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Ezgo ST 400 48V Owner's Manual & Service Manual
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Ezgo ST 400 48V Owner's Manual & Service Manual

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612307
OWNER'S MANUAL
&
SERVICE GUIDE
400 48V
ELECTRIC POWERED VEHICLE
ISSUED MAY 2009

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Summary of Contents for Ezgo ST 400 48V

  • Page 1 612307 OWNER'S MANUAL & SERVICE GUIDE 400 48V ELECTRIC POWERED VEHICLE ISSUED MAY 2009...

  • Page 2: Safety

    S A F E T Y 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 TAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual. 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 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852 Page i Owner’s Manual and Service Guide...

  • 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 GENERAL ..........................ix BEFORE INITIAL USE ......................1 Fig. 1 Initial Service Chart ......................1 PORTABLE CHARGER INSTALLATION ......................1 Fig. 2 Proper Charger Installation ..................... 2 Fig.
  • Page 6 TABLE OF CONTENTS HAULING ................................12 SERVICE AND MAINTENANCE ....................12 SERIAL NUMBER PLATE AND LOCATION ....................13 Fig. 13 Serial Number Plate and Location ................13 PERIODIC SERVICE SCHEDULE ........................14 Fig. 14 Periodic Service Schedule ..................14 TIRE INSPECTION ............................15 BRAKES ................................

  • Page 7: Safety Information

    S A F E T Y I N F O R M AT I O N 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 E T Y I N F O R M AT I O N 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. Some commu- nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi- nances.
  • Page 9 S A F E T Y I N F O R M AT I O 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 E T Y I N F O R M AT I O N GENERAL The following text is provided as recommended by part II of ANSI/ITSDF B56.8 - 2006. The manufacturer strongly endorses the contents of this specification. 6 GENERAL SAFETY PRACTICES 6.1 Introduction 6.1.1 Like other machines, carriers can cause injury if improperly used or maintained.
  • Page 11 S A F E T Y I N F O R M AT I O N (1) Arrange for the modification or alteration to be designed, tested, and implemented by an engineer(s) expert in carrier(s) and their safety; (2) Maintain a permanent record of the design, test(s), and implementation of the modification or alteration; (3) Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals;...
  • Page 12 S A F E T Y I N F O R M AT I O N 6.7 Lighting for Operating Area The user, in accordance with his responsibility to survey the environment and operating conditions, shall determine if the carrier requires lights and, if so, shall equip the carrier with appropriate lights. 6.8 Control of Noxious Gases and Fumes When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be main- tained within limits specified in the American Conference of Governmental Industrial Hygienists publication,:Threshold...
  • Page 13 S A F E T Y I N F O R M AT I O N Read and follow operators’ manual 7.3.1.1 Do not operate carrier under the influence of drugs and alcohol. 7.3.1.2 Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger other persons. 7.3.1.3 Riding on the carrier by persons other than the operator is authorized only on personnel seat(s) provided by 7.3.1.4...
  • Page 14 S A F E T Y I N F O R M AT I O N Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered, 7.3.3.2 operate with extra caution. Handle only loads within the capacity of each cargo area of the carrier as specified by the manufacturer. 7.3.3.3 Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manu- 7.3.3.4...
  • Page 15 S A F E T Y I N F O R M AT I O N k) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s rec- ommendations.

  • Page 16: 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 the ceiling of buildings necessitating proper ventilation. vehicle, we ask you to spend some time reading this Five air exchanges per hour is considered the minimum Owner’s Manual and Service Guide.

  • Page 17: Controls And Indicators

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Provide Protection From Elements Looping the DC cord through the steering wheel when charg- ing, serves as a good reminder to store the cord out of the way when finished with charging.

  • Page 18: Direction Selector

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Direction Selector (PDS only) Neutral State of Charge Meter Reverse Forward Reverse Neutral, as sho wn ef Dsl 1 Key/Light Switch Ref Kes 1...

  • Page 19: Combination Service 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 Notes, Cautions and Warnings Depressing the accelerator pedal will release the park brake if it is engaged. This is a feature to assure the vehi- cle is not driven with the park brake engaged.

  • Page 20: 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 Before operating, check to ensure no one is behind the vehicle. A loadbed warning label is affixed to the inside front of the bed (see Appendix A).

  • Page 21: Precision Drive System

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings driving on poor surfaces, such as loose dirt, All occupants must be seated. Keep entire wet grass, gravel, etc. body inside vehicle and hold on while vehi- cle is in motion S t a y i n d e s i g n a t e d a r e a s a n d a v o i d...

  • Page 22: Walk-Away Feature

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Walk-Away Feature High Pedal Disable Feature High pedal disable prevents undesired acceleration if the Walk-Away limits vehicle movement without driver input, direction selector lever is changed, or the key is turned slowing the vehicle to 2 mph (3 kph) and sounding an on while the accelerator is depressed.

  • Page 23: Starting Vehicle On A Hill

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings speeds should be limited to no more than the maximum STARTING VEHICLE ON A HILL speed on level ground (see vehicle specification). Limit speed by releasing the accelerator and applying service brake.

