Ezgo Express S4 Owner's Manual
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Ezgo Express S4 Owner's Manual

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OWNER'S MANUAL
Express S4 72V
690158 - B
ISSUED MAY 2019
REVISED SEPTEMBER 2020

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Summary of Contents for Ezgo Express S4

  • Page 1 OWNER’S MANUAL Express S4 72V 690158 - B ISSUED MAY 2019 REVISED SEPTEMBER 2020...
  • Page 2 Read and comply with all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. California Proposition 65 WARNING Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including phthalates and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 3 OWNER’S MANUAL 72V ELECTRIC VEHICLE Express S4 Starting MODEL YEAR 2020 MANUFACTURER INFORMATION Textron Specialized Vehicles, Inc. 1451 Marvin Griffin Road. Augusta, Georgia, USA 30906-3852 1-800-774-3946 Technical Assistance & Warranty 1-888-438-3946 Service Parts 011-706-798-4311 International www.ezgo.com...
  • Page 4 ELCOME Thank you for purchasing this vehicle. Before driving your new vehicle, read this owner’s manual to familiarize your- self with safe driving practices, operation, features and controls. This manual contains instructions for minor maintenance only. Information about major repairs can be found in the repair manual.

  • Page 5: Table Of Contents

    ABLE OF ONTENTS INTRODUCTION MANUFACTURER’S INTENDED USE ........................7 WARRANTY AND REGISTRATION ......................... 7 BATTERY PROLONGED STORAGE ........................7 BATTERY DISPOSAL ............................... 8 VEHICLE IDENTIFICATION NUMBERS ......................... 8 REPAIR AND PARTS MANUALS ..........................8 SAFETY LABELS SAFETY LABELS ..............................9 Operation Warning Label (662185) ........................
  • Page 6 ABLE OF ONTENTS Brake Pedal ..............................18 Parking Brake Pedal ............................18 ACCELERATOR PEDAL ............................18 HIP RESTRAINTS ..............................18 SEAT BOTTOM ...............................18 GLOVE BOX / STORAGE COMPARTMENTS .......................18 CHARGER RECEPTACLE .............................18 CANOPY TOP AND WINDSHIELD (IF EQUIPPED) ....................18 FLIP SEAT/LOAD DECK ............................19 OPERATION SAFETY ..................................21 BEFORE INITIAL USE ............................21 PRE-RIDE INSPECTION ............................21...
  • Page 7 BATTERY STORAGE ............................. 43 BATTERY CHARGING ............................44 AC Voltage ..............................44 TROUBLESHOOTING ............................44 Using A Hydrometer ............................45 TRANSPORTING THE VEHICLE ........................... 46 Hauling the Vehicle ............................46 Towing the Vehicle ............................46 SPECIFICATIONS EXPRESS S4 72V- VEHICLE SPECIFICATIONS ....................47...
  • Page 8 ABLE OF ONTENTS...

  • Page 9: Manufacturer's Intended Use

    A literature package is included with the purchase of a new vehicle. The package contains the following items: • Vehicle Warranty Statement • Vehicle Registration Card (registration can also be done at www.ezgo.com) Use Original Equipment Manufacturer (OEM) approved parts to keep the vehicle warranty effective.

  • Page 10: Battery Disposal

    NTRODUCTION BATTERY DISPOSAL Lead-acid batteries are recyclable. Return discarded batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, put any residue in acid-resistant containers with absorbent material such as sand. Dispose in accordance with local, state and federal regulations for acid and lead com- pounds.

  • Page 11: Safety Labels

    AFETY SAFETY LABELS SAFETY LABELS Safety and warning labels are on the vehicle for your protection. Read carefully and comply with the instructions on the labels. If any label shown in this manual is different from the label on your vehicle, always follow the instructions on the vehicle label.
  • Page 12 AFETY...

  • Page 13: Maximum Cargo Load / Maximum Weight Capacity

    AFETY SAFETY For questions about the vehicle or the material in this manual, see the contact information on page 1 or the back of this publication. MAXIMUM CARGO LOAD / MAXIMUM WEIGHT CAPACITY Exceeding the weight capacities can cause the loss of vehicle control and possible injury or death.

  • Page 14: Unauthorized Operation

    AFETY • Do not drive on excessively steep hills. Evaluate the terrain before descending a hill. Drive slowly and deliberately. Use the brake to limit speed and maintain control. Sudden braking or turning can cause the loss of vehicle control. Drive straight down the hill.

