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Textron EZGO MPT 800 Owner's Manual
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Textron EZGO MPT 800 Owner's Manual

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REVISED NOVEMBER 2006

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Summary of Contents for Textron EZGO MPT 800

  • Page 1 REVISED NOVEMBER 2006...

  • Page 2: Safety

    S A FE TY SAFETY 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 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 material in this manual.

  • Page 4: General Information

    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/LIGHT SWITCH ............................2 LOW OIL PRESSURE INDICATOR LIGHT ......................2 Fig.
  • Page 6 TABLE OF CONTENTS TOWING ................................11 NEUTRAL LOCK .............................. 11 HAULING ................................12 Fig. 16 Neutral Lock ....................... 12 SERVICE AND MAINTENANCE ....................12 SERIAL NUMBER PLATE AND LOCATION ....................13 Fig. 17 Serial Number Plate & Location ................. 13 PERIODIC SERVICE SCHEDULE ........................

  • Page 7: Safety Information

    S A FE T Y IN FO RMAT IO N 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 S A F ET Y IN FO RMAT IO N 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 S A FE T Y IN FO RMAT IO N • Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. •...
  • Page 10 S A F ET Y IN FO RMAT IO N Notes: Owner’s Manual and Service Guide Page viii...
  • Page 11 S A FE T Y IN FO RMAT IO N GENERAL The following text is provided as recommended by part II of American Society of Mechanical Engineers / American National Standards Institute ASME/ANSI B56.8-2006. The manufacturer strongly endorses the contents of this specifi- cation.
  • Page 12 S A F ET Y IN FO RMAT IO N 4.5.2 The user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs of ANSI/NFPA 505, are strictly complied with, and shall familiarize carrier operators with it. Hazardous Locations 4.6.1 The user shall determine the hazard classification of the particular atmosphere or location in which the car-...
  • Page 13 S A FE T Y IN FO RMAT IO N and when used improperly, and surface conditions, grade, and other conditions of the environment in which the carrier is to be operated; (e) operational performance tests and evaluations during, and at completion of, the program. Personnel and Burden Carrier Operator Responsibility 5.3.1 Operators shall abide by the following safety rules and practices in paras.
  • Page 14 S A F ET Y IN FO RMAT IO N 5.5.11 Slow down when approaching, or on, wet or slippery surfaces. 5.5.12 Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly, 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.
  • Page 15 S A FE T Y IN FO RMAT IO N (d) Block chassis before working underneath it. (e) Before disconnecting any part of the engine fuel system of a gasoline or diesel powered carrier with gravity feed fuel systems, be sure shutoff valve is closed, and run engine until fuel system is depleted and engine stops running. (f) Before disconnecting any part of the engine fuel system of LP gas powered carriers, close the LP gas cylinder valve and run the engine until fuel in the system is depleted and the engine stops running.
  • Page 16 S A F ET Y IN FO RMAT IO N Notes: Owner’s Manual and Service Guide Page xiv...
  • Page 17 S A FE T Y IN FO RMAT IO N GENERAL The following text is provided as recommended by part II of ANSI/NGCMA 130.1-2004. EZGO, as a member of the National Golf Car Manufacturer’s Association (NGCMA), strongly endorses the content of this specification. PART II: MAINTENANCE AND OPERATIONS 5 General safety practices Introduction...
  • Page 18 S A F ET Y IN FO RMAT IO N Areas where pedestrians and golf cars could interact should be avoided by rerouting the golf car traffic or the pedes- trian traffic. If avoidance of the interaction is not possible or is highly impractical, signs shall be erected warning pedes- trians of the golf car traffic.
  • Page 19 S A FE T Y IN FO RMAT IO N labels, as necessary, which shall be affixed in their proper place on the golf car if and as designated in the owner’s manual. 7 Fuels handling and storage/battery charging Ventilation Maintenance and storage areas shall be properly ventilated to avoid fire hazards in accordance with applicable fire codes and ordinances.
  • Page 20 S A F ET Y IN FO RMAT IO N Notes: Owner’s Manual and Service Guide Page xviii...

  • Page 21: Before Initial Use

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions 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 22: Key/Light Switch

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings KEY/LIGHT SWITCH Located on the seat support panel, this lever permits the selection of either ‘F’ (forward) or ‘R’ (reverse) (Ref Fig. 3 Located on the dash panel, this switch enables the basic on page 2).

  • Page 23: Accelerator Pedal

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ACCELERATOR PEDAL OPTIONAL FRONT DISC BRAKES The front disc brakes activate as the brake pedal reaches the ’park’ or ’latch’ position. Depressing the brake pedal further will increase the effectiveness of the front brakes Unintentional movement of the accelerator ped-...

  • Page 24: Manual Lift Bed Operation

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Never fill a gas can in the bed of a vehicle. Stat- ic discharge could ignite gasoline vapor and cause an explosion.

  • Page 25: Operating The Vehicle

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OPERATING THE VEHICLE vehicle is to be left unattended, engage the park brake, move direction selector to for- ward position, turn key to ‘OFF’...

  • Page 26: Cold Starting

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Maximum oil level When the direction selector is in the reverse position, a warning DO NOT OVERFILL signal will sound to indicate that the vehicle is ready to run in reverse.

  • Page 27: Battery

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Do not refuel near open flame or electrical not idle; therefore, the battery cannot be charged while items which could produce a spark.

  • Page 28: 12 Volt Power Outlet

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 12 VOLT POWER OUTLET When pressure washing exterior of vehicle, do not use Overuse of accessories may drain the battery and leave pressure in excess of 700 psi.

  • Page 29: Repair

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings REPAIR Center of Front Axle LIFTING THE VEHICLE Tool List Qty. Required Floor jack ..............1 Jack stands ..............

  • Page 30: Wheel Installation

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To reduce the possibility of severe injury If the tire is to be removed or mounted, the tire changing caused by a broken socket when removing machine manufacturer’s recommendations must be fol- wheels, use only sockets designed for...

  • Page 31: Fuse Replacement

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The vehicle is equipped with a starter/generator and does not idle. When starting the engine, the starter/gen- Turn Signal Lens Inside erator functions as a starter and with the engine running,...

  • Page 32: Hauling

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HAULING SERVICE AND MAINTENANCE To reduce the possibility of severe injury or To reduce the possibility of severe injury or death from improper servicing techniques: death while transporting vehicle: Do not attempt any type of servicing opera-...

  • Page 33: 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 Notes, Cautions and Warnings 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 Lift Flap on Access Panel which could result in an explosion.

  • Page 34: Periodic Service Schedule

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions 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 35: Tire Inspection

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Check for leaks at tank, cap, system lines, filters, pump, carburetor FUEL SYSTEM Check system lines for cracks/deterioration THROTTLE/GOVERNOR LINKAGE Check operation and governed speed Check for loose or missing hardware and components...

  • Page 36: Changing The Oil

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The oil should be checked with the engine warm. The The selection of oil is dependent upon the service that vehicle must be on a level surface with the park brake the vehicle will perform.
  • Page 37 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Clean the area around the filter. Oil drainage is accom- plished by removing the three bolts securing the oil filter to the engine.

  • Page 38: Starter/Generator Belt Tension

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Inspect oil fill cap ‘O’ ring and replace if necessary. Install the oil fill cap. Run the vehicle for one or two minutes and check the filter for oil leaks.

  • Page 39: Battery Cleaning

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BATTERY CLEANING 1 1/2 gallons (6 liters) To reduce the possibility of damage to vehicle or floor, 1 quart Clear Water (1 liter)
  • Page 40 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings method of identifying subtle loss of performance over time. Periodic Brake Test for Mechanical Brakes The purpose of this test is to compare the braking perfor- mance of the vehicle to the braking performance of new or ‘known to be good’...

  • Page 41: Air Intake And Cooling Fins

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings raising the vehicle). Remove passenger side wheel/tire. REAR AXLE Carefully wipe off dirt and debris from master cylinder The rear axle is provided with a lubricant level check plug and cap before opening.

  • Page 42: Lubrication

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ter in accordance with the Periodic Service Schedule Putting more than three pumps of grease in a grease fit- ting could damage grease seals and cause premature (Ref.

  • Page 43: Hardware

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings electrical items which could produce a Use care when tightening fasteners and refer to the spark. Technician’s Repair and Service Manual for specific torque values.

  • Page 44: Capacities And Replacement Parts

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.
  • Page 45 GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 25...

  • Page 46: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS ™ STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 780 lbs (355kg) fuel capacity 36 lbs (16 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY 800 lbs (362 kg) (including operator, passenger, cargo bed and accessories) GROUND CLEARANCE...

  • Page 47: Mpt 1200

    GENERAL SPECIFICATIONS ™ 1200 STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 860 lbs (390kg) fuel capacity 36 lbs (16 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY 1200 lbs (544 kg) (including operator, passenger, cargo bed and accessories) GROUND CLEARANCE...

  • Page 48: Industrial™ 800

    GENERAL SPECIFICATIONS ™ INDUSTRIAL STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 860 lbs (390kg) fuel capacity 36 lbs (16 kg) TIRES (4 ply rated) 18 x 5.70 x 8 (4 ply rated) TIRE PRESSURE 35 - 45 psi (241 - 310 kPa) LOAD CAPACITY 800 lbs (362 kg) (including operator, passenger, cargo bed and accessories) GROUND CLEARANCE...

  • Page 49: Industrial Mpt™ 1200

    GENERAL SPECIFICATIONS ™ INDUSTRIAL 1200 STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 860 lbs (390kg) fuel capacity 36 lbs (16 kg) TIRES (4 ply rated) 18 x 5.70 x 8 (4 ply rated) TIRE PRESSURE 35 - 45 psi (241 - 310 kPa) LOAD CAPACITY 1200 lbs (544 kg) (including operator, passenger, cargo bed and accessories) GROUND CLEARANCE...
  • Page 50 GENERAL SPECIFICATIONS 10 in 47 in (25 cm) (119 cm) 66 in (168 cm) (Front) 37.5 in (95 cm) 103 in (262 cm) (Rear) 35 in (89 cm) 38 in (97 cm) 47 in MPT ™ 800 (119 cm) INDUSTRIAL ™ 800 18 in (46 cm) 47 in...
  • Page 51 GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER MPT ™ 800 19 ft (5.8 m) MPT ™ 1200 22 ft (6.7 m) INDUSTRIAL ™ 800 19 ft (5.8 m) INDUSTRIAL ™...
  • Page 52 GENERAL SPECIFICATIONS Notes: Owner’s Manual and Service Guide Page 32...

  • Page 53: Vehicle Warranties

    VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 33...

  • Page 54: Domestic Warranty

    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 Page 34...
  • Page 55 EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Fuji 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 56 VEHICLE WARRANTIES - FEDERAL (2006) deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte- nance. As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 57: California Evaporative Emission Control Warranty Statement

    YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board and the E-Z-GO Division of Textron Inc. (E-Z-GO) are pleased to explain the evaporative emission control system (EECS) on your 2007 gasoline powered vehicle. In California, new equipment that uses small off-engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
  • Page 58 VEHICLE WARRANTIES - CALIFORNIA (2007) emission related parts will be provided without charge to the owner if the part is under warranty. EVAPORATIVE EMISSION CONTROL WARRANTY PARTS LIST: Fuel Line, fuel line fittings, and fuel line clamps. MAINTENANCE STATEMENT: The owner is responsible for the performance of all required maintenance as defined in the owner’s manual.

  • Page 59: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
  • Page 60 LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms: (2,3,4,6,9,36,37, 35962-G01 38,39,40,29) 35962G01 35964G01 See Following Pages For Explanation Of These Pictograms: 71131-G01 (19,43,44,45) 71131G01 74443G01 74443G01 See Following Pages For See Following Pages Explanation For Explanation Of Of These These Pictograms: Pictograms:...
  • Page 61 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 62 LABELS AND PICTOGRAMS CLEAN UP GASOLINE DO NOT EXPOSE SPILLS WITH WATER BEFORE STARTING TO FLAME ENGINE UNLEADED DO NOT GASOLINE DISPOSE OF BATTERIES DO NOT IN LANDFILL SPILL FUEL ON A HOT ENGINE DO NOT DRIVE ON GROUND HIGHWAY FUEL PUMP WINDSHIELDS LOW OIL PRESSURE...
  • Page 63 LABELS AND PICTOGRAMS KEEP CLEAR OPERATE HAND OR FROM FINGERS CAN DRIVERS SIDE BE TRAPPED ONLY POSITION KEEP ARMS AND LEGS POSITION WITHIN VEHICLE HEADLIGHTS TO OPERATE VEHICLE IN FORWARD: TURN KEY TO ON UNLOCKED MOVE DIRECTION SELECTOR TO FORWARD DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY LOCKED...
  • Page 64 LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD NOTE: All Pictograms may not apply to your product. Ref Pic 1-4 Owner’s Manual and Service Guide Appendix A - 6...

  • Page 65: Declaration Of Conformity (Europe Only)

    DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Appendix B - 1...
  • Page 66 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION Owner’s Manual and Service Guide Appendix B - 2...
  • Page 67 DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Appendix B - 3...
  • Page 68 DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Appendix B - 4...
  • Page 69 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.

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