WELCOME
The following information is needed when contacting us concerning service or parts for your vehicle:
Vehicle Model: ___________________________________________________________
PIN or Serial Number: _________________________________________________
Manufacture Date Code: ___________________________________________________
CALIFORNIA Proposition 65
Operating, servicing and maintaining a passenger vehicle or off-road vehicle
can expose you to chemicals including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the State of California to cause
cancer and birth defects or other reproductive harm. To minimize exposure,
avoid breathing exhaust, do not idle the engine except as necessary, service
your vehicle in a well-ventilated area and wear gloves or wash your hands
frequently when servicing your vehicle. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.
WELCOME
Thank you for purchasing a TEXTRON OFF ROAD vehicle. Before driving your new vehicle, read this owner’s manual to familiarize yourself with safe driving
practices, operation, features and controls.
Visit us online at www.textronoffroad.com for the latest news, new product information, career opportunities and more.
This manual contains instructions for minor maintenance only. Information about major repairs can be found in the TEXTRON OFF ROAD repair manual.
Your TEXTRON OFF ROAD dealer has thorough knowledge of your vehicle and wants your total satisfaction with your purchase. We recommend you return
to your dealership for all of your service needs during, and after the warranty period.
Repair or replacement parts can be purchased at your TEXTRON OFF ROAD dealer or through the manufacturer’s parts and accessories department.
To locate your nearest dealer,
call 1-888-438-3946 or
visit www.textronoffroad.com
TEXTRON SPECIALIZED VEHICLES
1451 Marvin Griffin Rd.
Augusta, GA 30906 USA
All information in this owner’s manual is based on the latest product information at the time of publication. Due to constant improvements in the design
and quality of production components, some discrepancies may be found between your vehicle and the information presented in this publication. The content in this publication is intended for reference use only. The manufacturer is not liable for omissions or inaccuracies. Any reprinting or reuse of the content in this publication, whether whole or in part, is expressly prohibited.
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
specifications. Such modifications can cause serious personal injury or death. Textron Off Road prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Textron Off Road reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes
on units sold previously.
The information contained in this manual may be revised periodically by Textron Off Road, and therefore is subject to change without notice.
TEXTRON OFF ROAD DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND
CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this manual.
TABLE OF CONTENTS
INTRODUCTION
MANUFACTURER’S INTENDED USE ..................................................................................................................... 4
WARRANTY AND REGISTRATION ......................................................................................................................... 4
VEHICLE IDENTIFICATION NUMBERS ................................................................................................................. 5
REPAIR AND PARTS MANUALS ............................................................................................................................. 5
SAFETY
SAFETY LABELS ...................................................................................................................................................... 7
Operator Warning (P/N 665178) ....................................................................................................................... 7
Battery Warning (P/N 640561) ..........................................................................................................................7
Rear Passenger Safety Warning (P/N 628943) ................................................................................................ 7
Load Deck Warning (P/N 630398) .................................................................................................................... 8
SEAT BELTS ............................................................................................................................................................8
MAXIMUM CARGO LOAD / MAXIMUM WEIGHT CAPACITY ................................................................................. 8
TIRE PRESSURE ..................................................................................................................................................... 8
OPERATOR SAFETY ............................................................................................................................................... 8
Unauthorized Use ............................................................................................................................................. 9
Operating without Instruction ............................................................................................................................ 9
Alcohol or Drugs ............................................................................................................................................... 9
Seat Belts .......................................................................................................................................................... 9
Passenger ......................................................................................................................................................... 9
BEFORE OPERATING ............................................................................................................................................. 9
Load Operation ............................................................................................................................................... 10
Driving in Reverse ........................................................................................................................................... 10
Driving a Damaged Vehicle ............................................................................................................................ 10
Driving at High Speeds ................................................................................................................................... 10
Driving on Pavement ....................................................................................................................................... 10
Driving on Public Roads .................................................................................................................................. 10
Turning ............................................................................................................................................................ 10
Jumps and Stunts ........................................................................................................................................... 10
Unfamiliar Terrain ........................................................................................................................................... 10
Obstacles ........................................................................................................................................................ 10
Climbing Hills .................................................................................................................................................. 10
Driving Downhill .............................................................................................................................................. 10
Stalling on a Hill .............................................................................................................................................. 10
Parking on a Hill ..............................................................................................................................................10
Tires ................................................................................................................................................................ 10
Slippery Terrain ............................................................................................................................................... 11
Driving on Ice .................................................................................................................................................. 11
Vehicle Lifting .................................................................................................................................................. 11
Vehicle Modification ........................................................................................................................................ 11
FEATURES AND CONTROLS
GENERAL INFORMATION ..................................................................................................................................... 13
Key Switch / Direction Selector .......................................................................................................................13
State of Charge Meter ..................................................................................................................................... 13
Light Switch ..................................................................................................................................................... 13
Max Speed / Range Switch ............................................................................................................................. 13
Auxiliary Switch Positions ............................................................................................................................... 13
12 Volt Power Outlet ....................................................................................................................................... 13
Cupholder ....................................................................................................................................................... 13
Accelerator Pedal ............................................................................................................................................ 14
Brake Pedal .................................................................................................................................................... 14
Charger Receptacle ........................................................................................................................................ 14
1
TABLE OF CONTENTS
Taillights .......................................................................................................................................................... 14
Side Nets ........................................................................................................................................................ 14
Seat Belts ........................................................................................................................................................ 14
Rear Seat / Load Deck .................................................................................................................................... 14
OPS / Top / Windshield ................................................................................................................................... 14
OPERATION
SAFETY .................................................................................................................................................................. 15
BEFORE INITIAL USE ............................................................................................................................................ 15
Initial Service Chart .........................................................................................................................................16
PRE - RIDE INSPECTION ...................................................................................................................................... 16
PORTABLE CHARGER .......................................................................................................................................... 16
USING THE CHARGER .......................................................................................................................................... 17
OPERATING THE VEHICLE ..................................................................................................................................17
Key Switch Operation ..................................................................................................................................... 18
Park Brake Release Switch ............................................................................................................................ 18
Emergency Park Brake Release .....................................................................................................................18
Max Speed / Range Switch ............................................................................................................................. 18
Light Switch Operation ....................................................................................................................................19
Brake Operation ..............................................................................................................................................19
Accelerator Operation ..................................................................................................................................... 19
Seat Belt Operation ......................................................................................................................................... 19
Common Sense Operation ............................................................................................................................. 19
Environmental Concerns ................................................................................................................................. 20
Starting and Driving ......................................................................................................................................... 20
Starting the Vehicle on a Hill ...........................................................................................................................20
Coasting .......................................................................................................................................................... 20
Towing a Trailer .............................................................................................................................................. 20
Terrain ............................................................................................................................................................. 20
Rear Facing Seat/Load Deck ..........................................................................................................................20
Winch Operation ............................................................................................................................................. 21
Winch Application ........................................................................................................................................... 21
MAINTENANCE
VEHICLE CLEANING AND CARE .......................................................................................................................... 23
Routine Maintenance ...................................................................................................................................... 23
LIFTING THE VEHICLE .......................................................................................................................................... 24
Lift Entire Vehicle 24
Lift Front of Vehicle 24
Lift Rear of Vehicle. 25
Lower Vehicle 25
LIGHT BULB REPLACEMENT ............................................................................................................................... 25
Headlight Bulb 25
Taillight Bulb 25
WHEELS AND TIRES ............................................................................................................................................. 25
Tire Repair 25
Wheel Installation 25
Unidirectional Tires 26
Wheel Alignment .............................................................................................................................................26
BRAKES .................................................................................................................................................................. 26
Master Cylinder ...............................................................................................................................................27
Bleeding Brakes ..............................................................................................................................................27
POWERTRAIN ........................................................................................................................................................ 28
Axles ............................................................................................................................................................... 28
Front and Rear Axles ...................................................................................................................................... 28
2
TABLE OF CONTENTS
Checking the Lubricant Level .......................................................................................................................... 28
BATTERY CHARGING AND MAINTENANCE .......................................................................................................29
Battery Safety 29
Battery Disposal 29
Battery 29
Battery Maintenance 29
At Each Charging Cycle 29
Monthly 29
Temperature Affects Battery Capacity 30
Electrolyte Level and Water 30
Cleaning Batteries 31
Clean batteries: ...............................................................................................................................................32
Battery Removal and Installation 32
Prolonged Storage 33
Battery Charging 33
Battery Troubleshooting ..................................................................................................................................33
Hydrometer . ................................................................................................................................................... 34
Using A Hydrometer 35
HARDWARE ........................................................................................................................................................... 36
SPECIFICATIONS
SPECIFICATIONS CHART ..................................................................................................................................... 37
MAINTENANCE LOG
MAINTENANCE LOG .............................................................................................................................................39
3
INTRODUCTION
INTRODUCTION
The PROWLER EV is an off road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
The following symbols appear throughout this manual and on your vehicle. Your safety is involved when these symbols are used. Become familiar with their
meanings before reading the manual.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
The PROHIBITION SAFETY SIGN indicates an action NOT to take in order to avoid hazard.
The MANDATORY ACTION SIGN indicates an action that NEEDS to be taken to avoid a hazard.
Failure to comply with the warnings in this manual can result in severe injury or death.
Read this entire manual carefully before operating this vehicle. Do not attempt to operate this vehicle until you have thorough knowledge of the controls and features.
Regular inspections and maintenance, along with good operating techniques, will help ensure your safe enjoyment of the capabilities and reliability of this vehicle.
Manufacturer’s Intended Use
• The TEXTRON OFF ROAD PROWLER EV is designed and manufactured for off road use only. Use on public streets, roads or highways is illegal in most
areas and increases the risk of an accident involving other vehicles and people. This vehicle does not meet FMVSS (Federal Motor Vehicle Safety Standards) for public street, road or highway use.
• Check all laws and regulations before choosing an area to operate the PROWLER EV .
Warranty and Registration
The PROWLER EV includes product warranties. All information, including coverage, limitations, exclusions and how to obtain warranty service is included in
the literature package with the purchase of the vehicle. It can also be found at textronoffroad.com.
Registration of the vehicle will be done by the dealer at the time of purchase.
4
Vehicle Identification Numbers
INTRODUCTION
Front of Vehicle
Seat Wrap
PIN Plate
Serial Number
Part A
Serial Number
Part B
PIN Label
Bumper
Key Number
Record the vehicle identification numbers and key number (on the key) in the spaces provided below.
Remove the spare key and store it in a safe place. An ignition key can be duplicated only if the key number is provided. If all keys are lost and the key
number is unknown, the ignition switch must be replaced.
The information below is required when ordering parts from TEXTRON OFF ROAD.
Vehicle Model Number: _________________________________________________________________
Frame PIN: __________________________________________________________________________
Key Number: _________________________________________________________________________
Repair and Parts Manuals
The following manuals can be purchased through a TEXTRON OFF ROAD dealer:
• repair manual
• parts manual
5
INTRODUCTION
6
SAFETY
SAFETY
Safety Labels
Safety and warning labels are on the vehicle for your protection. Read and comply with the instructions on the labels. If any label shown in this manual is different from the label on your vehicle, always follow the instructions on the vehicle label.
If a label comes off or becomes illegible, contact your TEXTRON OFF ROAD dealer to get a replacement. Replacement safety labels are available at no
charge to you. The part number is provided in this manual, printed on the label, or can be provided by your dealer.
Operator Warning (P/N 665178)
Located on the dash to the left of the steering column.
www.textronoffroad.com
cm
MIN 150
665178
Battery Warning (P/N 640561)
Located on the battery hold down.
LEAD
640561
RETURN
RECYCLE
Rear Passenger Safety Warning (P/N 628943)
Rear passenger safety label located on the armrest of the rear seat.
7
SAFETY
Load Deck Warning (P/N 630398)
Located on the underside of the rear seat bottom/load deck.
Failure to follow these instructions could
Maximum deck load is 400 lbs. (181 kg)
The center of gravity of the load must not exceed 12 inches (30 cm) above the deck floor.
The load must be as far forward as possible and secured.
Top heavy loads may cause vehicle instability or tip over.
Drive slowly straight up or down slopes and in turns.
NEVER allow passengers to ride on load deck.
Seat Belts
Operating the vehicle while not wearing the seat belt increases the risk of serious injury or death in the event of rollover, loss of control, or sudden stopping.
All riders must wear seat belts at all times.
result in DEATH or SERIOUS INJURY
630398
Maximum Cargo Load / Maximum Weight Capacity
Exceeding the weight capacities can cause loss of vehicle control and possible injury or death.
Maximum Cargo Load (Flip Seat Load Deck) 400 lbs. (181 kg)
Maximum Vehicle Weight Capacity 940 lbs. (426 kg)
• Do not exceed the maximum cargo load for any area of the vehicle.
• Do not exceed the maximum vehicle weight capacity (includes weight of operator, passengers, cargo and accessories).
Tire Pressure
Improper tire pressure or uneven tire pressure can cause loss of vehicle control and possible injury or death.
Maintaining correct tire inflation pressure is essential for safe vehicle operation. Correct tire pressure for the front and rear tires is 12 psi (83 kPa).
Operator Safety
Safe and responsible use of this vehicle is necessary to prevent dangerous conditions for the operator, passengers and other people in the area of operation. This section of the manual provides information on the safe operation of the vehicle. Make sure you read, understand and comply with all of this information to decrease the risk of personal injury or death.
Serious injury or death can occur if you do not follow the instructions and procedures shown in this owner’s manual.
• Read this entire manual and all product labels carefully. Follow the safety information and operating procedures described.
• Do not carry a passenger until you have a minimum of two hours driving experience on this vehicle.
• Keep feet, legs, hands and arms inside the vehicle at all times.
• The driver must keep both hands on the steering wheel and both feet on the floor or pedals.
• Inspect the vehicle before each use to make sure it is in safe operating condition. Perform the pre-ride inspection described in this manual. See page 16.
• Always have the vehicle checked by an authorized dealer after an accident.
• Always turn the key to the OFF position and remove before you leave the vehicle.
• Remove the key when the vehicle is not in use to prevent accidental operation, unauthorized use by someone without a driver’s license and proper training.
Additional information about safety is included throughout this manual or can be obtained from your local TEXTRON OFF ROAD dealer.
Failure to operate the PROWLER EV as instructed can cause collision, loss of control or rollover resulting in severe injury or
death. Follow all safety warnings in this section of the owner’s manual. See the OPERATION section of the owner’s manual
for operating procedures and additional safety information.
8
SAFETY
Unauthorized Use
This vehicle is for adult use only. Any person who does not have a valid driver’s license is not permitted to operate the vehicle.
Leaving the keys in the key switch allows unauthorized use of the vehicle by an unlicensed driver. Always remove the key when the vehicle is not in oper-
ation.
Operating without Instruction
Operation of this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the
vehicle correctly in different situations and on different types of terrain.
All operators must read, understand and comply with the owner’s manual and all warning and instruction labels before operating the vehicle.
Alcohol or Drugs
Operation of the vehicle during or after consuming alcohol or drugs can adversely affect operator judgment, reaction time, balance and
perception.
Never drink alcohol or use drugs or medications before or during operation of the vehicle.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of vehicle control, accident or sudden stop. Seat belts can decrease the severity of injury in these circumstances.
The operator and passengers must wear seat belts at all times.
Passenger
Children may need assistance to remain properly seated with seat belt fastened.
Keep arms, hands, legs and feet inside the vehicle at all times.
Before Operating
Perform the Pre - Ride Inspection on page 16 before each use to make sure the vehicle is in safe operating condition. Failure to inspect and confirm that
the vehicle is safe to operate increases the risk of an accident.
Follow all inspection and maintenance procedures and schedules described in this owner’s manual. See Routine Maintenance on page 23.
9
SAFETY
Load Operation
The weight of cargo and occupants affects vehicle operation. Carefully calculate how the vehicle is loaded and how to safely operate it. Follow the instructions in this manual for loading, tire pressure, and speed.
Do not exceed weight capacities specified for your vehicle. Capacities are listed in Maximum Cargo Load / Maximum Weight Capacity on page 8 of this man-
ual, and also on the label affixed to the load deck. As passenger weight increases, cargo weight needs to be adjusted to ensure the maximum vehicle weight
capacity is not exceeded.
See Tire Pressure on page 8 for pressure specifications.
Verify tire pressure, and drive slowly and carefully to maintain control of the vehicle if driving under any of the following conditions:
• passengers and/or cargo exceeds half the maximum weight capacity
• driving in rough terrain
• driving over obstacles
• towing
• climbing a hill
Driving in Reverse
Make sure the area behind the vehicle is clear before operating in reverse. After making sure it is clear and safe to operate in reverse, accelerate slowly.
Avoid making sharp turns in reverse.
Driving a Damaged Vehicle
Driving a damaged vehicle is not safe.
If your vehicle has been involved in any type of accident, have it inspected by a qualified service provider to verify that it is safe for operation.
Driving at High Speeds
High speed operation increases risk of loss of control. Always drive at a speed that is appropriate for the terrain, visibility, operating conditions and your skill
and experience level. Use the brake to control speed and maintain control of the vehicle.
Driving on Pavement
The tires on your PROWLER EV are designed only for off road use; not for use on pavement. Driving the vehicle on paved surfaces can affect handling
characteristics and increase tire wear.
If possible, avoid driving on paved surfaces. If unavoidable, drive slowly, travel short distances and avoid sudden turns or stops.
Driving on Public Roads
Driving your PROWLER EV on public streets, roads or highways could result in a collision with another vehicle. Never drive this vehicle on any public street,
road or highway, including dirt and gravel roads, unless they are designated for off road use. Most areas prohibit the operation of this vehicle on public
streets, roads or highways, and can result in traffic violations and fines.
Turning
Improper or careless turning can cause loss of traction, loss of control, accident or rollover. Do not turn quickly or at sharp angles. Do not turn at high speeds.
Practice turning at slow speeds before attempting to turn at faster speeds.
Jumps and Stunts
Attempting wheelies, jumps or other stunts increases the risk of an accident or rollover. Never attempt wheelies, jumps or other stunts. Avoid exhibition driving.
Unfamiliar Terrain
Drive slowly and cautiously on unfamiliar terrain to prevent an accident or rollover. Unfamiliar terrain can contain hidden rocks, bumps or holes that can
cause loss of control or rollover. Constantly monitor for changing terrain conditions.
Obstacles
Check for obstacles before operating in an unfamiliar area. Do not drive over obstacles that are too large for the vehicle or your driving abilities.
Climbing Hills
Do not climb hills that are too steep for the vehicle or your driving abilities. Practice driving on small hills before attempting to drive on larger hills. Loss of
vehicle control or rollover can result from climbing hills incorrectly.
Driving Downhill
Inspect the terrain before descending a hill. Avoid driving across hills. Use the brake to limit speed and maintain control. Loss of vehicle control or rollover
can result from driving downhill incorrectly.
Stalling on a Hill
A rollover can result from stalling or rolling backward while climbing a hill. Drive uphill at a constant speed.
Parking on a Hill
Refer to Parking the Vehicle on page 18.
Tires
Operating the vehicle with incorrect tires or with incorrect or uneven tire pressure can cause loss of control or an accident. Always use the size and type tires
specified for the vehicle. See SPECIFICATIONS CHART on page 37. Always maintain correct tire pressures as specified in Tire Pressure on page 8.
10
SAFETY
Slippery Terrain
Driving on rough, wet or loose terrain increases the risk of loss of traction or control, accident or rollover. Drive slowly and use correct turning procedures
when operating on slippery surfaces.
Tires that have lost traction, and then regain traction suddenly, can cause loss of vehicle control or rollover.
Driving on Ice
Severe injury or death can result if the vehicle and operator fall through ice. Never operate the vehicle on a frozen body of water unless the ice is determined to be thick enough to support the weight and moving force of the vehicle, occupants, cargo and other vehicles operating in the same area.
Check with local authorities and residents to confirm ice conditions and thickness over your entire route. Operators assume all risk associated with frozen
bodies of water.
Vehicle Lifting
The vehicle must be on a firm and level surface for lifting. Remain constantly aware that the vehicle is not stable during the lifting process. Do not get
under a vehicle until you verify that it is stable on the jack stands. Never get under a vehicle while it is on a jack only. Put wheel chocks in front and behind
the wheels that are not being lifted. Do not allow anyone to remain or get on the vehicle at any time during the lifting process.
Read and comply with all warnings and follow the lifting procedures described on page 24.
Vehicle Modification
Do not install any accessory not approved by TEXTRON OFF ROAD. Do not modify the vehicle to increase speed or power. Any modifications or installation of accessories not approved by TEXTRON OFF ROAD can create a safety hazard and increase the risk of injury.
The warranty will be terminated if the vehicle is modified to increase vehicle speed or power.
The warranty may be terminated if original (or equivalent) replacement parts are not installed on the vehicle.
The addition of some accessories can change the handling characteristics of the vehicle. Use only TEXTRON OFF ROAD approved accessories, and
familiarize yourself with their function and effect on the vehicle.
11
SAFETY
12
FEATURES AND CONTROLS
FEA TURES AND CONTROLS
General Information
NOTICE: If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the
‘OFF’ position.
Max Speed/Range
State of Charge
Meter
Switch
Light Switch
Key Switch
Park Brake
Release
Glove Box
Cup Holder
Accelerator
Brake
Pedal
Pedal
Key Switch / Direction Selector
Located on the dash to the right of the steering wheel, this is a four position switch. It allows the operator to turn the electrical system off completely by moving the key to the OFF position; or select Reverse, Neutral, or Forward by rotating the key. When the key is in the OFF position, the park brake will engage.
State of Charge Meter
The illuminated state of charge meter is located on the dash. It indicates the amount of usable power in the batteries, with ‘F’ indicating a full charge on the
battery pack and ‘E’ indicating the batteries are low.
Light Switch
Located on the right side of the key switch, this ON/OFF switch controls the lights. In the ON position, the headlights and taillights illuminate.
Max Speed / Range Switch
This is a two position switch located on the dash to the right of the key switch.
The top position is the Max Speed setting. It allows the vehicle to travel up to 24.5 MPH. This setting diminishes distance capability for increased speed
advantage.
The bottom position is the Max Range setting. It limits the top speed of the vehicle to 16 MPH, which conserves battery power in order to extend travel distance.
Auxiliary Switch Positions
There are three empty spaces on the dash to allow for additional switches to control added lights or accessories.
12 Volt Power Outlet
Located in the lower part of the dash above the cup holder, the 12 volt outlet supplies constant power for additional equipment equipped with a 12 volt plug.
NOTICE: Do not draw more than 10 AMPS through the 12V outlet.
Cupholder
A cupholder is provided for convenience of vehicle occupants.
Accelerator Pedal
The accelerator pedal is located on the floorboard to the right of the brake pedal. Its function is to control the speed of the vehicle.
13
FEATURES AND CONTROLS
Brake Pedal
The brake pedal is located on the floor to the left of the accelerator pedal. The brake pedal function is to slow or stop the moving vehicle.
Park Brake
This vehicle is equipped with an InteliBrake™ system on the motor. The park brake will automatically engage when the accelerator has been released and the
vehicle drops below 2 MPH or the key switch is in the “OFF” position. See “Park Brake Release” for towing and loading information. For disengaging without
motor power see “Emergency Park Brake Release”.
Charger Receptacle
The polarized receptacle for charging the batteries is located under the dash on the driver
side. The cover must be opened to access the receptacle.
Taillights
The taillights are located in the rear fenders.
Charger
Receptacle
Side Nets
Side nets are a standard safety feature provided with the vehicle and must be properly
secured before operating vehicle.
Seat Belts
The vehicle is equipped with seat belts for the driver and passengers. Seat belts must be
worn at all times by all occupants when vehicle is in motion.
For more operational and safety information, see Seat Belt Operation on page 21.
Seat Belt
Side Net
14
FEATURES AND CONTROLS
Rear Seat / Load Deck
The rear facing seat is designed for two occupants.
The rear seat can be converted to a load deck by unfolding the seat bottom.
OPS / Top / Windshield
The standard vehicle is equipped with an OPS (Operator Protection System); vehicle
may be equipped with an optional top, and/or windshield.
The OPS and top provide some protection from smaller falling objects, but will not protect against large falling objects such as trees or heavy limbs.
The windshield deflects oncoming wind from occupants, but will not protect against flying objects and tree limbs.
The top and windshield provide some protection from the elements; however, they will not keep occupants dry in a downpour.
The OPS and top do not provide protection from roll over or falling objects.
The windshield does not provide protection from tree limbs or flying objects.
Remove windshield and store securely before transporting this vehicle on a trailer. The windshield is not designed to with-
stand highway speeds.
15
FEATURES AND CONTROLS
16
Safety
OPERATION
OPERATION
Failure to operate the vehicle correctly can result in a collision, loss of control, accident or rollover, and cause serious injury or death. Read and comply with all safety warnings in the safety section of this owner’s manual.
Improper use of this vehicle could result in severe injury or death. The vehicle is a light duty utility vehicle, NOT an All Terrain Vehicle (ATV).
When driving vehicle, consider the terrain, traffic conditions and the environmental factors which affect the terrain and the ability to control the vehicle.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass or gravel.
Maintain a safe speed when driving up or down a hill. Use brake to control speed when traveling down an incline. A sudden
stop or change of direction may result in loss of control.
To prevent loss of control, do not move the direction selector while the vehicle is in motion. Moving the direction selector
while vehicle is in motion will result in the park brake being engaged.
Slow down before and during turns. All turns should be made at reduced speed.
Do not drive through water that is more than 12 inches (30 cm) deep.
To prevent inadvertent movement when the vehicle is left unattended turn key to OFF position and remove key from switch.
Always bring the vehicle to a complete stop before shifting the direction selector.
Do not take vehicle out of gear while in motion (coast).
Check area behind vehicle before operating in reverse.
All occupants must be seated with seat belts fastened and front side nets latched. Keep entire body inside vehicle and hold
on while vehicle is in motion.
This vehicle is not a toy and using it while engaging in horseplay is dangerous.
Plan carefully before using the vehicle to go significant distances over unfamiliar terrain. Remember that a one hour drive
may take many hours to walk back should the batteries become discharged, or vehicle become stuck on unsuitable terrain.
Before Initial Use
NOTICE: Record the four digit key number and store in a safe place. Indi-
vidual keys can only be replaced if the key number is known.
Without a key number the entire ignition switch will have to be
replaced if keys are lost.
Make a note of the key number in the event that new keys must be ordered.
The key number is stamped into the key.
The key number must match the number on the key switch.
Be sure you understand the vehicle, its equipment and how to use it safely.
Read, understand and follow the safety and operation label on the dash panel.
Although the vehicle has been designed to provide safe and reliable operation,
maintaining good performance depends, to a large extent, on the operator.
Before a new vehicle is put into operation, the items shown in the INITIAL SER-
VICE CHART must be performed.
Initial Service Chart
Item Service Operation
Battery Charger Remove from vehicle and read operating instructions.
Batteries Charge, Batteries must be fully charged before initial use.
Seats Remove protective plastic covering.
Brakes Check operation; adjust if necessary.
Tires Check air pressure; adjust if necessary.
Vehicle Inspection Visually inspect overall vehicle for leaks or damage that may have developed in shipping.
Check hydraulic fluid level; add if necessary
See “Wheels and Tires” See page 25. for inflation recommendations.
Inspect for loose hardware; tighten if necessary.
15
OPERATION
Pre - Ride Inspection
Inspect and verify that the vehicle is in safe operating condition before each use to decrease the risk of an accident. Check the items in the table to help ensure safe and reliable operation.
Item Check
Brake system/pedal travel Check for proper operation.
Brake fluid Check for correct level.
Park Ensure vehicle does not roll when the key is in the OFF position.
Front suspension Inspect. Lubricate if necessary. Check for loose or missing hardware.
Rear suspension Inspect. Lubricate if necessary. Check for loose or missing hardware.
CV boots Inspect for damage. Replace if necessary.
Steering Check for smooth and free operation.
Tires Check condition and pressure.
Wheel hardware Check for loose or missing hardware.
Frame hardware Check for loose or missing hardware.
Battery Check battery charge level.
Switches and indicator lights Check operation.
Headlights Check operation.
Brake light / taillights Check operation.
Seat belts Check entire length of belt for damage. Check latch operation.
Side Nets Inspect side nets and latches for damage. Check for loose or missing hardware.
Hydrogen gas is generated as a natural part of the lead acid battery charging process. A 4% concentration of hydrogen
gas is explosive and could cause severe injury or death. Charging must take place in an area that is adequately ventilated (minimum of 5 air exchanges per hour).
To reduce the chance of battery explosion that could result in severe injury or death, never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc.
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will
collect in the ceiling of buildings necessitating proper ventilation.
Five air exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water heaters and furnaces.
Portable Charger
Use the portable charger ONLY on 72 volt battery systems. Other usage may cause personal injury and damage. Lead
acid batteries may generate explosive hydrogen gas during normal operation. Keep sparks, flames, and smoking materials away from batteries. Provide adequate ventilation during charging. Never charge a frozen battery. Study all battery
manufacturers’ specific precautions such as recommended rates of charge and removing or not removing cell caps
while charging.
Risk of electric shock. Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances. A grounded outlet is required to reduce risk of electric shock – do not use
ground adapters or modify plug. Do not touch uninsulated portion of output connector or uninsulated battery
terminal.
Disconnect the AC supply before making or breaking the connections to the battery while charging. Do not open or disassemble charger. Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow ,
been dropped, or otherwise damaged in any way – refer all repair work to qualified personnel. Not for use by children.
The portable charger is shipped with the vehicle. Prior to vehicle or charger operation, the charger must be removed from the vehicle. A dedicated circuit
is required for the charger. Refer to the charger manual for appropriate circuit protection. For optimum performance and shortest charge times, place the
charger in an area with adequate ventilation and relatively free of dirt, mud, or dust. If the charger is operated in an outdoor location, rain and sun protection
must be provided. The charger may get hot during operation and must be placed such that risk of contact by people is reduced.
NOTICE: Looping the DC cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished
with charging. The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away.
16
To reduce the possibility of a physical hazard that could result in an electrical shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle.
An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution.
Using the Charger
Before use, read the charger manufacturer’s operation manual that is supplied with the charger.