  • Page 15: Load Operation

    AFETY Load Operation The weight of cargo and occupants affects vehicle operation. Carefully calculate how the vehicle is loaded and how to safely operate it. Follow the instructions in this manual for loading guidelines and tire pressure. Do not exceed weight capacities specified for your vehicle. Capacities are listed in Maximum Cargo Load / Maximum Weight Capacity on page 11 of this manual, and also on the label affixed to rear hand rail.

  • Page 16: Tires

    AFETY Tires Operating the vehicle with the incorrect tires or with the incorrect or uneven tire pressure can cause loss of control or an accident. Always use the size and type of tires specified for the vehicle. See Vehicle Specification for proper tire type and size.
  • Page 17 AFETY • To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks away from the battery. • Hydrogen gas is produced as the batteries are charged, Charge the batteries only in well ventilated areas. • Maintain constant awareness that some components are heavy, spring loaded, corrosive, explosive, can cause high amperage, or get extremely hot.
  • Page 18 AFETY...

  • Page 19: Features And Controls

    EATURES AND ONTROLS FEATURES AND CONTROLS NOTICE: Some accessories continue to operate with the key in the OFF position. Leaving these accessories activated after the vehicle is shut down can cause the battery to discharge. KEY SWITCH Speed / Range •...

  • Page 20: Steering Wheel

    EATURES AND ONTROLS STEERING WHEEL The steering wheel allows the driver to control the direction of travel. BRAKE PEDALS The brake pedal on vehicles with mechanical brakes is a combination brake and parking brake pedal. Brake Pedal Parking Brake Pedal The brake pedal is the bottom left pedal on the floorboard.

  • Page 21: Flip Seat/Load Deck

    EATURES AND ONTROLS This vehicle is not equipped with seat belts, and the canopy top is not designed to provide rollover protection. In addi- tion, the canopy top does not protect against falling objects, nor does the windshield protect against flying objects and tree limbs.
  • Page 22 EATURES AND ONTROLS...

  • Page 23: Operation

    PERATION OPERATION SAFETY Failure to operate the vehicle correctly can result in a collision, loss of control, accident or rollover, and cause serious injury or death. Follow all operation procedures in this section of the manual. Read and comply with all safety warnings in the safety section of this owner’s manual.

  • Page 24: Environmental Awareness

    PERATION ENVIRONMENTAL AWARENESS When driving the vehicle, be careful of potential environmental hazards like steep slopes, rocks, tree branches, etc. that could cause an incident that could result in vehicle damage, personal injury or death. There is a risk of fire when the vehicle is operated near combustible material. Always be respectful of the environment.

  • Page 25: Pedal-Up Braking

    PERATION Pedal-Up Braking Pedal-up braking is regenerative braking that occurs when the accelerator pedal is released while the vehicle is mov- ing. Example: If all of the following events occur: • the vehicle is being driven down a slope • the accelerator pedal is released the pedal-up braking decreases speed until the vehicle stops or the accelerator pedal is applied.

  • Page 26: Starting And Stopping The Vehicle

    PERATION STARTING AND STOPPING THE VEHICLE Unintentional roll-back of the vehicle could cause severe personal injury or vehicle dam- age. To reduce the possibility of vehicle roll-back, keep the brake fully pressed until the motor has started. Remove the charger plug from the receptacle and correctly store the cord before you move the vehicle. Sit in the driver’s seat.

  • Page 27: Braking

    PERATION BRAKING When carrying cargo or towing a trailer, the weight of the load will increase the braking distance required to slow or stop the vehicle. Not allowing for increased braking dis- tance under load can cause an accident or injury. Release the accelerator pedal completely.

  • Page 28: Driving Uphill

    PERATION DRIVING UPHILL When driving up a hill, follow these guidelines: • Drive straight up the hill. • Avoid excessively steep hills. • Keep both feet on the floor or pedals. • Check the terrain before driving up a hill. Do not try to climb hills that have excessively slippery or loose surfaces. •...

  • Page 29: Driving In Reverse

    PERATION DRIVING IN REVERSE When driving in reverse, follow these guidelines: • Check that the area behind the vehicle is clear of obstacles and people. • Check left and right fields of vision before driving in reverse. • Do not back down a steep hill. •...

  • Page 30: Maximum Cargo Load / Maximum Weight Capacity

    PERATION Maximum Cargo Load / Maximum Weight Capacity Maximum Vehicle Weight Capacity 800 lb (363 kg) Maximum Load Deck Capacity 250 lb (113 kg) • Do not exceed the maximum cargo load capacity. • Do not exceed the maximum vehicle weight capacity (includes weight of operator, passenger, cargo, and accesso- ries).

  • Page 31: Vehicle Maintenance

    AINTENANCE VEHICLE MAINTENANCE MAINTENANCE SAFETY To prevent serious injury or death, follow the procedures and comply with the safety information in this manual while performing vehicle service or maintenance. Use the tools shown in the tool list and wear the specified safety equipment when per- forming vehicle service or maintenance.

  • Page 32: Scheduled Maintenance

    AINTENANCE SCHEDULED MAINTENANCE Consistent inspection, adjustment, and lubrication of some components are necessary to maintain the vehicle so that it remains in safe and reliable condition. Refer to the SCHEDULED MAINTENANCE CHART on page 30 for detailed requirements. Inspect, clean, lubricate, adjust, and replace parts as necessary. Use E-Z-GO or equivalent replacement parts. Record the maintenance items performed along with details in the MAINTENANCE LOG beginning on page 49.

  • Page 33: Recommended Lubricants And Fluids

    AINTENANCE Interval (perform at interval Item Remarks Page that comes first) Hours Calendar Tie rods Monthly Check for excess play, bent rods, loose or missing hardware. Inspect strut for leaks. Check hubs and kingpins, for excessive Front suspension Monthly play, worn bushings, loose or missing hardware. Rear axle Monthly Check for leakage;...

  • Page 34: Lifting The Vehicle

    AINTENANCE LIFTING THE VEHICLE Read and comply with all of the following warnings and lifting procedures to prevent the possibility of the vehicle falling and causing serious injury or death. For some maintenance procedures, it is necessary to lift the vehicle. Comply with the following warnings and follow the lifting procedure to ensure the safety of you, your vehicle and surroundings.

  • Page 35: Vehicle Cleaning And Care

    AINTENANCE VEHICLE CLEANING AND CARE Keeping your vehicle clean is not only beneficial to its appearance, but can also help extend the life of various compo- nents. Washing the Vehicle NOTICE: Do not use a pressure washer to wash the vehicle. High water pressure can damage components. Some products, including insect repellents and chemicals, will damage plastic surfaces.

  • Page 36: Tire Pressure

    AINTENANCE Tire Pressure Maintaining correct tire inflation pressure is essential for safe vehicle operation. You can vary the inflation pressure, within the recommended range to suit the condition of the terrain. TIRE PRESSURE RANGE TERRAIN CONDITIONS RECOMMENDATION Inflate to higher pressure within the range; never exceed hard surfaces or pavement maximum pressure indicated.

  • Page 37: Wheel Installation

    AINTENANCE Wheel Installation Lug Nut Torque 65 - 85 ft.lbs. (88 - 115 Nm) NOTICE: To decrease the risk of component damage, do not tighten the lug nuts Lug Nut Tightening Pattern to more than the specified torque. NOTICE: Always install lug nuts using a cross sequence pattern to ensure the even seating of the wheel against the hub.

  • Page 38: Brake Light

    AINTENANCE Brake Light Remove the two phillips head screws securing lens Rear Fender and pull lens out of housing to access the brake light bulb. Remove the light bulb and install a new bulb, making sure bulb makes good contact with socket. Lens Replace the lens and reinstall the phillips head screws.

  • Page 39: Rear Axle

    AINTENANCE 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. Refer to the Service and Repair Manual for the fluid replacement procedure.

  • Page 40: Brakes

    AINTENANCE BRAKES Always inspect the pedal travel before operating a vehicle to confirm some brake func- tion is present. All driving brake tests must be done in a safe location with regard for the safety of all personnel. NOTICE: Over time, a subtle loss of performance may take place. It is, therefor, important to establish the standard with a new vehicle.

  • Page 41: Battery

    AINTENANCE BATTERY A battery is described as two dissimilar metals immersed in an acid. If the acid is absent or if the metals are not dis- similar, a battery has not been created. The batteries in this vehicle are lead acid. A battery does not store electricity, but it can produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy.

