Greenlee 28809-G01 User Manual

OWNER’S MANUAL
AND SERVICE GUIDE

28809-G01

GASOLINE POWERED REFRESHMENT VEHICLE

ISSUED APRIL 2005

SAFETY

r

For any questions on material contai ned 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. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.

Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.

For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.
Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemicals known

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

BATTERIES

AND RELATED PARTS

CONTAIN LEAD

WASH HANDS

AFTER HANDLING!

WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,

chemicals known to cause cancer and reproductive harm.

Be sure that this manual remains as part of th e permanent service record should the vehicle be sold.

NOTES, CAUTIONS AND WARNINGS

Throughout this guide NOTE, CAUTION and WARNING
will be used.

A NOTE indicates a condition that should be
observed.

A CAUTION indicates a condition that
may result in damage to the vehicle.

A WARNING indicates a

! !

hazardous condition that
could result in severe

injury or death.

! !

quantities, to cause cancer, birth defects, or other
reproductive harm.

The exhaust emissions of this vehicles’ engine

complies with regulations set forth by the Envi­ronmental Protection Agency (EPA) of the United States of
America (USA) at time of manufacture. Significant fines could
result from modifications or tampering with the engine, fuel,
ignition or air intake systems.

Engine exhaust from this
product contains chemi­cals known, in certain

!

<

14

˚

25

%

DO NOT

DRIVE ACROSS

SLOPES IN

EXCESS OF 14˚

Observe these NOTES, CAUTIONS and WARNINGS;
be aware that servicing a vehicle requires mechanical
skill and a regard for conditions that could be hazardous.
Improper service or repair may damage the vehicle or

! !

compounds. Wash hands after handling.

Battery posts, terminals
and related accessories
contain lead and lead

render it unsafe.

This spark ignition system meets all require-

ments of the Canadian Interference-Causing
Equipment Regulations.

Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleu
du Canada.

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

OWNER’S MANUAL

AND SERVICE GUIDE

GASOLINE POWERED

REFRESHMENT VEHICLE

REFRESHER® 1200

Starting Model Year 2004

E-Z-GO Division of TEXTRON, Inc. reserves the right to make de sign ch an ges witho u t ob ligation to mak e th es e cha nge s on units pr ev io us ly s old an d t he in fo r­mation contained in this manual is sub ject to change without notice.

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.

TO CONTACT US
NORTH AMERICA:

TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]

INTERNATIONAL:
PHONE: [phone], FAX: [phone]

E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Owner’s Manual and Service Guide

Page i

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.

Overfilling battery may void the warranty.

Tampering with or adjusting the governor to permit vehicle to operate at above factory

specifications will void the vehicle warranty.

When servicing engines, all adjustments and replacement component s must be per original

vehicle specifications in order to maintain the United States of America Federal and State

emission certification applicable at the time of manufacture.

BATTERY PROLONGED STORAGE

All batteries will self discharge over time. The rate of self discharge varies depending on the

ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls

below -75° F (-60° C).

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Owner’s Manual and Service Guide

TABLE OF CONTENTS

SAFETY ................................................................................................................ inside covers

GENERAL INFORMATION ...................................... ... ... ... ... .... ... ....................................... ... ... . ii

SAFETY INFORMATION ......................................................................................................... vii

REFRESHMENT UNIT ...............................................................................................................1

MOUNT VENDING UNIT TO REFRESHMENT VEHICLE ..................................................................................1

FRONT STRUT INSTALLATION ........................................................................................................................1

WINDSHIELD AND MIRROR INSTALLATION ...................................................................................................1

Fig. 1 Mounting the Refreshment Unit ......................................................................................2

CANOPY FRAME INSTALLATION ....................................................................................................................2

CANOPY INSTALLATION ...................................................................................................................................2

DRAIN VALVE INSTALLATION ..........................................................................................................................2

REFRESHMENT UNIT REMOVAL .....................................................................................................................2

REFRESHMENT UNIT OPERATION, MAINTENANCE AND CLEANING ..........................................................3

REFRESHMENT UNIT REPLACEMENT PARTS ...............................................................................................5

BEFORE INITIAL USE ..............................................................................................................5

CONTROLS AND INDICATORS ............................................................................................... 5

KEY/LIGHT SWITCH ...........................................................................................................................................6

DIRECTION SELECTOR .....................................................................................................................................6

CHOKE ................................................................................................................................................................6

FUEL GAUGE ......................................................................................................................................................6

LOW OIL PRESSURE INDICATOR LIGHT .........................................................................................................6

ACCELERATOR PEDAL .....................................................................................................................................7

COMBINATION SERVICE AND PARK BRAKE PEDAL......................................................................................7

FRONT DISC BRAKES (OPTIONAL) ..................................................................................................................7

HORN ..................................................................................................................................................................7

OPERATING THE VEHICLE ..................................................................................................... 7

RUN-IN ................................................................................................................................................................8

COLD STARTING ................................................................................................................................................8

STARTING AND DRIVING ..................................................................................................................................8

STARTING THE VEHICLE ON A HILL ................................................................................................................9

COASTING ..........................................................................................................................................................9

FUEL ....................................................................................................................................................................9

BATTERY ............................................................................................................................................................9

LABELS AND PICTOGRAMS ...........................................................................................................................10

SUN TOP AND WINDSHIELD ...........................................................................................................................10

12 VOLT POWER OUTLET ...............................................................................................................................10

TOWING A TRAILER ........................................................................................................................................10

VEHICLE CLEANING AND CARE .......................................................................................... 10

VEHICLE CLEANING ........................................................................................................................................10

REPAIR ................................. .................................................... ............................................... 11

LIFTING THE VEHICLE ....................................................................................................................................11

Fig. 2 Front Strut, Windshield and Mirror Installation ................................................................3

Operation ................................................................................................................................................3

Cleaning ..................................................................................................................................................3

Fig. 3 Canopy Installation .........................................................................................................4

Fig. 4 Emptying Water from Bins ..............................................................................................5

Maintenance ...........................................................................................................................................5

Fig. 5 Initial Service Chart .........................................................................................................5

Fig. 6 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge ............................................6

Fig. 7 Direction Selector ...........................................................................................................6

Fig. 8 Choke .............................................................................................................................6

Fig. 9 Accelerator and Brake Controls ......................................................................................7

Fig. 10 Horn Button ...................................................................................................................7

Fig. 11 Check Oil Level on Dipstick ..........................................................................................8

Fig. 12 Fueling ..........................................................................................................................9

Fig. 13 12 Volt Power Outlet ...................................................................................................10

Fig. 14 Lifting the Vehicle .......................................................................................................11

Owner’s Manual and Service Guide

Page iii

TABLE OF CONTENTS

WHEELS AND TIRES ....................................................................................................................................... 12

Tire Repair ........................................................................................................................................... 12

Wheel Installation ................................................................................................................................. 12

Fig. 15 Wheel Installation ....................................................................................................... 12

LIGHT BULB REPLACEMENT ......................................................................................................................... 13

FUSE REPLACEMENT .................................................................................................................................... 13

VEHICLE WITH A DISCHARGED BATTERY ................................................................................................... 13

TRANSPORTING VEHICLE ....................................................................................................14

TOWING ........................................................................................................................................................... 14

NEUTRAL LOCK .............................................................. ..................... .................... ....................................... 14

HAULING .......................................................................................................................................................... 14

SERVICE AND MAINTENANCE ..............................................................................................15

SERIAL NUMBER LABEL LOCATION ............................................................................................................. 15

PERIODIC SERVICE SCHEDULE .................................................................................................................. 16

TIRE INSPECTION ........................................................................................................................................... 18

CHECKING THE OIL LEVEL ............................................................................................................................ 18

CHANGING THE OIL ........................................................................................................................................ 18

STARTER/GENERATOR BELT TENSION ....................................................................................................... 20

BATTERY CLEANING ...................................................................................................................................... 21

BRAKES ........................................................................................................................................................... 21

Hydraulic Front Disc Brakes ............................................................................................................................. 22

AIR INTAKE AND COOLING FINS=- ............................................................................................................... 23

REAR AXLE ...................................................................................................................................................... 23

AIR CLEANER INSPECTION AND REPLACEMENT ....................................................................................... 23

LUBRICATION .................................................................................................................................................. 24

SPARK PLUGS ................................................................................................................................................. 24

PROLONGED STORAGE ................................................................................................................................ 24

HARDWARE ..................................................................................................................................................... 25

CAPACITIES AND REPLACEMENT PARTS.................................................................................................... 26

GENERAL SPECIFICATIONS..................................................................................................27

Fig. 16 Headlight and Turn Signal Bulb Replacement ............................................................ 13

Fig. 17 Tail and Brake Light Bulb Replacement ..................................................................... 13

Fig. 18 Neutral Lock ............................................................................................................... 14

Fig. 19 Periodic Service Schedule ......................................................................................... 16

Fig. 20 Clean Entire Dipstick .................................................................................................. 18

Fig. 21 Check Oil Level on Dipstick ....................................................................................... 18

Fig. 22 Oil Viscosity Chart ...................................................................................................... 19

Fig. 23 Clean Top of Engine .................................................................................................. 19

Fig. 24 Remove Oil Filter ....................................................................................................... 19

Fig. 25 Clean Oil Filter ........................................................................................................... 19

Fig. 26 Blowing Out Oil Filter ................................................................................................. 19

Fig. 27 Add Engine Oil ........................................................................................................... 20

Fig. 28 Checking Belt Tension with Gauge ............................................................................ 20

Fig. 29 Checking Belt Tension Manually ................................................................................ 20

Adjusting the Belt ................................................................................................................................. 21

Fig. 30 Adjusting Belt Tension ............................................................................................... 21

Fig. 31 Preparing Acid Neutralizing Solution .......................................................................... 21

Fig. 32 Typical Brake Performance Test ................................................................................ 22

Periodic Brake Test for Mechanical Brakes ......................................................................................... 22

Fig. 33 Cleaning Air Intake ..................................................................................................... 23

Fig. 34 Cleaning the Cooling Fins .......................................................................................... 23

Fig. 35 Add, Check and Drain Rear Axle Lubricant ............................................................... 23

Checking the Lubricant Level ............................................................................................................... 23

Canister Type Air Cleaner .................................................................................................................... 23

Cleaning the Air Filter Element ............................................................................................................ 23

Fig. 36 Canister Type Air Cleaner .......................................................................................... 24

Fig. 37 Lubrication Points ....................................................................................................... 24

Fig. 38 Torque Specifications .................................................................................................25

Fig. 39 Capacities and Replacement Parts ............................................................................ 26

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Owner’s Manual and Service Guide

TABLE OF CONTENTS

REFRESHER® 1200...........................................................................................................................................28

Fig. 40 Vehicle Dimensions.....................................................................................................29

Fig. 41 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter ............30

LIMITED WARRANTIES........................................................................................................... 31

DOMESTIC WARRANTY...................................................................................................................................32

INTERNATIONAL WARRANTY (2004)..............................................................................................................33

FEDERAL EMISSION COMPONENT DEFECT WARRANTY...........................................................................35

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT.....................................................................37

DECLARATION OF CONFORMITY (EUROPE ONLY)............................................................ 41

LABELS AND PICTOGRAMS.................................................................................. Appendix A

Owner’s Manual and Service Guide

Page v

TABLE OF CONTENTS

Page vi

Owner’s Manual and Service Guide

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. To reduce the chance of personal injury or property damage, the following must be carefully observed:

Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z­GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured
vehicle is modified an any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER
FERERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of
Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer
MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for
LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the
requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the S t ate laws applicable in the
places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final
Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.

E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.

The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPER-

A TED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STA TE

REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-Z-

GO, I am directing that E-Z-GO Branch personnel, Distributo rs and Dealers advise all customers to adhere to this

SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has rea-

son to believe may be operated in personal transportation applications.

Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or

through the Internet at the website for t he U.S. Dep a rtment of Transportation - at Dockets and Reg ulation , then t o Title

49 of the Code of Federal Regulations (Transportation).

GENERAL

Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and pruden t dr ivin g pr ac tice s.

Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. The manufacturer strongly suggests that all users and maintenance personnel read this
entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein.

If you have any questions regardin g this vehicle, contact your closest representative or write to the address o n the
back cover of this publication, Attention: Product Service Department.

The manufacturer reserves the right to make design changes without obligation to make these changes on units previ­ously sold and the information contained in this manual is subject to change without notice.

The manufacturer 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.

This vehicle conforms to the current applicable standard(s) for safety and performance requirements.

Owner’s Manual and Service Guide

Page vii

SAFETY INFORMATION

These vehicles are designed a n d m anufactured 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 commu­nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi­nances.

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may

reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and
disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the
vehicle.

Vehicles that are capable of higher speeds must limit their speed to no more than the sp eed of other vehicles when
used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,
terrain and common sense.

GENERAL OPERATION

Always:

• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.

• Read and observe all warnings and operation instruction labels affixed to the vehicle.

• Follow all safety rules established in the area where the vehicle is being operated.

• Reduce speed to compensate for poor terrain or conditions.

• Apply service brake to control speed on steep grades.

• Maintain adequate distance between vehicles.

• Reduce speed in wet areas.

• Use extreme caution when approaching sharp or blind turns.

• Use extreme caution when driving over loose terrain.

• Use extreme caution in areas where pedestrians are present.

MAINTENANCE

Always:

• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.

• Ensure that repairs are performed by those that are trained and qualified to do so.

• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing
any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

• 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 cove r exposed terminals with an insulating material.

Page viii

Owner’s Manual and Service Guide

SAFETY INFORMATION

• 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.

• Support the vehicle using wheel chocks and jack stands. Never get under a vehicle that is supported by a jack. Lift
the vehicle in accordance with the manufacturer’s instructions.

• Empty the fuel tank or plug fuel hoses to prevent fuel leakage.

• Maintain the vehicle in an area away from exposed flame or perso ns who are smoking.

• Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.

• Test drive the vehicle after any rep a irs or mainten ance. All tests must be conducted in a safe area that is free of both
vehicular and pedestrian traffic.

• Replace damaged or missing warning, caution or information labels.

• Keep complete records of the maintenance history of the vehicle.

The manufacturer cannot an ticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that could result in severe
personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury,
refer the repair or maintenance to a qualified mechanic.

VENTILATION

Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.
Never fuel a vehicle in an area that is subject to flame or spar k. Pay p articular att ention to natur al gas or prop ane water

heaters and furnaces.
Never work around or operate a vehicle in an e nvironment t hat does no t ventilat e exhaust ga ses f rom the ar ea. Carb on

monoxide is a dangerous gas that can cause unconsciousne ss and is potentially lethal.

Owner’s Manual and Service Guide

Page ix

Notes:

SAFETY INFORMATION

Page x

Owner’s Manual and Service Guide

SAFETY INFORMATION

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

GENERAL

The following text is provided as recommended by part II
of American Society of Mechanical Engineers / American
National Standards Institute (ASME/ANSI) B56.8-1988.
The manufacturer strongly endorses the contents of this
specification.

PART II
FOR THE USER

4 GENERAL SAFETY PRACTICES

4.1 Introduction

4.1.1 Like other machines, carriers can cause injury

if improperly used or maintained. Part II contains broad
safety practices applicable to carrier operations. Before
operation, the user shall establish such additional spe­cific safety practices as may reasonably be required for
safe operation.

4.2 Stability

4.2.1 Experience has shown that this vehicle, which

complies with this standard, is stable when properly
operated and when operated in accordance with specific
safety rules and practices established to meet actual
operating terrain and conditions. However, improper
operation, faulty maintenance, or poor housekeeping
may contribute to a condition of instability and defeat the
purpose of the standard. Some of the conditions which
may affect stability are failure of the user to follow safety
practices; also, ground and floor conditions, grade,
speed, loading, the operation of the carrier with improper
loads, battery weight, dynamic and static forces, and the
judgement exercised by the carrier operator.

(a) The user shall train carrier operators to adhere
strictly to the operating instructions stated in this Stan­dard.

(b) The user shall survey specific operating conditions
and environment, and establish and train carrier opera­tors to comply with additional, specific safety practices.

4.3 Namepla tes, Markings, Capacity, and Modifica-

tions

4.3.1 The user shall maintain in a legible condition

all nameplates, warnings, and instructions which are
supplied by the manufacturer.

4.3.2 The user shall not perform any mod ificatio n or

addition which affects capacity or safe operation, or
make any change not in accordance with the owner’s
manual without the manufacturer’s prior written authori­zation. Where authorized modificati ons have been made,
the user shall ensure that capacity, operation, warning,
and maintenance instruction plates, tags, or decals are
changed accordingly.

4.3.3 As required under paras. 4.3.1 or 4.3.2, the
manufacturer shall be contacted to secure new name­plates, warnings, or instructions which shall then be
affixed in their proper place on the carrier.

4.4 Fuel Handling and Storage

4.4.1 The user shall supervise the storage and han-

dling of liquid fuels (when used) to be certain that it is in
accordance with appropriate paragraphs of American
National Standards Institute/National Fire Protection
Association (ANSI/NFPA) 505 and ANSI/NFPA 30.

4.4.2 Storage and handling of liquefied petroleum
gas fuels shall be in accordance with appropriate para­graphs of ANSI/NFPA 505 and ANSI/NFPA 58. If such
storage or handling is not in complia nce with these stan­dards, the user shall prevent the carrier from being used
until such storage and handling is in compliance with
these standards.

4.5 Changing and Charging Storage Batteries for

Electric Personnel and Burden Carriers

4.5.1 The user shall require battery changing and

charging facilities and procedures to be in accordance
with appropriate paragraphs of ANSI/NFPA 505.

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.

4.6 Hazardous Locations

4.6.1 The user shall determine the hazard classifi-

cation of the particular atmosphere or location in which
the carrier is to be used in accordance with ANSI/NFPA

505.

4.6.2 The user shall permit in haza rdous areas only
those carriers approved and of the type required by
ANSI/NFPA 505.

4.7 Lighting for Operating Areas

4.7.1 The user, in accordance with his responsibility

to survey the environment and operating condition s, shall
determine if the carrier requires lights and, if so, shall

Owner’s Manual and Service Guide

Page xi

SAFETY INFORMATION

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

equip the carrier with appropriate lights in accordance
with the manufacturer’s recommendations.

4.8 Control of Noxious Gases and Fumes

4.8.1 When equipment powered by internal com-

bustion engines is used in enclosed areas, the atmo­sphere shall be maintained within limits specified in the
American Conference of Governmental Industrial
Hygienists publication, “Threshold Limit Values for
Chemical Substances and Physical Agents in the Work­room Environment”. This shall be accomplished by venti­lation provided by the user, and/or the installation, use,
and proper maintenance of emission control equipment
recommended or provided by the manufacturer of the
equipment.

4.9 Warning Device(s)

4.9.1 The user shall make periodic inspections of

the carrier to be certain that the sound-producing and/or
visual device(s) are maintained in good operating condi­tion.

4.9.2 The user shall determine if operating condi­tions require the carrier to be equipped with additional
sound-producing and/or visual devices and be responsi­ble for providing and maintaining such devices, in accor­dance with the manufacturer’s recommendations.

5 OPERATING SAFETY RULES AND

PRACTICES

5.1 Personnel and Burden Carrier Operator

Qualifications

5.1.1 Only persons who are trained in the proper

operation of the carrier shall be authorized to operate the
carrier. Operators shall be qualified as to visual, auditory,
physical, and mental ability to safely operate the equip­ment according to Section 5 and all other applicable
parts of this Standard.

5.2 Personnel and Burden Carrier Operators’

Training

5.2.1 The user shall conduct an operators’ training

program.

5.2.2 Successful completion of the operators’ train­ing program shall be required by the user before opera­tion of the carrier. The program shall be presented in its
entirety to all new operators an d not con densed f or those
claiming previous experience.

5.2.3 The user should include in the operators’ train-

ing program the following:

(a) instructional material provided by the manufac-

turer;

(b) emphasis on safety of passengers, material loads,

carrier operator, and other employees;

(c) general safety rules contained within this Standard
and the additional specific rules determined by the user
in accordance with this Standard, and why they were for­mulated;

(d) introduction of equipment, control locations and
functions, and explanation of how they work when used
properly 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.

5.3 Personnel and Burden Carrier Operator

Responsibility

5.3.1 Operators shall abide by the following safety

rules and practices in paras. 5.4, 5.5, 5.6, and 5.7.

5.4 General

5.4.1 Safeguard the pedestrians at all times. Do not

drive carrier in a manner that would endanger anyone.

5.4.2 Riding on the carrier by persons other than the
operator is authorized only on personnel seat(s) provided
by the manufacturer. All parts of the body shall remain
within the plan view outline of the carrier.

5.4.3 When a carrier is to be left unattended, stop
carrier, apply the parking brake, stop the engine or turn
off power, turn off the control or ignition circuit, and
remove the key if provided. Block the wheels if machine
is on an incline.

5.4.4 A carrier is considered unattended when the
operator is 25 ft. (7.6 m) or more from the carrier which
remains in his view, or whenever the operator leaves the
carrier and it is not within his view. When the operator is
dismounted and within 25 ft. (7.6 m) of the carrier still in
his view, he still must have controls neutralized, and the
parking brake(s) set to prevent movement.

5.4.5 Maintain a safe distance from the edge of
ramps and platforms.

5.4.6 Use only approved carriers in hazardous loca­tions, as defined in the appropriate safety standards.

5.4.7 Report all accidents involving personnel,

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Owner’s Manual and Service Guide

SAFETY INFORMATION

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

building structures, and equipment.

5.4.8 Operators shall not add to, or modify, the car-

rier.

5.4.9 Carriers shall not be parked or left unattended
such that they block or obstruct fire aisles, access to
stairways, or fire equipment.

5.5 Traveling

5.5.1 Observe all traffic regulation s, incl uding autho -

rized speed limits. Under normal traffic conditions keep
to the right. Maintain a safe distance, based on speed of
travel, from a carrier or vehicle ahead; and keep the car­rier under control at all times.

5.5.2 Yield the right of way to pedestrians, ambu­lances, fire trucks, or other carriers or vehicles in emer­gency situations.

5.5.3 Do not pass another carrier or vehicle travel­ing in the same direction at intersections, blind spots, or
at other dangerous locations.

5.5.4 Keep a clear view of the path of travel,
observe other traffic and personn el, and maintain a safe
clearance.

5.5.5 Slow down or stop, as conditions dictate, and
activate the sound-producing warning device at cross
aisles and when visibility is obstructed at other locations.

5.5.6 Ascend or descend grades slowly.

5.5.7 Avoid turning, if possible, and use extreme

caution on grades, ramps, or inclines; normally travel
straight up and down.

5.5.8 Under all travel conditions the carrier shall be
operated at a speed that will permit it to be brought to a
stop in a safe manner.

5.5.9 Make starts, stops, turns, or direction rever­sals in a smooth manner so as not to shift the load,
endanger passengers, or overturn the carrier.

5.5.10 Do not indulge in dangerous activities, such as
stunt driving or horseplay.

5.5.11 Slow down when approaching, or on, wet or
slippery surfaces.

5.5.12 Do not drive carrier onto any elev ator 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. It is
advisable that all other personnel leave the elevator
before a carrier is allowed to enter or exit.

5.5.13 Avoid running over loose objects, potholes,

and bumps.

5.5.14 To negotiate turns, reduce speed to improve
stability, then turn hand steering wheel or tiller in a
smooth, sweeping motion.

5.6 Loading

5.6.1 Handle only stable and safely arranged loads.

When handling off-center loads which cannot be cen­tered, operate with extra caution.

5.6.2 Handle only loads within the capacity of the
carrier as specified on the nameplate.

5.6.3 Handle loads exceeding the dimensions used
to establish carrier capacity with extra caution. Stability
and maneuverability may be adversely affected.

5.7 Operator Care of Personnel and Burden

Carriers

5.7.1 At the beginning of each shift during which the

carrier will be used, the operator shall check the carrier
condition and inspect the tires, warning devices, lights,
battery(s), speed and directional contr ollers, brakes, and
steering mechanism. If the carrier is found to be in need
of repair, or in any way unsafe, the matter shall be
reported immediately to the designated authority and the
carrier shall not be operated until it has been restored to
safe operating condition.

5.7.2 If during operation the carrier becomes unsafe
in any way, the matter shall be reported immediately to
the designated authority, and the carrier shall not be
operated until it has been restored to safe operating con­dition.

5.7.3 Do not make repairs or adjustments unless
specifically authorized to do so.

5.7.4 The engine shall be stopped and the operator
shall leave the carrier while refueling.

5.7.5 Spillage of oil or fuel shall be carefully and
completely absorbed or evaporated and fuel tank cap
replaced before starting engine.

5.7.6 Do not operate a carrier with a leak in the fuel
system or battery(s).

5.7.7 Do not use open flam es for checking electro­lyte level in storage battery(s) or liquid level in fuel tanks.

6 MAINTENANCE PRACTICES

6.1 Introduction

Owner’s Manual and Service Guide

Page xiii

SAFETY INFORMATION

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

6.1.1 Carriers may become hazardous if mainte­nance is neglected. Therefore, maintenance facilities,
trained personnel, and procedures shall be provided.
Such facilities may be on or off the premises.

6.2 Maintenance Procedures

6.2.1 Maintenance and inspection of all carriers

shall be performed in conformance with the manufac­turer’s recommendations and the following practices.

(a) A scheduled preventive maintenance, lubrication,

and inspection system shall be followed.

(b) Only qualified and authorized personnel shall be

permitted to maintain, repair, adjust, and inspect carriers.

(c) Before undertaking maintenance or repair, follow
the manufacturer’s recommendations for immobilizing
the carrier.

(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, a nd
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.

(g) Operation to check performance of th e carr ier shall
be conducted in an authorized area where safe clear­ance exists.

(h) Before commencing operation of the carrier, follow
the manufacturer’s instructions and recommended pro­cedures.

(i) Avoid fire hazards and have fire protection equip­ment present in the work area. Do not use an open flame
to check level or leakage of fuel, battery electrolyte, or
coolant. Do not use open pans of fuel or flammable
cleaning fluids for cleaning parts.

(j) Properly ventilate the work area.

(k) Handle LP gas cylinders with care. Physical dam­age, such as dents, scrapes, or gouges, may danger­ously weaken the tank and make it unsafe for use.

(l) Brakes, steering mechanisms, speed and direc­tional control mechanisms, warning devices, lights, gov­ernors, guards, and safety devices shall be inspected
regularly and maintained in a safe operating condition.

(m) Special carriers or devices designed and
approved for hazardous area operation shall be

inspected to ensure that mainten ance preser ves th e orig­inal approved safe operating features.

(n) Fuel systems shall be checked for leaks and condi­tion of parts. If a leak is found, action shall be taken to
prevent the use of the carrier until the leak has been
eliminated.

(o) The carrier manufacturer’s capacity, operation,
and maintenance instruction plates, tags, or decals shall
be maintained in legible condition.

(p) Batteries, motors, speed and directional control­lers, limit switches, protective devices, electrical conduc­tors, and connections shall be inspected and maintained
in conformance with manufacturers recommended pro­cedures.

(q) Carriers shall be kept in a clean condition to mini­mize fire hazards and facilitate detection of loose or
defective parts.

(r) Modifications and additions which affect capacity
and safe machine operation shall not be performed by
the customer or user without manufacturer’s prior written
authorization; where authorized modifications have been
made, the user shall ensure that capacity, operation,
warning, and maintenance instruction plates, tags, or
decals are changed accordingly.

(s) Care shall be taken to ensure that all replacement
parts are interchangeable with the original parts and of a
quality at least equal to that provided in the original
equipment.

END OF ASME/ANSI B56.8 - 1988 TEXT

Page xiv

Owner’s Manual and Service Guide

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, we ask you to spend some time reading this
Owner’s Manual and Service Guide. This guide contains
the information that will assist you in maintaining this
highly reliable vehicle. Some illustrations may show
items that are optional for your vehicle. This guid e covers
the operation of several vehicles; therefore, some picto­rial views may not represent your vehicle. Physical differ­ences in controls will be illustrated.

This vehicle has been designed and manu factured as a
‘World Vehicle’. Some countries have individual require­ments to comply with their specifications; therefore,
some sections may not apply in your country.

Most of the service procedures in this guide can be
accomplished using common automotive hand tools.
Contact your service representative on servicing the
vehicle in accordance with the Periodic Service Sched­ule.

Service Parts Manuals and Technician’s Repair and Ser­vice Manuals are available from a local Distributor, an
authorized Branch or the Service Parts Department.
When ordering parts or requesting information for your
vehicle, provide vehicle model, serial number and manu­facture code.

REFRESHMENT UNIT

The vending unit is equipped with two beverage compart­ments, a cold storage compartment, a consumable ice
compartment, a food display cabinet, two cup dispensers
and a trash bin. Available accessories are listed in illus­tration (Ref. Fig. 1 on page 2).

Tool List Qty. Required

Ratchet, 3/8" drive....................................................... 1

Socket, 1/2", 3/8" drive................................................ 1

Wrench, 1/2" ............................................................... 1

Phillips screwdriver ..................................................... 1

Wrench, 7/16" ............................................................. 1

Drill.............................................................................. 1

Socket adapter, 1/4" drive........................................... 1

Socket, 5/16", 1/4" drive...................... .... .................... 1

MOUNT VENDING UNIT TO REFRESHMENT
VEHICLE

The vending unit is

! !

procedures must be used when installing unit to
reduce the possibility of severe injury and/or damage

heavy. Care and proper
lifting equipment and

to the unit. Be sure hands and fingers are clear of unit
while placing unit on frame.

The refreshment unit is shipped on a palle t. While re sting
on pallet, the unit should be handled with a forklift. If a
forklift is not available, be sure an adequate number of
assistants are available to safely lift the vending unit.

Orient vending unit so that door on unit will be facing the
rear of the vehicle when unit is placed on the mounting
frame (Ref. Fig. 1 on page 2). Using a forklift, lift the
refreshment unit and pallet level with the bed of refresh­ment vehicle. Lift the refreshme nt unit of f of th e palle t and
carefully place it onto the mounting frame on vehicle.
Align the four mounting holes on refreshment unit with
corresponding holes on vehicle mount ing frame. Secure
unit to frame with four 5/16 - 18 X 1 1/4" bolts (item 1),
eight 5/16" flat washers (item 2) and fo ur 5/16 - 18 lock
nuts (item 3). Tighten hardware firmly.

FRONT STRUT INSTALLATION

Position front strut (item 4) and braces (item 5) as shown
(Ref. Fig. 2 on page 3) and secure to vehicle at each side
of the cowl with four 5/16 - 18 X 2 1/2" bolts (item 6), four
5/16" lock washers (item 7), two spacers (item 8) and six
3/8" flat washers (item 9). Secure top of braces with two
5/16 - 18 X 2 1/4" bolts (it em 10 ), fo ur 5/ 16" lock washe rs
(item 11) and two 5/16 - 18 lock nuts (item 12). Attach
canopy frame mounting plate (item 13) to front strut
using two 1/4 - 20 X 1 1/2" bolts (item 14), four 1/4" flat
washers (item 15) and two 1/4 - 20 lock nuts (item 16) as
shown. Tighten hardware firmly.

WINDSHIELD AND MIRROR INSTALLATION

! !

Typical operation of a
Refresher

®

vehicle on a

golf course may expose
operator to possibility of being struck by a golf ball.
Always operate vehicle with windshield in place.

Insert two bumpers (item 17) and four grommets (item

18) into holes in windshield (item 19) as sh ow n (Ref. Fig.
2 on page 3). Position windshield and mirror brackets
(item 20) as shown. Secure windshield and mirror brack­ets to front strut with four 1/4 - 20 X 1 3/4" b olt s (ite m 21),
four spacers (item 22), four 1/4" washers (item 23) and
four 1/4 - 20 lock nuts (item 24). Tighten hardware firmly.
Thread mirrors (item 25) onto mirror brackets and tighten
securely.

Owner’s Manual and Service Guide

Page 1

OPERATION AND SERVICE INFORMATION

)

A
A

S
C
B
M
H
C
C

R

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

vailable Refreshment Unit
ccessories Include:

ign Boards
ondiment T r ay
ottle Caddy

ini Bottle Carrier
umidor
redit Card Machine Mount
ash Drawer

1

2

Consumable Ice

(This Compartment Only

ef Rfi 1

Fig. 1 Mounting the Refreshment Unit

CANOPY FRAME INSTALLATION

Orient the two canopy frame section s en d to en d a ligni ng
five existing mounting holes as shown (Ref. Fig. 3 on
page 4) and fasten together with five 1/4 - 20 X 2" bolts
(item 26), ten 1/4" flat washers (item 27) and five 1/4 - 20
lock nuts (item 28). Orient the assembled canopy frame
as shown and rest front of frame on top m ounting plate
and rear of frame on refreshment unit st ruts. Secure can­opy frame to refreshment unit struts with two 1/4 - 20 X 1
1/4" bolts (item 29), four 1/4" flat washers (item 30) and
two 1/4 - 20 lock nuts (item 31) as shown. Secure canopy
frame to front strut with two 1/4 - 20 X 2" bolts (item 32),
four 1/4" flat washers (item 33) and two 1/4 - 2 0 lock nuts
(item 34) as shown. Tighten hardware firmly.