To prevent a physical hazard that could result in an electrical shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle.
An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution.
The charger cord is equipped with a polarized connector that fits into a matching receptacle on
the vehicle. The receptacle is located under the driver side dash of the vehicle.
Open the receptacle cover to access the receptacle. Always check to be sure the receptacle is
free from dirt and debris before inserting the charger cord. Once charging is complete and the
charger cord is removed, close the receptacle cover to prevent dirt and debris from entering
the receptacle area.
OPERATION
Charger
Receptacle
Charger
Receptacle
17
OPERATION
Operating The Vehicle
Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance.
Read the following warnings before attempting to operate the vehicle.
To reduce the possibility of severe injury or death resulting from loss of vehicle control, the following warnings must be observed:
When driving vehicle, consider the terrain, traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.
Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline. A
sudden stop or change of direction may result in loss of control.
Slow down before and during turns. All turns should be made at reduced speed.
Never drive vehicle up, down, or across an incline that exceeds 14° (25% grade).
Do not permit more occupants on the vehicle than it is designed to carry. Refer to SPECIFICATIONS for seating capac-
ity.
To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings
must be observed:
To prevent inadvertent movement when the vehicle is left unattended, engage the park brake by turning the key to ‘OFF’
position and remove key from switch.
Always bring the vehicle to a complete stop before shifting the direction selector.
Do not turn the key while in motion (coast) the parking brake will engage.
Check the area behind the vehicle before operating in reverse.
All occupants must be seated with seat belts fastened and front side nets latched. Keep entire body inside vehicle and
hold on while vehicle is in motion.
Key Switch Operation
When the key is rotated to the far left, the vehicle electrical system is off and not operational; the park brake is
engaged in the OFF position. Rotate the key to the right to the first position, labeled R for reverse. The next position to the right, labeled N is neutral. Rotate to the far right position, labeled F, for forward.
Max Speed/Range
Switch
Light Switch
Key Switch
To prevent inadvertent operation of the vehicle when left unattended, the key should be turned to the OFF position and removed from the switch.
To reduce the possibility of component damage, the vehicle must be stopped completely before turning the key.
Parking the Vehicle
NOTICE: When parking the vehicle inside a garage or structure, the space must be well ventilated. Part the vehicle away from any source of flame
or sparks, including any appliance with a pilot light.
Park the vehicle on a flat surface if possible. If parking on an incline is unavoidable, consider chocking the wheels as shown in the follow-
ing illustration to keep the vehicle from rolling.
1. Press the brake to stop the vehicle.
2. Turn the key switch to OFF.
3. Remove the key from the ignition to prevent unauthorized use.
4. If parking on an incline, consider chocking the wheels on the downhill end as shown.
18
OPERATION
Park Brake Release Switch
This vehicle is equipped with an IntelliBrake™ parking brake that engages automatically. Keep the Park Brake Release Switch in the bottom position,
labeled “RUN”, at all times except for when the vehicle needs to be towed. In the event the vehicle needs to be towed, park the vehicle on flat ground and
slide the red locking feature on the switch down and rock the switch upward into the “Park Brake Release” position. This will allow the vehicle to free-wheel.
Switching the Park Brake Release Switch to Park Brake Release will release the park brake and allow the vehicle to
freewheel. This may result in serious injury or death if performed on an incline. NEVER attempt to tow the vehicle
without releasing the park brake.
Emergency Park Brake Release
If the park brake release switch does not deactivate the park brake or if the
vehicle experiences a power failure you can release the park brake using the
following steps. This method is for emergency purposes only, and should only
be used if necessary.
NOTICE: Leaving the key engaged while the park brake is released for
long periods of time will result in a complete discharge of the
battery pack.
1. Chock the wheels so that the vehicle cannot roll.
2. Turn the key to the “OFF” position and remove the key.
3. Remove the seat bottom.
4. Locate connectors labeled 1,2,3,4 zip tied to main wiring harness between the passenger side battery and the row of three batteries in the middle.
5. Disconnect both sets of connectors, and connect 1 to 3 and 2 to 4.
6. Insert the key and turn to the “N” position, this will release the park brake.
7. Carefully remove the wheel chocks in the direction the vehicle needs to be moved.
8. Turn the key to the “OFF” position once the car has been moved.
9. Disconnect both sets of connectors, and connect 1 to 2 and 3 to 4 returning the vehicle to normal operation.
Front of Vehicle
Max Speed / Range Switch
Press the top of the switch to select the Max Speed setting. This setting allows the vehicle to travel up to 24.5
MPH, diminishing distance capability for increased speed advantage.
Press the bottom of the two position switch to select the Max Range setting. This setting limits top speed to 16
MPH, which conserves battery power in order to extend the distance the vehicle is capable of traveling before
the batteries need to be recharged.
Light Switch Operation
Press the top of the two position switch to activate the headlights and taillights. Press the bottom of the switch
to turn them off.
Brake Operation
This vehicle is equipped with four wheel hydraulic brakes.
Press the brake pedal to control speed or bring vehicle to a stop.
Accelerator Operation
With the key switch in forward (F) or reverse (R), pressing the accelerator pedal starts the
electric motor and activates the vehicle. When the pedal is released, the motor deactivates and the vehicle will decelerate. To stop the vehicle more quickly, press the brake
pedal.
Brake
Pedal
Max Speed/Range
Switch
Light Switch
Key Switch
Accelerator
Pedal
19
OPERATION
Seat Belt Operation
Seat belts must be worn by all occupants whenever vehicle is in motion.
Make sure seat belts are free from twists and latch securely.
Position shoulder belt across the top of the shoulder; do not place shoulder belt under the arm.
Keep belts snug and positioned low on hips. Loose fitting belts significantly reduce protection.
The vehicle is equipped with seat belts for the number of occupants it is designed to carry; do not exceed the recom-
mended number of occupants for the vehicle.
Seat belts are designed for one occupant per belt. Do not attempt to secure more than one person in a seat belt.
Seat belts must be worn at all times by all occupants when vehicle is in motion.
To keep seat belts in proper working condition, do the following:
• Inspect the seat belt webbing and hardware periodically. Check for cuts, frays or loose parts. Replace components if excessive wear or damage is
noticed.
• Keep seat belts clean and dry. To clean, use mild soap and warm water. Do not use bleach, dye or abrasive cleaners as this will weaken the belt webbing
material.
• Do not insert any foreign objects into the retractor mechanism.
• Periodically check for smooth operation and replace if the mechanism is not operating properly.
To properly secure the seat belts:
1. Pull the metal tab on the seat belt across the body toward the appropriate buckle located near the center of the seat.
2. Insert tab into buckle. (A click will be heard when the tab is securely latched).
3. Position the lap belt as low as possible on the hips, not at the waist.
4. Adjust to ensure a snug fit by pulling the shoulder portion upward.
The retractor will lock the belt during sudden stops. It may also lock if occupant leans forward quickly. Slow, easy motions allow the belt to travel freely.
To release the safety belt, press the buckle release button and allow the belt to retract. If the belt does not retract, check for a twist in the belt.
Common Sense Operation
Never transport loaded firearms on or in vehicle.
Check that firearms are unloaded with the safety engaged and are properly secured with muzzle pointing in a safe direc-
tion before operating vehicle. Be aware of other firearms in proximity to operator and passengers.
This vehicle is not a toy. If not operated properly and responsibly, it can cause severe injury or death to the operator, passengers or bystanders. All operators
should possess a valid driver’s license. Children should not be permitted to operate the vehicle. Children may not have the skill, judgment or strength to operate this or similar vehicles.
Alcohol, drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely. Always review side effects of any medication with a doctor or pharmacist before operating vehicle.
Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when operating vehicle in rough or densely wooded
terrain.
When driving at full speed on a dirt road, loose surfaces or wet grass, vehicle stopping distance will increase. If the vehicle is fully loaded, it requires longer to
stop than with no load. When operating vehicle in wet weather conditions, remember that the brakes may need to be lightly applied in order to provide enough
friction to dry the brake unit. If wet, the brakes lose much of their effect.
Slow down when on unfamiliar terrain. Slow down when cresting a hill in an area that is not familiar.
Some hills are too steep to climb. If attempting to climb a hill that is too steep or if unable to achieve adequate traction, do not attempt to turn around on the
hill. Slowly back straight down the hill using the brake pedal to control speed.
Environmental Concerns
As a responsible user, practice respect for all wildlife and their habitat. Respect private property and comply with all
local laws and regulations governing the use of light duty utility vehicles. To prevent severe injury or death while driving, be aware of environmental hazards such as steep slopes, overhanging limbs, etc.
Starting and Driving
• Make sure that the accelerator pedal is NOT pressed (no pressure on it).
• Place key in switch and turn to desired position.
• Press the accelerator pedal to move the vehicle.
Make sure the key switch is in the OFF position and the key is removed from the switch before exiting the vehicle.
This vehicle is to be operated by licensed drivers only.
Do not attempt to operate the vehicle while under the influence of drugs or alcohol.
Never turn the key switch to OFF while the vehicle is in motion; doing so can cause loss of control and lead to serious injury or death.
On a downhill slope, it is possible for the vehicle to achieve speeds greater than if it were operating on flat terrain. Limit downhill speed to 5 mph (8 kph) with
use of the brake pedal.
Caution must also be used on an uphill slope and speed should be limited to no more than 5 mph (8 kph).
If allowed to travel too fast on an uphill or downhill slope, loss of control may occur, possibly causing serious injury or death.
20
OPERATION
Use caution when traveling through water and never operate vehicle in water over 12 inches (30 cm) deep.
Starting the Vehicle on a Hill
Do not hold vehicle on hill by using accelerator and motor. This will cause premature and excessive wear to drive train components.
To reduce the possibility of permanent damage to the drive system, it is important to prevent excessive roll-back when starting the vehicle on a hill.
Press accelerator with right foot while releasing brake pedal.
Coasting
To reduce the possibility of severe injury or death from coasting above recommended speeds, limit speed with brake pedal.
On steep hills, it is possible for the vehicle to coast at greater speeds than possible on a flat surface. To reduce possible loss of vehicle control and severe
drivetrain damage, speeds should be limited to no more than the maximum governed speed on level ground (see SPECIFICATIONS). Limit speed by applying pressure to the brake pedal.