  • Page 24: Vehicle Cleaning And Care

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

  • Page 25: Wheels And Tires

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings caused by a broken socket when removing wheels, use only sockets designed for impact Center of wrench use.

  • Page 26: 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 For vehicles with headlights mounted in cowl, locate the anchored to floor. Wear OSHA approved safety two screws on backside of cowl that secure headlight equipment when mounting/demounting tires.

  • Page 27: Transporting 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 are available from a local Distributor, an authorized Do not attempt any type of servicing opera- Branch or the Service Parts Department.

  • Page 28: 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 applied at recommended intervals, is the best guarantee for keeping the vehicle both dependable and economical. Lift Flap on Access Panel Before any electrical service is performed on PDS model Part A and B...

  • Page 29: 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 Representa- tive or see the Repair and Service Manual for this vehicle.

  • Page 30: 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 loose or missing hardware and components HARDWARE AND FASTENERS Tighten or replace missing hardware SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables &...

  • Page 31: Rear Axle

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings vehicle should stop aggressively. The wheel brakes may or may not lock. Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched.

  • Page 32: Pds System Test

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Generally, three grades of hardware are used in the vehi- cle. Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head.

  • Page 33: 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 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 34: Battery Maintenance

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings A battery does not store electricity, but is able to produce Electrolyte Level and Water electricity as the result of a chemical reaction which The correct level of the electrolyte is 1/2"...

  • Page 35: 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 meet the requirements of the water purity table (Ref Fig. Battery Cleaning 21 on page 20). To prevent battery damage, be sure that all battery caps (if equipped) are tightly installed.

  • Page 36: Battery 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 of sodium bicarbonate (baking soda) and brush clean if Battery Replacement required. Before any electrical service is performed on PDS model vehicles, the Run-Tow/Maintenance switch must be To prevent battery explosion that could result in placed in the ‘Tow/Maintenance’...

  • Page 37: Battery Charging

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings a discharged state, sulfating takes place on and within the plates. This condition is not reversible and will cause permanent damage to the battery.

  • Page 38: Ac Voltage

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings which is accomplished by measuring the specific gravity of the electrolyte. The greater the concentration of sulfu- ric acid, the more dense the electrolyte becomes.

  • Page 39: Using A Hydrometer

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings reading of 1.254. Similarly if the temperature was 70° F (21° C), subtract four points (.004) from the Bulb 1.250 to give a corrected reading of 1.246 (Ref Fig.
  • Page 40 GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 27...
  • Page 41 GENERAL SPECIFICATIONS MODEL: ST 400 E TYPE: ELECTRIC POWERED TRUCK MODEL YEAR: 2009 Part No:. 612134 MODEL: ST 40048V TYPE: ELECTRIC POWERED TRUCK MODEL YEAR: 2009 PRODUCT SPECIFICATION Part No:. 612134 CONFIGURATION HIGHLIGHTS Precision Drive System™ (PDS): Programmable to terrain PRODUCT SPECIFICATION Solid State continuously variable seperately excited speed controller Eight, 6 Volt Deep Cycle Batteries...

  • Page 42: General Specifications

    73 in (185 cm) 65.5 in (166 cm) Rear 38 in (96.5 cm) Front 44.5 in 38.5 in (97.8 cm) (113 cm) ST 400 48V 30.5 in (77 cm) Fig. 28 Vehicle Dimensions Owner’s Manual and Service Guide Page 29...

  • Page 43: Fig. 29 Vehicle Dimensions, Incline Specifications And Turning Clearance Diameter

    RECOMMENDED MAX SIDE TILT 25% or 14 o MAX 25% or 14 o MAX TURNING CLEARANCE DIAMETER ST 400 48V 22 ft (6.7 m) Fig. 29 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter Owner’s Manual and Service Guide Page 30...

  • Page 44: Limited Warranties

    WARRANTY LIMITED WARRANTIES Page 31 Owner’s Manual and Service Guide...

  • Page 45: (U.s. And Canada)

    WARRANTY 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. Page 32 Owner’s Manual and Service Guide...

  • Page 46: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Appendix A - 1 Owner’s Manual and Service Guide...
  • Page 47 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 See Following 74443G01 Pages For See Following Pages Explanation For Explanation Of Of These These Pictograms: Pictograms:...
  • Page 48 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. MAXIMUM LOAD BED XXX kg CAPACITY WARNING USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE...
  • Page 49 LABELS AND PICTOGRAMS DO NOT CLEAN UP GASOLINE SPILLS WITH WATER EXPOSE TO FLAME BEFORE STARTING 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 50 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 51 LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD NOTE: All Pictograms may not apply to your product. Ref Pic 1-4 Appendix A - 6 Owner’s Manual and Service Guide...

  • Page 52: Declaration Of Conformity (Europe Only)

    DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Appendix B - 1 Owner’s Manual and Service Guide...
  • Page 53 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION Appendix B - 2 Owner’s Manual and Service Guide...
  • Page 54 Read and understand the following warnings before attempting Read and understand the following text and warnings before to operate the vehicle: attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. To prevent personal injury or death, observe It is virtually impossible to anticipate all possible compo- nent failures or the manner in which each component...
  • Page 55 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 This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc.