Textron EZGO TXT FLEET 2010 Owner's Manual & Service Manual

Gasoline powered fleet golf car

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Owner's Manual & Service Guide

Issued February 2010

Revised August 2012

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Page 1 Owner’s Manual & Service Guide Issued February 2010 Revised August 2012...
Page 2: Safety
SA FE TY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds 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.
Page 3 TXT FLEET (CARB) Starting Model Year 2010 The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice.
Page 4: General Information
GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.
Page 5: Table Of Contents
TABLE OF CONTENTS SAFETY ........................ inside covers GENERAL INFORMATION ....................... ii SAFETY INFORMATION ......................v BEFORE INITIAL USE ......................1 Fig. 1 Initial Service Chart ....................... 1 CONTROLS AND INDICATORS ....................1 KEY ..................................2 Fig. 2 Key Switch ........................1 LOW OIL PRESSURE INDICATOR LIGHT ......................
Page 6 TABLE OF CONTENTS Fig. 14 Clean Entire Dipstick....................15 Fig. 15 Check Oil Level on Dipstick ..................15 CHANGING THE OIL............................16 Fig. 16 Oil Viscosity Chart....................... 16 Fig. 17 Cleaning Top of Engine....................16 Fig. 18 Remove Oil Filter ......................16 Fig.
Page 7: Safety Information
SA FE TY IN F O RM AT ION SAFETY INFORMATION This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
Page 8 SA FE TY IN F O RM AT ION This vehicle conforms to the current applicable standard(s) for safety and performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on public streets.
Page 9 SA FE TY IN F O RM AT ION • Use specified replacement parts. Never use replacement parts of lesser quality. • Use recommended tools. • Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle.
Page 10 SA FE TY IN F O RM AT ION NOTES: Page viii Owner’s Manual and Service Guide...
Page 11: Before Initial Use
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings Thank you for purchasing this vehicle. Before driving the Vehicle battery must be fully charged before initial use. vehicle, we ask you to spend some time reading this Check for correct tire inflation.
Page 12: Key
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings on page - 2). Vehicle should be left in ‘F’ when unat- tended. To prevent engine damage, do not operate engine until oil pressure is corrected.
Page 13: Combination Brake And Park Brake Pedal
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings OPERATING THE VEHICLE Horn Park Service Brake Brake Improper use of the vehicle or the lack of proper mainte- nance may result in damage or decreased performance.
Page 14: Run-In
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings park brake, move direction selector to for- ward position, turn key to ‘OFF’ position and NOTICE remove key.
Page 15: Starting The Vehicle On A Hill
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings To operate vehicle: severe drivetrain damage, speeds should be limited to no • more than the maximum governed speed on level ground Apply the service brake, place the key in the key switch and turn it to the ‘ON’...
Page 16: Battery
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings The windshield does not provide protection from tree limbs or flying objects. Fuel To prevent damage to the vehicle, do not hold on to sun 1"...
Page 17: Vehicle Cleaning And Care
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings VEHICLE CLEANING AND CARE NOTICE If the engine does not start or runs improperly after washing, VEHICLE CLEANING remove the spark plug wires (by pulling the spark plug boots, never the wires).
Page 18: Wheels And Tires
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings Place the jack at the center of the front axle. Raise the vehicle enough to place jack stands under the frame crossmember as indicated.
Page 19: Wheel Installation
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings effective way to repair a puncture in the tread is to use a commercial tire plug. 'Cross Sequence' NOTICE Tire plug tools and plugs are available at most automotive parts...
Page 20: Transporting Vehicle
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings TRANSPORTING VEHICLE HAULING TOWING To reduce the possibility of severe injury or death while transporting vehicle: Secure the vehicle and contents.
Page 21: Service And Maintenance
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings SERVICE AND MAINTENANCE water. Aerosol containers of battery terminal pro- tectant must be used with extreme care. Insulate metal container to reduce the pos- sibility of can contacting battery terminals To reduce the possibility of severe injury or...
Page 22: Serial Number Plate And Location
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings SERIAL NUMBER PLATE AND LOCATION Two serial number and manufacture date code label are on the vehicle. One is placed on the body below the driver side seat.
Page 23: Periodic Service Schedule
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings PERIODIC SERVICE SCHEDULE    Check Clean, Adjust, etc. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle.
Page 24 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings  Check for bent/binding linkage rod  Check for damage or wear to latch arm or catch bracket PARK BRAKE ...
Page 25: Tire Inspection
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings TIRE INSPECTION Tire condition should be inspected per the Periodic Ser- vice Schedule (Ref. Fig. 13 on page 13). Inflation pres- sures should be checked when the tires are cool.
Page 26: Changing The Oil
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings Changing the Oil drain pan under engine. Wipe top of the engine clean with a cloth (Ref Fig.