Towing a Trailer
The vehicle is equipped with a 2-inch receiver. The trailer and its load must not exceed 1000 lbs (454 kg) and no more than 100 lbs (46 kg) tongue weight
may be attached to the hitch. Remember that the overall capacity of the vehicle, operator, passenger, contents of load bed and accessories must be reduced
to compensate for the trailer and load.
The range of motion of the trailer is limited by the ball and hitch. The trailer should not be used on rough trails or over objects such as logs, large rocks,
holes, etc.
Never install baskets or extensions using the hitch receivers. Such items will change the performance characteristics of vehicle and result in unsafe handling, possible roll over or vehicle damage.
Terrain
The vehicle is NOT designed for use on public roads. The vehicle may be used on established trails or open terrain that is free from stumps, large rocks or
holes. The vehicle should not be used to cross water that is more than 12 inches (30 cm) deep or fast moving water.
Be aware of steep slopes and overhanging limbs.
When traveling up or down steep slopes, do not attempt to turn the vehicle around on the slope.
Be aware that vehicle stopping distance increases when driving on wet grass, dirt roads or loose surfaces.
Rear Facing Seat/Load Deck
Do not allow passengers to ride on load deck. Severe injury or death could result if a passenger should fall out, if vehicle is involved in an accident, or if vehicle makes a sudden maneuver.
The rear facing seat will accommodate two passengers with a combined weight of less than 400 lbs (181 kg). Seat belts are
available for passengers on the rear facing seat, and should be used according to Seat Belt Operation on page 20.
The seat bottom can be folded out to form a load deck. When using the load deck, position the load as far forward as possible and securely fasten it down.
The maximum load is 400 lbs (181 kg) and the center of gravity must not be higher than 12" (30 cm) above the load deck.
Winch Operation
This vehicle may be equipped with an optional winch. Read, understand and follow all of the information supplied with the winch on the operation and use of
the winch before attempting to operate it.
Winch Application
A winch may be used for a number of purposes, including pulling the vehicle if it loses traction on unsuitable terrain.
Improper use of the winch could result in a number of conditions that could cause severe injury or death to operator, occupants of vehicle or bystander.
It is impossible to predict all conditions that the winch could be used, therefore the following warnings should not be considered as complete. Before operating the winch, consider the possible dangers and take precautions to protect yourself, your passenger and any bystanders.
21
OPERATION
To prevent severe injury or death to operator, occupants or bystanders, consider the following when selecting an object to attach the cable to:
Make sure the object cannot be pulled over or otherwise damaged.
The object the winch cable is attached to could fall on the vehicle and it’s occupants.
If attaching the winch to a dead tree, a section could fall.
When pulling vehicle with winch, pull straight only. Do not permit cable to contact the side of the drum.
Do not pull vehicle at an angle. If the vehicle is pulled at an angle, it could turn over causing severe injury or death to
anyone in the area. The winch cable could also become overstressed and break causing severe injury or death to anyone struck by the cable.
To prevent severe injury or death, read and understand the following warnings before attempting to use the winch:
The winch is not intended to be used in any hoisting operation.
The rolling load capacity of the winch decreases with the steepness of the slope.
The winch is designed for intermittent duty only.
The electric motor should not be allowed to become excessively hot. If the motor becomes uncomfortably hot to the
touch, stop winching and allow the motor to cool.
Always wear thick leather gloves when handling the wire cable.
Replace frayed wire cable with a direct factory replacement only.
Never operate the winch with less than five (5) full turns of cable around the drum.
If the winch motor stalls from overloading, do not continue to activate the winch remote control. The wire cable may become
overstressed.
Do not attempt to pull loads exceeding the manufacturers maximum load rating.
Have all persons and pets leave the area while operating winch. Never allow anyone to remain in the vehicle.
To prevent damage to the wire cable, never hook the cable to itself. Always use a nylon sling.
Nylon
Damper
Sling
Do Not Hook Cable to Itself
Stay clear of the winch, the cable and the cable hook. Place a heavy cloth, jacket or blanket over the cable to act as a damper should the cable break when
operating the winch.
When operating the winch, keep the entire area in view.
Never release the free spool clutch while the cable is under load.
Never work around the winch drum or the winch cable while it is under tension.
Unplug the winch switch before working on the winch drum in order to prevent inadvertent operation.
When operating winch, take up slack slowly. Stop winch before cable becomes tight and inspect all winching connections. Check winch attachment, hook
attachment, nylon sling (if required) and load attachment.
Do not pull at an angle. This will cause the wire cable to pile up on one end of the winch. This may jam the winch causing damage to the cable and/or the winch.
22
Use a Nylon Sling and Install
a Damper when Winching
OPERATION
Pulling the vehicle at an angle can cause damage to the front suspension and may cause the vehicle to overturn. When pulling vehicle, pull straight only.
Incorrect
Correct
Do Not Pull at Angle
If the vehicle is being used as an anchor to winch a load, it should have the parking brake applied and chocks installed on all wheels.
Never use the winch to lift people or other overhead loads.
Do not use the winch to secure loads. Use a tie down designed for the job.
Do not apply shock loads to the winch.
Do not attempt to modify or weld the winch.
23
OPERATION
24
MAINTENANCE
Maintenance
Vehicle Cleaning and Care
To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.
When pressure washing exterior of vehicle, do not use pressure in excess of 700 psi and maintain a 12” minimum
distance from spray nozzle to painted surface. To reduce the possibility of cosmetic damage, do not use any abrasive
or reactive solvents to clean plastic parts.
injury to operator or bystander, damage to seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi to wash
exterior of vehicle.
Clean windshield with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish or Plexus® plastic cleaner available
from the service parts department.
Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp
cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive appearance as well as durable protection. Frequent washing with lukewarm or cold water and mild
detergent is required to preserve the painted surfaces.
Occasional cleaning and waxing with non-abrasive products designed for ‘clear coat’ automotive finishes will enhance the appearance and durability of the
painted surfaces.
Corrosive materials used as fertilizers or dust control can collect on the under-body of the vehicle. These materials will cause corrosion of under-body parts
unless flushed occasionally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be
loosened to ease its removal, taking care not to chip or otherwise damage paint.
Routine Maintenance
Preventive maintenance, applied at recommended intervals, is the best guarantee for keeping the vehicle dependable.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the PERIODIC SERVICE SCHEDULE for appropriate
service intervals.
It is important that proper techniques and cleaning materials be used. Using excessive water pressure may cause severe
23
MAINTENANCE
Lifting the Vehicle
TOOLS
• Floor Jack
• Jack Stands
• Wheel Chocks
To reduce the possibility of severe injury or death from a vehicle falling from a jack:
Always place chocks in front and behind the wheels not being raised.
Be sure the vehicle is on a firm and level surface.
Never get under a vehicle while it is supported by a jack.
Use jack stands and test the stability of the vehicle on the stands.
Use extreme care since the vehicle is very unstable during the lifting process
When lifting the vehicle, position the jack and jack stands at the areas indicated.
Remove payload from vehicle before lifting. No one should be in or on the vehicle while lifting.
Lift Entire Vehicle
1. Place wheel chocks in front and behind each front wheel.
2. Center jack under rear axle tube next to differential housing or under the
skid plate.
3. Raise vehicle and position jack stands under the frame where the leaf
spring mounting bracket is welded to the frame.
4. Lower the jack and test the stability of the vehicle on the two jack stands.
5. Place the jack under the center front of the car just behind the bumper.
6. Raise the vehicle and position the jack stands under the frame where the
instrument panel support is attached to the frame.
7. Lower the jack and test the stability of the vehicle on all four jack stands.
Lift Front of Vehicle
1. Place wheel chocks in front and behind rear wheels.
2. Place the jack under the center front of the car just behind the bumper.
3. Raise the vehicle with jack and position the jack stands under the frame
where the instrument panel support is attached to the frame.
4. Lower the jack and test the stability of the vehicle on jack stands.
5. The jack may be left under the center front of the frame while the front end
of the vehicle is on the jack stands.
24
Lift Rear of Vehicle.
1. Place wheel chocks in front and behind front wheels.
2. Center jack under rear axle tube next to differential housing or under the skid plate.
3. Raise vehicle with jack and position jack stands under the frame where the leaf spring mounting bracket is welded to the
frame.
4. Lower the jack and test the stability of the vehicle on the two jack stands.
5. The jack may be left under rear axle tube while the rear end of the vehicle is on the jack stands.
Lower Vehicle
Lower the vehicle by reversing the lifting sequence.
Light Bulb Replacement
To reduce the possibility of premature bulb failure, do not touch new bulbs with bare fingers. Use clean, dry tissue or paper towel to handle the glass portion of the bulb.
MAINTENANCE
Headlight Bulb
Turn key switch to OFF and remove key from switch.
Locate the headlight bulb socket on the backside of the light assembly.
Turn bulb socket a quarter turn counterclockwise to unlock.
Pull out bulb and socket, remove old bulb from the socket.
Insert new bulb in socket and position bulb socket into headlight housing and
rotate socket a quarter turn clockwise to secure.
Taillight Bulb
The taillight contains an LED light board rather than a light bulb, if the LEDs burn
out the whole light will have to be replaced.
Wheels and Tires
A tire explosion can cause severe injury or death. Never exceed the inflation pressure rating on the tire sidewall.
To reduce the possibility of tire explosion, pressurize tire with small amounts of air applied intermittently to seat
beads. Due to the low volume of the small tires, overinflation can occur in seconds. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face and eyes from escaping air when removing a valve core.
Use caution when inflating tires. Overinflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause severe injury.
To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for impact wrench use.
Inside
of Cowl
Headlight
Bulb
Tire Repair
TOOLS
• Lug Wrench, 3/4” • Impact Socket, 3/4”
• Impact Wrench • Torque Wrench, ft. lbs.
Generally, the most cost effective way to repair a flat tire resulting from a puncture in the tread portion is to use a commercial tire plug.
If the tire is flat, raise vehicle and remove wheel. Refer to ‘Lifting the Vehicle’ for proper lifting procedure and safety information. Inflate tire to the maximum
recommended pressure, immerse tire in water to locate the leak and mark the leak with chalk. Insert tire plug in accordance with manufacturer’s specifications.