CANOPY INSTALLA TION

Wipe canopy frame with a clean cloth. Unfold canopy

Secure each mounting flap to inner surface of canopy
frame with #10 X 1/2" self tapping screws (item 35)
evenly spaced approximately 9" apart as shown. To pre­vent “gathering” of canopy material during installation,
use the aid of assistants to hold the canopy taut while
securing to canopy frame. For best results, begin secur­ing the canopy at the middle of each side and proceed to
each end of frame.

DRAIN VALVE INSTALLATION

Locate the drain hose ends and drain valve mounting
holes under the rear of unit. Orient each drain valve
assembly with spigot facing rearward. Attach each valve
assembly to unit with two 1/4 - 20 X 3/4" scre ws. Slide
the hose clamps onto the end of each drain hose. Push
the hose ends onto the drain valves and tighten clamps.

REFRESHMENT UNIT REMOVAL

and locate clearance openings in the mounting flap.
Drape canopy over frame and orient canopy on frame so
that clearance openings match strut attachment points
and canopy frame juncture (Ref. Fig. 3 on page 4). With
the aid of assistants, pull canopy t a ut over canopy fr ame .
Fold mounting flap up inside canopy frame as shown.

! !

procedures must be used when removing unit to
reduce the possibility of severe injury and/or damage

The vending unit is
heavy. Care and proper
lifting equipment and

Page 2

Owner’s Manual and Service Guide

OPERATION AND SERVICE INFORMATION

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

14

15

19

15

16

12

11

10

6

Ref Rfi 2

5

7

9

8

Fig. 2 Front Strut, Windshield and Mirror Installation

to the unit. Be sure hands and fingers are clear of unit
while lowering.

the unit is removed from pallet and placed directly onto a flat
surface. Remove drain valves from refreshment unit before
removing unit.

Refreshment unit removal is the reverse order of installa­tion. The unit should be lifted onto a pallet being careful
not to damage drains and then handle d with a forklift. If a
forklift is not available, be sure an adequate number of
assistants are available to safely lift the vending unit and
pallet.

REFRESHMENT UNIT OPERATION, MAIN­TENANCE AND CLEANING

Operation

! !

Clean this compartment and the driver side drain
valve before and after each use to reduce the possible
contamination of consumable ice.

13

21

23

18

22

4

17

20

18

9

The drain valves protrude below the
frame of the unit and can be damaged if

Consumable ice must be
stored in the rear driver
side compartment only.

24

25

Canned Beverage Compartments - The canned bever­age compartments are designed to carry canned bever­ages and cooling ice. Cold snacks (sandwiches, fruit,
candy etc.) can also be served from these compartments
by inserting the product into a plastic food con tainer. Pre­cooling the canned beverages will minimize the amount
of ice required to keep the product cool. Maintaining ice
in the canned beverage compartment when the cont a iner
is not in service will help to maintain a colder temperature
when the unit is put back into service.

Consumable Ice Compartment - The consumable ice
compartment, located in the rear driver side of the bever­age container is to be used for consumable ice only (Ref.
Fig. 1 on page 2). This compartment is equipped with it's
own drain per FDA requirements and should not be used
for canned goods or other products.

Trash Compartment - The trash compartment is located
in the rear of the vehicle. The aluminum trash bin should
be lined with a disposable plastic bag to maintain cleanli­ness. The trash bin is removable from the rear door only.

Drains - The two spigot valves, located under the rear of
the beverage container, drain the compartments. To open
the valves, simply turn the valve han dles away from the
vehicle (Ref. Fig. 4 on page 5). To close the valves, turn
the valve handles to a position parallel with the vehicle. It
is recommended that the valves be left in an open posi­tion while the vehicle is in service.

Cup Dispensers - The cup dispensers are designed to
carry cups ranging from 14 to 20 ounces. To adjust the
cup dispenser for your size and type of cup, remove the
outer collar, insert a sleeve of cups into the dispenser,
and turn the adjusting screw until the cups are securely
held in the cup dispenser. Re-install the outer collar.

Shelves are to be used for any type of dry good such as
chips, peanuts, hats, golf balls etc.

Air Pot - The three one gallon Air Pots are for serving hot
or cold beverages.

Cleaning

Interior Aluminum Surfaces - The interior surfaces

should be cleaned on a daily basis using a soap and
water solution. Thoroughly rinse after cleaning.

Exterior Painted Surfaces - The painted surfaces
should be cleaned on a daily basis using a soap and
water solution.

Exterior Aluminum Surfaces - The aluminum surfaces
should also be cleaned on a daily basis using a soap and
water solution. Periodic cleaning with an aluminum or

Owner’s Manual and Service Guide

Page 3

OPERATION AND SERVICE INFORMATION

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Canopy
Frame

20

21

24

Mounting
Flap

22

21

Top Mounting
Plate

Front Strut

21
22

21

20

22

21

21

23

ID Plate
(Inside)

Page 4

Ref Rfi 3

Fig. 3 Canopy Installation

Owner’s Manual and Service Guide