fault isolation information to get the best service from the product. To decrease the risk of personal injury or property damage, read and follow all safety information and operational procedures in this manual.
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Page 11: General Operation
SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL OPERATION Read the following warnings before attempting to operate the vehicle. When you leave the vehicle, turn the key to the OFF position and remove the key from the vehicle. Drive the vehicle only as fast as terrain and conditions allow. -
Page 12: Maintenance
SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove all jewelry before you service the vehicle. Do not allow loose clothing or hair to contact the moving parts. Do not touch hot objects. -
Page 13: Labels And Pictograms
SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LABELS AND PICTOGRAMS TO OPERATE VEHICLE: - TURN KEY TO ON OBEY LOCAL DO NOT OPERATE REMAIN SEATED - MOVE DIRECTION SELECTOR TO RULES AND NO PUBLIC UNDER DRUG/ALCOHOL... - Page 14 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...
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Page 15: General Specifications
GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS MODEL: HD Electric TYPE: ELECTRIC 72V POWERED TRUCK MODEL YEAR: 2016 Part No:. 644586 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Solid State continuously variable AC speed controller Full torque, reduced speed reverse... -
Page 16: Vehicle Dimensions
GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE DIMENSIONS 10.5 in. (27 cm) 52 in. (132 cm) Front 78 in. (198 cm) 37 in. (94 cm) 111 in. -
Page 17: Turning Diameter And Incline Information
GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING DIAMETER AND INCLINE INFORMATION TURNING CLEARANCE DIAMETER 24 ft (7.3 m) Owner’s Guide... - Page 18 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...
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Page 19: Introduction
INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INTRODUCTION FEATURES General Information If the vehicle has accessories that were installed at the factory, some accessories continue to operate with the key switch in the OFF position. -
Page 20: Direction Selector
INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 3. Direction Selector To prevent loss of control or possible damage to the vehicle, do not move the direction selector while the vehicle is in motion. The direction selector is found on the seat wrap panel and allows the operator to select F (forward) or R (reverse) or N (neutral). -
Page 21: Ac Outlet (If Equipped)
INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 8. AC Outlet (if equipped) The AC outlet is found on the panel below the driver seat. The AC outlet supplies power to the onboard charger. Connect the grounded AC cord to the outlet to charge the batteries. -
Page 22: Electric Truck Bed Lift Switch
INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 17. Electric Truck Bed Lift Switch The switch for the electric lift is on the driver’s side of the seat panel. The switch actu- ates the electric lift to raise and lower the truck bed. - Page 23 INTRODUCTION 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 24 INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...
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Page 25: Operating Procedures
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. OPERATING PROCEDURES SERIAL NUMBER LOCATION The PIN plate is attached to the frame below the seat wrap panel. Two serial number and manufacture date code labels are on the vehicle. -
Page 26: Charger
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Explosive hydrogen gas is created during the charge cycle of the batteries. Good ventilation is necessary to remove gas from closed spaces. -
Page 27: How To Operate The Vehicle
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The on-board charger is below the driver side of the truck bed. The on-board charger is wired to the batteries. Before you charge the batteries make sure you: •... -
Page 28: Key And Light Switch Operation
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driver and passengers must stay in their seats while the vehicle is in motion. Always keep feet, legs, hands and arms inside vehicle while in motion. Incorrect and irresponsible operation of this vehicle can cause dangerous conditions for the operator, passengers and other people in the area. -
Page 29: Direction Selector Operation
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Direction Selector Operation To prevent loss of control, do not move the direction selector to a different position while the vehi- cle is in motion. -
Page 30: Truck Bed Operation
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Truck Bed Operation Failure to follow these instructions can cause personal injury, damage the vehicle or cause the vehicle to tip over. -
Page 31: Truck Bed Handle/Latch Operation
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Truck Bed Handle/Latch Operation Truck Bed Handle/Latch Use caution when you operate the truck bed latch to make sure the truck bed does not accidentally drop during lift or lower procedure. -
Page 32: Pedal-Up Braking
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Speed Control/Regenerative Braking The motor speed is sensed and controlled by the controller. As the vehicle accelerates downhill, the speed sensor causes the motor to electrically control the speed of the vehicle through regenerative braking. -
Page 33: Anti-Roll Back Feature
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Anti-Roll Back Feature Anti-Roll Back, like Walk-Away, limits reverse motion of the vehicle down a slope to less than 2 mph (3 kph). See Walk- Away Feature for more information. -
Page 34: Starting Vehicle On A Hill
OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Starting Vehicle On A Hill To decrease the risk of roll-back, do not release the brake until the motor has started. Do not use the accelerator and motor to hold the vehicle on a hill. - Page 35 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 36 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...
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Page 37: Maintenance
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE VEHICLE CLEANING AND CARE Read and understand all instructions supplied by the manufacturer of the pressure washer before use. -
Page 38: Battery Disposal
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Disposal Return used batteries to the manufacturer or lead smelter for recycling purposes. For neutralized spills, put residue in acid-resistant containers with absorbent material, sand or earth and discard according to state and federal regulations for acid and lead compounds. -
Page 39: Wheels And Tires
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Put the jack at the center of the front axle. Lift the vehicle enough to put two jack stands below the front frame crossmember as shown. -
Page 40: Wheel Installation
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use caution when you inflate the tires. Because of the low volume of the small tires, over inflation can occur in seconds. Over inflation can cause the tire to separate from the wheel or cause a tire explosion. -
Page 41: Light Bulb Replacement
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIGHT BULB REPLACEMENT To decrease the risk of premature bulb failure, do not allow your fingers to contact new bulbs. Use clean, dry paper or paper towels to touch the glass part of the bulb. -
Page 42: Transporting Vehicle
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRANSPORTING VEHICLE Towing Do not ride or allow other people on the vehicle being towed. Do not try to tow the vehicle with ropes, chains or any device different from a tow bar approved by the factory. -
Page 43: Routine Maintenance
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wear eye protection when you service the vehicle. Be careful when you do work around batteries, use solvents or compressed air. To decrease the risk of electrical arc, which can cause a battery explosion, dis- able all electrical loads from the battery before you remove the battery wires. -
Page 44: Brakes
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKES Dry, Level, Clean, Paved Surface Accelerate to maximum speed. Always inspect the pedal travel before you operate a vehicle to confirm some brake function is found. -
Page 45: Rear Axle
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE The only maintenance necessary for the first five years is the inspection of the rear axle for lubricant leakage. Unless leakage is visible, the lubricant needs to be replaced after five years. -
Page 46: Hardware
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HARDWARE Normally, three classes of standard hardware and three classes of metric hardware are used in the vehicle. Grade 5 hardware is identified by the three marks on the hexagonal head;... -
Page 47: Battery Charging And Maintenance
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY CHARGING AND MAINTENANCE Safety Always obey the following warnings when working on or near batteries. To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks away from the batteries. -
Page 48: Battery
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery A battery is described as two dissimilar metals immersed in an acid. If the acid is absent or if the metals are not dissimi- lar, a battery has not been created. - Page 49 MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A battery being charged will ’gas’ with most gassing occurring at the end of the charging cycle. This gas is hydrogen which is Vent Cap lighter than air.
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Page 50: Battery Cleaning
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Clean all electrolyte spills to the body and eyes with clear water. -
Page 51: Battery Replacement
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Replacement Remove the battery hold downs and cables. Remove the batteries with a commercially available lifting device. If the batteries are cleaned and acid in the battery rack area is neutralized as recommended, no corrosion to the battery racks or surrounding area should be found. -
Page 52: Prolonged Storage
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Prolonged Storage Disconnect the battery charger, controller and other electronic devices for extended storage. All connected electronic components cause the discharge of batteries. During storage, the batteries need attention to keep them maintained and prevent discharge. -
Page 53: Ac Voltage
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • The charger connector and cord set must be protected from damage. The charger connector and cord set must be used in an area where it is not possible for personnel to run over or trip over the cord set. -
Page 54: Using A Hydrometer
MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. quality hydrometers are equipped with an internal thermometer that will measure the temperature of the electrolyte and will include a conversion scale to correct the float reading. It is important to recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been operated. - Page 55 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 56 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...
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Page 57: Periodic Service Schedule
PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - Check pressure and inspect condition of tires &... - Page 58 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 Read the following warnings before operating vehicle: Read the following information and warnings before operating vehicle: In any product, components will eventually fail to perform prop- 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.
- Page 60 CONTACT US: Bad Boy Buggies 1451 Marvin Griffin Road Augusta, Georgia 30906-3852 USA FAX: 855-256-9900 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 without the express permission of E-Z-GO Division of Textron Inc.,...