Use caution when inflating tires. Due to the low volume of the small tires, overinflation can occur in seconds. Overinflation could cause the tire to separate
from the wheel or cause the tire to explode.
Recommended tire inflation pressure is 12 psi. Under no condition should inflation pressure be higher than recommended on tire sidewall. All four tires
should have the same pressure for optimum handling characteristics. Be sure to install the valve stem dust cap after checking or inflating. The vehicle is fitted with low volume tubeless tires mounted on one piece rims.
Wheel Installation
To reduce the possibility of component damage, do not tighten lug nuts to more than 75 ft. lbs. (101 Nm) torque.
NOTICE: It is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will assure even seating of the wheel against the
hub.
25
MAINTENANCE
With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger
tighten the lug nuts (1) in a ‘cross sequence’ pattern. Tighten the lug nuts to 65 to 75
ft. lbs. (88 to 101 Nm) torque in 20 ft. lbs. (27 Nm) increments following the ‘cross
sequence’ pattern.
Wheel Alignment
Driving over rough terrain may cause misalignment of the wheels. With four wheel independent suspension both front and rear wheels may need to be aligned.
TOOLS
• Tape Measure • Open End Wrench, 12mm
• Open End Wrench, 17mm • Open End Wrench, 19mm
Park the vehicle on a level surface, set the front wheels straight ahead. Turn the key switch
to OFF and remove the key.
With the vehicle empty (no passengers or payload) measure the distance between the center of the front set of tires. Measure both in front and behind the front tires, keeping the tape
measure parallel to the ground. The measurement behind the tires should be 1/8” to 1/4”
more than the measurement taken at the front of the tires to produce a toe-in condition.
Adjust both tie rods equally to obtain the correct toe-in. Hold tie rod (2) with an open
end wrench, loosen the jam nut (1) and turn the adjustment shaft (3) to move the
wheel in the desired direction.
Recheck the measurement at the front and at the rear of the front tires, if the 0” to 1/
8” toe-in has been achieved tighten the lock nut (1) on each tie rod.
Tire style may vary
3
Valve Stem Cap
43 inches
1
Cross Sequence
2
1
Brakes
This vehicle is equipped with four wheel hydraulic disc brakes and a motor brake. Check the fluid level at intervals specified in the PERIODIC SERVICE
SCHEDULE; if fluid leaks are noticed or the brake pedal seems soft, check the fluid level immediately. If the brake pedal is soft, the brake system should be
bled to remove air from the brake lines. Refer to Bleeding Brakes on page 27 for procedure.
26
MAINTENANCE
Master Cylinder
The master cylinder is located behind the driver side front wheel, mounted to the frame. Before removing the reservoir cap, clean any dirt or debris from around the reservoir and cap. Remove the cap and
check that the fluid level is between the MIN and MAX fill lines. Add DOT 3 brake fluid if necessary.
Check for leaks and all fitting connections.
Bleeding Brakes
TOOLS
• Hose • Clean Container
• Brake Fluid, DOT 3 • Wrench, 1/4” box end
The hydraulic brake system must be free of air to operate properly. Air can enter the system when
hydraulic parts are disconnected for servicing or replacement, or when the fluid level in the master cylinder reservoir is very low. Air in the system will give the brake pedal a spongy feeling when pressed.
NOTICE: An assistant is necessary to perform this procedure.
1. Use a clean cloth to wipe off the master cylinder reservoir and wheel cylinder bleeder valves. Clean each fitting before opening to prevent contaminating the system.
2. Open the master cylinder reservoir and top off with standard automotive DOT 3 brake fluid.
Never return brake fluid to the original container or reuse brake fluid due to the possibility of contamination by dirt,
grease, moisture. Contaminated brake fluid could cause failure of the braking system. Dispose of brake fluid in accordance with Federal, state and local codes.
3. Attach a short length of clear hose to the caliper bleed valve and insert the other end into a suitable clean container containing fresh, clean brake fluid.
NOTICE: Check the fluid level in the master cylinder frequently during this operation to pre-
vent air from entering the lines.
4. Start with the passenger side rear brake, then driver side rear brake, passenger side front brake
and finish with driver side front brake. Bleeding the brakes requires an assistant to pump the
brake pedal and keep pressure on the pedal. Bleed the brakes using the following procedure:
a. Build pressure in the brake system, if possible, by slowly pumping the brake pedal.
b. Open the bleeder valve while an assistant holds pressure on the brake pedal as the pedal
slowly goes through the full stroke.
c. Close the bleeder valve and have the assistant slowly release the brake pedal.
d. Repeat the process until no bubbles can be seen leaving the bleeder valve.
e. Close the valve and move to the next brake.
Bleeder
Hose
27
MAINTENANCE
Powertrain
To reduce the possibility of severe injury or death from improper servicing techniques:
DO NOT attempt any type of servicing operations before reading all notes, cautions and warnings in this manual.
Any servicing requiring adjustments to the powertrain while the motor is running must be made with all four drive
wheels raised and vehicle properly supported on jack stands.
To reduce the possibility of motor damage, never operate vehicle at full throttle for more than 4 - 5 seconds while vehi-
cle is in a ‘no load’ condition.
Reduce the possibility of accidental starting by disconnecting battery at negative terminal before servicing.
Wear eye protection when working on the vehicle. Use extra care when working around batteries, or using solvents or
compressed air.
To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical
loads from the battery before removing battery wires.
Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench ‘shorting out’ a battery, which could result
in an explosion.
The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte
spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.
Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda)
dissolved in 1 quart (1 liter) of water and flushed with water.
Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to reduce
the possibility of can contacting battery terminals which could result in an explosion.
It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual. Preventative maintenance,
applied at recommended intervals, is the best guarantee for keeping the vehicle both dependable and economical.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the PERIODIC SERVICE SCHEDULE for appropriate
service intervals.
To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, or frequent use with maximum load.
Axles
Front and Rear Axles
The only maintenance required for the first five years is the periodic inspection of the axles for
lubricant leakage. Unless leakage is evident, the lubricant need only be replaced after five
years. Refer to the Repair Manual for the fluid replacement procedure.
Checking the Lubricant Level
Clean the area around the check/fill plug and remove the plug. The correct lubricant level is just
below the bottom of the threaded hole. If lubricant is low, add lubricant as required. Add lubri-
cant slowly until it starts to seep from the hole. Install the check/fill plug. See CAPACITIES on
page 36 for lubricant information.
Check/Fill
Plug
28
Battery Charging and Maintenance
Battery Safety
Always observe the following warnings when working on or near batteries.
To prevent battery explosion that could result in severe personal injury or death, keep all smoking materials, open flames or sparks away from the batteries.
Hydrogen gas is formed when charging batteries. Do not charge batteries without adequate ventilation. A 4% concentration of hydrogen gas is explosive.
Be sure that the key switch is off and all electrical accessories are turned off before starting work on the vehicle.
Never disconnect a circuit under load at a battery terminal.
Batteries are heavy. Use proper lifting techniques to move them. Always lift the battery with a commercially available
battery lifting device. Use care not to tip batteries when removing or installing them; spilled electrolyte can cause
burns and damage.
Electrolyte in a storage battery is an acid solution which can cause severe burns to skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.
Always wear a safety shield or approved safety goggles when adding water or charging batteries.
Neutralize electrolyte spills with a solution of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1-1/2 gal-
lons (6 liters) of water and flush with water.
Overfilling batteries may result in electrolyte being spilled from the battery during the charge cycle. Expelled electro-
lyte may cause damage to the vehicle and storage facility.
Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to prevent
can from contacting battery terminals which could result in an explosion.
Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from shorting out a battery, which
could result in an explosion and severe personal injury or death.
MAINTENANCE
Battery Disposal
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and
lead compounds. Contact local and/or state environmental officials regarding disposal information.
Battery
A battery is defined as two dissimilar metals immersed in an acid. If the acid is absent or if the metals are not dissimilar, a battery has not been created. The
batteries most commonly used in these vehicles are lead acid.
A battery does not store electricity, but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of
electrical energy. The chemical reaction takes place faster in warm conditions and slower in cold conditions. Temperature is important when conducting tests
on a battery and test results must be corrected to compensate for temperature differences.
As a battery ages, it continues to perform adequately except that its capacity is diminished. Capacity describes the time that a battery can continue to provide its design amperes from a full charge.
A battery has a finite life, therefore good maintenance is designed to maximize the available life and reduce the factors that can reduce the life of the battery.
Battery Maintenance
TOOLS
• Insulated Wrench, 9/16” • Hydrometer
• Battery Carrier • Battery Maintenance Kit (P/N 25587G01)
• Battery Protective Spray
The batteries can be accessed by raising and removing the seat bottom and battery cover.
At Each Charging Cycle
To reduce the possibility of fire, never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle.
Before charging the batteries, inspect the plug of the battery charger and vehicle receptacle housing for dirt or debris.
Charge the batteries after each days use.
Monthly
• Inspect all wiring for fraying, loose terminations, corrosion or deterioration of insulation.
• Check that the electrolyte level is correct and add suitable water as required.
• Clean the batteries and wire terminations.
• Torque battery terminal nuts to 95 - 105 in. lbs. (11 - 12 Nm).
• Coat battery terminals with commercially available protectant.
• Replace all terminal covers.
29
MAINTENANCE
• Replace battery compartment cover and note service date on chart.
Temperature Affects Battery Capacity
Battery storage capacity is affected by the temperature; the colder it is, the less
energy it is able to store; as temperature increases, so does the storage capacity of
the battery.
The ideal battery temperature for deep cycle batteries is 77°F (25°C). At 32°F (0°C)
the storage capacity of the battery will be reduced by 20%. This means in cold
weather the vehicle will not travel as far as it would in warm weather.
Electrolyte Level and Water
The correct level of the electrolyte is 1/2” (13 mm) above the plates in each cell.
This level will leave approximately 1/4” - 3/8” (6 - 10 mm) of space between the
electrolyte and the vent tube. The electrolyte level is important since any portion of
the plates exposed to air will be ruined beyond repair. Also avoid filling with too
much water, which will result in electrolyte being forced out of the battery due to
gassing, and a decrease in volume of the electrolyte that results from the charging
cycle.