  • Page 42: Battery Cleaning

    AINTENANCE BATTERY CLEANING Clean the batteries according to the Periodic Service Schedule. Always wear eye protection when cleaning the battery. To prevent battery damage, make sure you correctly install all battery caps. NOTICE: To decrease the risk of damage to vehicle or floor, neutralize acid before you spray the battery with water.

  • Page 43: Electrolyte Level And Water

    AINTENANCE Electrolyte Level and Water Correct Electrolyte Level Maintaining correct electrolyte level is important because any part of Vent Cap the plates open to air will be damaged. Do not overfill batteries with water. Too much water pushes the elec- trolyte from the battery by release of gas and a decrease in volume of the electrolyte.

  • Page 44: Battery Replacement

    AINTENANCE Hand held watering devices available at automotive parts stores, Watering device similar to the type included in or automatic watering devices like the one included in the Bat- the Battery Maintenance Kit tery Maintenance Kit (P/N 25587-G01) can be used with an approved water supply.

  • Page 45: Battery Storage

    AINTENANCE Be careful when using aerosol containers near battery terminals. Always use a container with insulation to prevent an explosion. Connect the battery wires as shown. Front of Vehicle Tighten the battery post hardware to 90 - 100 in. lbs. (6 -8 Nm) torque. Do not over-tighten To Controller the terminal stud nut, this will cause a “mushroom”...

  • Page 46: Battery Charging

    AINTENANCE BATTERY CHARGING The battery charger is designed to completely charge the battery set. If the batteries are severely deep cycled, some automatic battery chargers contain an electronic module that will not activate and the battery charger will not operate. Automatic chargers determine the correct length of charge to the battery set and turns off when the batteries are charged.

  • Page 47: Using A Hydrometer

    AINTENANCE NOTICE: Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the elec- trolyte.

  • Page 48: Transporting The Vehicle

    AINTENANCE TRANSPORTING THE VEHICLE Do not ride or allow other people on a vehicle being transported on a trailer or being towed with another vehicle. Do not attempt to tow the vehicle with ropes or chains. Hauling the Vehicle Loose cargo or vehicle components can fly off when the vehicle is being transported. Secure or remove all cargo.

  • Page 49: Specifications

    PECIFICATIONS SPECIFICATIONS EXPRESS S4 72V- VEHICLE SPECIFICATIONS Item Specification Overall Length 107.5 in (273 cm) Overall Width 49.5 in (124.5 cm) Overall Height (No Canopy) 47.5 in (120.5 cm) (Top of steering wheel) Overall Height (With Canopy) 77.5 in (197 cm) Load Deck Width 40 in (101.5 cm)
  • Page 50 PECIFICATIONS Rear Tires Desert Eagle 23/10-14 (4ply) Frame Welded steel with DuraShield powder coat Front Body and Finish Injection Molded TPO Rear Body and Finish Injection Molded TPO Some items shown may be optional equipment...
  • Page 51 AINTENANCE MAINTENANCE LOG Record periodic maintenance in the following maintenance log. MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 52 AINTENANCE MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 53 AINTENANCE MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 54 AINTENANCE MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 55 NDEX recommended 31 fuse replacement 36 accelerating 24 accelerator pedal 18 anti-roll back feature 23 glove box 18 anti-stall feature 23 hauling, vehicle 46 battery headlight switch 17 disposal 8 headlights 35 prolonged storage 7 high pedal disable feature 23 battery charger 22 hip restraints 18 battery maintenance 39...
  • Page 56 NDEX safety vehicle cargo 11, 27, 28 cleaning 33 charging battery 14 hauling 46 driving downhill 13 identification numbers 8 driving in reverse 13 lifting 14 driving surface 13 specifications 47 driving uphill 13 starting and stopping 24 driving with passenger 12 towing 46 labels 9 transporting 46...
  • Page 57 Normal use, age, and wear on vehicle components can affect the safe operation and reliability of the vehicle. The rec- ommended Inspection and maintenance procedures are crucial for safety, performance, reliability and maximum lon- gevity of your vehicle. A damaged vehicle, or a vehicle that is not functioning properly is dangerous and must not be operated until repairs are made.
  • Page 58 1451 Marvin Griffin Road Augusta, GA, USA 30906-3852 1-800-774-3946 Technical Assistance & Warranty 1-888-438-3946 Service Parts www.ezgo.com Service Parts Manuals and Repair and Service Manuals are available for purchase. Copyrighted Material This manual may not be reproduced in whole or in...

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