Page 27: Starter/Generator Belt Tension
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings oil left in engine. The oil must be high quality oil that meets or exceeds API SF, SG, CC standards (Ref Fig. 21 on page - 17).
Page 28: Adjusting The Belt
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36 kg).
Page 29: Brakes
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings BRAKES Dry, Level, Clean, Paved Surface Accelerate To To reduce the possibility of battery explosion Maximum Speed that could result in severe injury or death, do not use metallic spray wand to clean battery...
Page 30: Periodic Brake Test For Mechanical Brakes
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings Periodic Brake Test For Mechanical Brakes engine’s air cooling system. Clean areas shown to prevent engine damage. Keep linkag- The purpose of this test is to compare the braking perfor- es, springs and controls clean.
Page 31: Air Cleaner Inspection And Replacement
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings Fill / Check Plug Air Filter Air Cleaner Element Canister Dust Air Cleaner Collector Cover Ref Air 2 Fig.
Page 32: Lubrication
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings LUBRICATION Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule (Ref Fig. 13 on page - 13).
Page 33: Capacities And Replacement Parts
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings Keep hands, clothing and jewelry away from moving parts. Use care not to contact hot objects.
Page 34: Hardware
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings HARDWARE Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific Periodically, the vehicle should be inspected for loose torque values.
Page 35: General Specifications
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 25...
Page 36 GENERAL SPECIFICATIONS Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings MODEL: TXT FLEET GOLF CAR TYPE: GASOLINE POWERED FLEET GOLF CAR MODEL YEAR: 2010 Part No:. 614164 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki...
Page 37 GENERAL SPECIFICATIONS Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings 68.0 in. (173 cm) 46.5 in. (118 cm) Front 4.25 in. 34 in. (86 cm) (10.8 cm) Ground Rear Clearance...
Page 38 GENERAL SPECIFICATIONS Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP 25% GRADE or 14 o MAX 25% GRADE or 14 o MAX TURNING CLEARANCE DIAMETER 19 ft.
Page 39 GENERAL SPECIFICATIONS Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings NOTES: Owner’s Manual and Service Guide Page 29...
Page 40 GENERAL SPECIFICATIONS Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Dangers and Warnings NOTES: Owner’s Manual and Service Guide Page 30...
Page 41: Labels And Pictograms
LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
Page 42 LABELS AND PICTOGRAMS 614121 MIN 150 < 14° 25% < 14° 25% 71145-G01 614121 71145G01 SAFETY AND OPERATION INSTRUCTIONS 27826G01 WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY. Operate from the driver's side only. For golf course and non-highway use only. Recommended to be operated only by authorized drivers (with valid drivers license) in designated areas.
Page 43 LABELS AND PICTOGRAMS WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD XXX lbs. AS POSSIBLE. XXX kg MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE...
Page 44 LABELS AND PICTOGRAMS CLEAN UP GASOLINE SPILLS WITH DO NOT WATER BEFORE DISPOSE OF STARTING ENGINE BATTERIES IN LANDFILL UNLEADED GASOLINE DO NOT DO NOT DRIVE ON SPILL FUEL HIGHWAY ON A HOT ENGINE WINDSHIELDS GROUND DO NOT FUEL PUMP PROVIDE PROTECTION FROM...
Page 45 LABELS AND PICTOGRAMS HEADLIGHTS KEEP ARMS AND LEGS WITHIN VEHICLE UNLOCKED TO OPERATE VEHICLE IN FORWARD: Q TURN KEY TO ON Q MOVE DIRECTION SELECTOR TO FORWARD Q DEPRESS ACCELERATOR PEDAL LOCKED AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE: Q TURN KEY TO ON Q MOVE DIRECTION SELECTOR TO REVERSE...
Page 46 LABELS AND PICTOGRAMS Notes: Owner’s Manual and Service Guide Appendix A - 6...
Page 47: Vehicle Warranties
VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Appendix B - 1...
Page 48 VEHICLE 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 vehicle serial number and manufacturer date code. Owner’s Manual and Service Guide Appendix B - 2...
Page 49 You are responsible for presenting your vehicle to E-Z-GO Division of Textron Inc. distribution center or service center as soon as the problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Page 50 VEHICLE WARRANTIES - CALIFORNIA (3) Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part. If the part fails before the first scheduled replacement, the part will be repaired or replaced by ABC, Inc.
Page 51 EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Kawasaki Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
Page 52 VEHICLE WARRANTIES - FEDERAL As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. E-Z-GO recommends that you retain all receipts covering maintenance on your engine, but E-Z-GO cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
Page 53: Declaration Of Conformity
DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Appendix C - 1...
Page 54 DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Appendix C - 2...
Page 55 DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Appendix C - 3...
Page 56 DECLARATION OF CONFORMITY NOTES: Owner’s Manual and Service Guide Appendix C - 4...
Page 57 Some components are heavy, spring loaded, highly cor- rosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, Read and understand the following warnings before attempting battery acid and hydrogen gas could result in serious to operate the vehicle: bodily injury to the technician/mechanic and bystanders if not treated with the utmost caution.
Page 58 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: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 Copyrighted Material...

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