115
110
105
100
95
90
85
80
75
70
65
60
55
PERCENT CAPACITY
50
45
40
35
30
F°
C°
-40
-40
-22
-30
32
14
-4
0
-10
-20
TEMPERATURE
5010682086301044012250140
60
DO NOT overfill batteries. The charging cycle will expel electrolyte and result in component damage.
If the battery electrolyte level is too high, the electrolyte
will block the vent tube and the gas will force it out of the vent tube and battery cap.
The water will evaporate but the sulfuric acid will remain where it can damage vehicle
components and the storage facility floor. Sulfuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery.
Vent Cap
Gas Vent
Expansion
Space
Vent
1/4 to 3/8 inch
(6 mm to 10 mm)
Plates
Electrolyte level should be at least 1/2” (13 mm) above the
plates and 1/4” to 3/8” (6 to 10 mm) below vent.
1/2 inch
(13 mm)
30
Over the life of the battery, a considerable amount of water is consumed. It is
important that the water used be pure and free of contaminants that could reduce
the life of the battery by reducing the chemical reaction. The water must be distilled
or purified by an efficient filtration system. Even if the water is colorless, odorless,
tasteless and fit for drinking, the water should be analyzed to see that it does not
exceed the impurity levels specified in the table.
An automatic watering gun or a battery watering jug, available from many auto
parts stores may be used to fill the batteries. These watering devices are accurate,
easy to use and allow for rapid filling. They also maintain the correct electrolyte
level within the battery cells.
Valve consistently fills
to a predetermined level
Impurity
Color
Suspended
Total Solids
Calcium & Magnesium Oxides
Iron
Ammonia
Organic & Volatile Matter
Nitrites
Nitrates
Chloride
Water Purity Table
Hand Held Watering Device
MAINTENANCE
Parts Per
Million
Clear
Trace
100
40
5
8
50
5
10
5
Distilled Water
Valve consistently fills
Electrolyte Level
to a predetermined level
Pure Water
Single Battery Cell
Automatic Watering Gun
NOTICE: The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates.
Electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.
Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liter) of water and flushed with water.
Always wear a safety shield or approved safety goggles when adding water or charging batteries.
Electrolyte Level
Single Battery Cell
Cleaning Batteries
When cleaning the outside of the batteries and terminals, do not use a water hose
without first spraying the batteries with a solution of baking soda (sodium bicarbonate) and water to neutralize any acid deposits. Use of a water hose without first
neutralizing the acid will move the acid from the top of the batteries to another area
of the vehicle or storage facility, where it will attack the metal structure or the concrete/asphalt floor. After hosing down the batteries, a residue will be left on the batteries, which is conductive and will contribute to the discharge of the batteries.
To prevent battery damage, be sure that all battery caps are tightly installed.
The batteries are located under the seat. The batteries can be accessed by raising and removing the seat bottom and battery
cover.
1 quart
(1 liter)
Clear Water
2 Teaspoons
(10 ml)
Sodium
Bicarbonate
(Baking Soda)
Plastic
Spray
Bottle
31
MAINTENANCE
Clean batteries:
1. Use a plastic spray bottle to spray the top and sides of the batteries with a solution of baking soda and water. The solution should consist of 2 teaspoons
(10 ml) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liter) of water.
2. In addition to the batteries, pay special attention to metallic components adjacent to the batteries. Spray these with the baking soda solution also.
3. Allow the solution to set for at least three minutes; then use a soft bristle brush or cloth to wipe the tops of the batteries to remove any residue that could
cause the batteries to self-discharge.
4. Rinse the entire area with low pressure clear water.
To prevent battery explosion that could result in severe personal injury or death, use extreme care with aerosol contain-
ers of battery terminal protectant. Insulate the metal container to prevent the metal can from contacting battery termi-
nals.
5. After batteries are clean and dry, coat terminals with a commercially available protectant. See previous WARNING.
Cleaning should take place once a month or more often under extreme conditions.
Battery Removal and Installation
To Solenoid
POS
NEG
POS
NEG
POS
POS
NEG
NEG
NEG
POS
POS
NEG
To Controller B-
Improper handling of high voltage wiring, batteries,
or control systems could result in serious or fatal injury by electric shock. Only qualified technicians should repair or
access high voltage wiring, battery packs, and associated systems.
To prevent battery explosion that could result in severe personal injury or death, use extreme care with aerosol contain-
ers of battery terminal protectant. Insulate the metal container to prevent the metal can from contacting battery termi-
nals, which could result in an explosion.
If the batteries are replaced, make sure they are the exact type and model originally supplied with the vehicle. Failure to
follow this caution can result in damage to the vehicles electrical system.
32
Prolonged Storage
During periods of storage, the batteries must be maintained to prevent discharge.
In winter conditions, the batteries must be fully charged to prevent the possibility of
freezing. A fully charged battery will not freeze in temperatures above -75° F (-60°
C). Although the chemical reaction is slowed in cold temperatures, the battery
must be stored fully charged, and disconnected from any circuit that could discharge the battery.
The batteries must be cleaned and all deposits neutralized and removed from the
battery case to prevent self discharge.
The battery charger may be left connected to the vehicle to maintain a full charge
on the batteries, provided the charger is plugged into an active electrical source. If
power to the electrical source is disconnected or interrupted, the battery charger
will continue to check the charge on the battery pack. This will draw power from the
battery pack and eventually drain the batteries if power is not restored in a timely
manner.
Battery Charging
The battery charger is designed to fully charge the battery set. If the batteries are
severely deep cycled, some automatic battery chargers contain an electronic module that may not activate and the battery charger will not function. Automatic chargers will determine the correct duration of charge to the battery set and will shut off
when the battery set is fully charged. Always refer to the instructions of the specific
charger being used.
Before charging, the following should be observed:
MAINTENANCE
O
O
C
F
+15
+5
-5
-15
-25
-35
-45
-55
-65
-75
-85
-95
-15
-21
-26
-32
-37
-43
-48
-54
-60
-65
-71
-9
1.100
1.140 1.180 1.220 1.260 1.300
1.120 1.160 1.200 1.240 1.280
E
L
E
C
T
R
O
L
Y
T
E
T
E
M
P
E
R
A
T
U
R
E
SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT
Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage.
• The electrolyte level in all cells must be at the recommended level and cover the plates.
• The charging must take place in an area that is well ventilated and capable of removing the hydrogen gas that is generated by the charging process. A
minimum of five air exchanges per hour is recommended.
• The charging connector components must be in good condition and free from dirt or debris.
• The charger connector must be fully inserted into the vehicle receptacle.
• The charger connector/cord set must be protected from damage and is located in an area to prevent injury that may result from personnel running over
or tripping over the cord set.
• The charger is automatically turned off during the connect/disconnect cycle and therefore no electrical arc is generated at the DC plug/receptacle contacts.
Battery Troubleshooting
In general, troubleshooting will be done for two distinct reasons:
• A battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturer’s warranty. Different manufacturers have different requirements. Consult the battery manufacturer or the manufacturer’s representative for
specific requirements.
• Determine why a particular vehicle does not perform adequately. Performance problems may result in a vehicle that runs slowly or in a vehicle that is
unable to operate for the time required.
A new battery must mature before it will develop its maximum capacity. Maturing may take up to 100 charge/discharge cycles. After the maturing phase, as
the battery ages, its capacity diminishes. The only way to determine the capacity of a battery is to perform a load test using a discharge machine following
manufacturer’s recommendations
A cost effective way to identify a poorly performing battery is to use a hydrometer to identify a battery in a set with a lower than normal specific gravity. Once
the problematic cell or cells are identified, the suspect battery can be removed and replaced. At this point there is nothing that can be done to salvage the
battery; however, the individual battery should be replaced with a good battery of the same brand, type and approximate age.
33
MAINTENANCE
Hydrometer
A hydrometer is used to test the state of charge of a battery cell. This is performed by
measuring the density of the electrolyte, which is accomplished by measuring the specific
gravity of the electrolyte. The greater the concentration of sulfuric acid, the more dense
the electrolyte becomes. The higher the density, the higher the state of charge.
Thermometer
Add to Float
Reading
Subtract
from Float
Reading
Cylinder
FloatBulb
Weight
To prevent battery explosion that could result in severe
Hydrometer
personal injury or death, never insert a metal thermometer into a battery. Use a hydrometer with a built in thermometer
that is designed for testing batteries.
Specific gravity is the measurement of a liquid that is compared to a baseline. The baseline is water which is assigned a base number of 1.000. The concentration of sulfuric acid to water in a new golf car battery is 1.280 which means that the electrolyte weighs 1.280 times the weight of the same volume of water. A
fully charged battery will test at 1.275 - 1.280 while a discharged battery will read in the 1.140 range.
NOTICE: Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one charge and discharge
cycle in order to permit the water to adequately mix with the electrolyte.
The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80° F (27° C). High quality hydrometers are equipped with
an internal thermometer that will measure the temperature of the electrolyte and will include a conversion scale to correct the float reading. It is important to
recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been operated.
34
Using A Hydrometer
1. Draw electrolyte into the hydrometer several times to permit the thermome-
ter to adjust to the electrolyte temperature and note the reading. Examine the
color of the electrolyte. A brown or gray coloration indicates a problem with
the battery and is a sign that the battery is nearing the end of its life.
2. Draw the minimum quantity of electrolyte into the hydrometer to permit the
float to float freely without contacting the top or bottom of the cylinder.
3. Hold the hydrometer in a vertical position at eye level and note the reading
where the electrolyte meets the scale on the float.
4. Add or subtract four points (.004) to the reading for every 10° F (6° C) the
electrolyte temperature is above or below 80° F (27° C). Adjust the reading
to conform with the electrolyte temperature, e.g., if the reading indicates a
specific gravity of 1.250 and the electrolyte temperature is 90° F (32° C), add
four points (.004) to the 1.250 which gives a corrected reading of 1.254. Similarly if the temperature was 70° F (21° C), subtract four points (.004) from
the 1.250 to give a corrected reading of 1.246.
5. Test each cell and note the readings (corrected to 80° F or 27° C). A varia-
tion of fifty points between any two cell readings (example 1.250 - 1.200)
indicates a problem with the low reading cell(s).
As a battery ages the specific gravity of the electrolyte will decrease at full charge.
This is not a reason to replace the battery providing all cells are within fifty points of
each other.
Since the hydrometer test is in response to a vehicle exhibiting a performance
problem, the vehicle should be recharged and the test repeated. If the results indicate a weak cell, the battery or batteries should be removed and replaced with a
good battery of the same brand, type and approximate age.
ELECTROLYTE
TEMPERATURE
°F °C
160 71
150 65
140 60
130 54
120 49
110 43
100 37
90 32
80 26
70 21
60 15
50 10
40 4
30 -1
20 -6
10 -12
+.032
+.030
+.028
+.026
+.024
+.022
+.020
+.018
+.016
+.014
+.012
+.010
+.008
+.006
+.004
+.002
0
-.002
-.004
-.006
-.008
-.010
-.012
-.014
-.016
-.018
-.020
-.022
-.024
-.026
-.028
MAINTENANCE
EXAMPLE #1
ELECTROLYTE TEMPERATURE
Above 80 °F (27 °C)
AMBIENT TEMPERATURE
Above 80 °F (27 °C)
ELECTROLYTE TEMPERATURE
Above 90 °F (32 °C)
HYDROMETER READING 1.250
1.250 + .004 = 1.254
CORRECTED SPECIFIC GRAVITY
READING
EXAMPLE #2
ELECTROLYTE TEMPERATURE
Above 80 °F (27 °C)
AMBIENT TEMPERATURE
Above 80 °F (27 °C)
ELECTROLYTE TEMPERATURE
Above 70 °F (21 °C)
HYDROMETER READING 1.250
1.250 - .004 = 1.246
CORRECTED SPECIFIC GRAVITY
READING
Hydrometer Temperature Correction
35
MAINTENANCE
Hardware
Periodically, the vehicle should be inspected for loose fasteners. Use care when tightening fasteners, refer to the Technician’s Repair and Service Manual for
specific torque values.
Generally, three classes of standard hardware and two classes of metric hardware are used in the vehicle. Grade 5 hardware can be identified by the three
marks on the hex head and grade 8 hardware is identified by six marks on the head. metric hardware is marked on the head with 8.8 or 10.9. Unmarked hardware is Grade 2.
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. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
BOLT SIZE
Grade 2
Grade 5
Grade 8
1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"
4
(5)
6
(8)
6
(8)
8
(11)
13
(18)
18
(24)
15
(20)
23
(31)
35
(47)
24
(33)
35
(47)
55
(75)
35
(47)
55
(75)
80
(108)
55
(75)
80
(108)
110
(149)
75
(102)
110
(149)
170
(230)
130
(176)
200
(271)
280
(380)
125
(169)
320
(434)
460
(624)
190
(258)
480
(651)
680
(922)
BOLT SIZE
Class 5.8
(Grade 2)
Class 8.8
(Grade 5)
Class 10.9
(Grade 8)
5.8
8.8
10.9
M4 M5 M6 M8 M10 M12 M14
1
(2)
2
(3)
3
(4)
2
(3)
4
(6)
6
(8)
4
(6)
7
(10)
10
(14)
10
(14)
18
(24)
25
(34)
20
(27)
35
(47)
49
(66)
35
(47)
61
(83)
86
(117)
55
(76.4)
97
(131)
136
(184)
Torque Specifications and Bolt Grades
CAPACITIES AND REPLACEMENT PARTS
CAPACITIES REPLACEMENT PARTS
Front Axle Oil 13.8 oz. 90 wt. Gear Oil LED Headlight Bulb P/N 651411G03
Rear Axle Oil 13.8 oz. 90 wt. Gear Oil Headlight Bulb P/N 651411G01
Brake Fluid DOT 3 Mini Fuse 32V 10A 636455G12
Mini Fuse 32V 15A 636455G13
Mini Fuse 32V 20A 636455G14
Mini Fuse 125V 10A 636455G05
Mini Diode 400V 1A 647667
72V Relay 650845
36
MAINTENANCE
PERIODIC SERVICE SCHEDULE
C - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE
REMARKS
Before each use DAILY
DAILY
WEEKLY
20 hrs
MONTHLY
50 hrs
QUARTERLY
125 hrs
SEMI-ANNUAL
250 - 300 hrs
ANNUAL
Tires - Check pressure and inspect condition of tires & rims. C C C C C C
Hardware - Check for loose or missing. C C C C C C
Reverse Warning Indicator C C C C C C
Overall Vehicle Condition C C C C C C
Battery Pack - Check state of charge, condition, loose terminals, corrosion,
hold down & hardware.
Brake Pedal - Check for smooth operation C C C C C C
Parking Brake - Check for correct hold capability. C C C&A C&A C&A C&A
Accelerator - Check for smooth operation. C C C C C C
Charger / Receptacle - Inspect charger connector and receptacle. C C C C C C
Brakes - Conduct brake performance test; adjust if required. C&A C&A C&A C&A
Wiring - Inspect for loose connections, broken or missing insulation. C C C C
Direction Selector - Inspect attachment and mechanism. C&A C&A C&A C&A
Steering Assembly - Check for excess play, loose or missing hardware. C C C C
Tie Rods - Check for excess play, bent rods, loose or missing hardware. C C C C
Front Axle - Check for damage to axle, loose or missing hardware. C C C
Rear Axle - Check fluid level, oil leakage, noise, loose or missing hardware. C C C C
Parking Brake - Inspect linkage rods, latch arm and catch bracket. C C C
Parking Brake - Lubricate with light oil. Do not lubricate cables or brake latch. C&A C&A C&A
Rear Axle - Drain & replace fluid. R
Rear Suspension - Inspect for shock oil leakage, worn bushings, loose or
missing hardware.
Front Suspension - Inspect for strut oil leakage, excessive play in hubs or
kingpins, worn bushings, loose or missing hardware.
Front Wheel Alignment - Inspect for unusual tire wear. C&A C&A C&A
Steering Assembly - Inspect bellows and pinion seal for damage and leakage. C C
Rack End Ball Joint - Check for noise and loose or missing hardware. C C
C C CL CL CL CL
CCC
CCC
5 YEARS
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.
37
MAINTENANCE
38
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS CHART
Item Specification
Total Capacity 940 lb (426 kg)
Towing Capacity 1,000 lb (453.6 kg)
Speed Maximum 24.5 mph ( kph)
Range Maximum 16 mph ( kph)
Overall Length 111.8 in (284 cm)
Overall Width 53 in (134.6 cm)
Overall Height 76.8 in (195.1 cm)
Overall Weight 1,685 lb (764 kg)
Wheelbase 69 in (175 cm)
Ground Clearance - Frame Center 16.5 in (42 cm)
Ground Clearance - Axle 10 in (25 cm)
Hitch 2 in (5 cm)
Front Tires 25 X 8 - 12
Rear Tires 25 X 10 - 12
Wheels Steel
Steering Rack and Pinion
Front Suspension Independent MacPherson Struts
Rear Suspension Solid Leaf Spring
Brake System 4 - Wheel Hydraulic Disc
Parking Brake IntelliBrake™ System
Battery
Motor Type 72V (Front and Rear)
Horsepower 38 HP
Drivetrain 72V AC Electric
Gear Selection Dash Mounted Direction Selector Switch (Forward - Neutral - Reverse)
Differentials Open
Regenerative Braking Yes
Charger Off - Board 72V Charger
Charge Time Approximately 8 - 12 hours
Frame Structurally Welded High - Strength Steel
Finish
Standard Color Black
Optional Color TrueTimber⌐ Kanati Camo
Instrumentation
Seating
Storage Components
Safety Components
72V Battery System
6 - 12V Heavy-Duty Deep Cycle Batteries
DuraShiled Powder Coat; Automotive Quality
Impact - Resistant TPO Plastic
In - Dash Battery Status Indicator
12V DC Outlet
Forward Facing Bench Seat
Convertible Rear - Facing Bench Seat
Fold - Down Cargo Deck
Glove Box
3 - Point Seat Belts (2 Front, 2 Rear)
Safety Nets
1.75 in. Formed Tube OPS
1.5 in. Diameter Tubing Brush Guard
Headlights
Taillights
Impact - Resistant Fender Flares
37
SPECIFICATIONS
38
Record periodic maintenance in the following maintenance log.
MAINTENANCE LOG
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
39
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
40
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
41
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
42
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
43
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
44
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
45
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
46
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
47
MAINTENANCE LOG
48
NOTICE: Read the following warnings before oper-
ating vehicle:
To prevent personal injury or
death, observe the following:
When vehicle is to be left unattended, engage park
brake, move direction selector to neutral, turn key to
OFF position and remove from key switch.
Drive vehicle only as fast as terrain and safety considerations allow. Consider environmental factors
which effect the terrain and the ability to control the
vehicle.
Avoid driving fast down hill. Sudden stops or change of direction may result in loss of control. Use service brake to control speed when traveling down an incline.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.
In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible component failures or the manner in which they may fail.
A vehicle requiring repair indicates that it is no longer functioning as designed and therefore should
be considered potentially hazardous.
Use extreme care when working on vehicle. When
diagnosing, removing or replacing any components
that are not operating properly, take time to consider the safety of yourself and others around you
should the component move unexpectedly.
Some components are heavy, spring loaded, highly
corrosive, explosive, may produce high amperage
or reach high temperatures. Battery acid and hydrogen gas could result in serious bodily injury to the
technician/mechanic and bystanders if not treated
with utmost caution. Be careful not to place hands,
face, feet or body in a location that could expose
them to injury should an unexpected situation
occur.
All travel should be directly up or down hills; use extra care if ever forced to drive across an incline.
Stay in designated areas and avoid steep slopes. Activate the park brake when the vehicle is parked.
Keep feet, legs, hands and arms inside vehicle at all times.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in
reverse.
Slow down before and during turns. All turns should
be executed at reduced speed.
Always bring vehicle to a complete stop before turn-
ing the key to select direction.
See GENERAL SPECIFICATIONS for vehicle load
and seating capacity.
NOTICE: Read the following information and warn-
ings before operating vehicle:
Always use the appropriate tools listed in the tool list and wear approved safety equipment.
Before working on vehicle,
remove all jewelry (rings, watches, necklaces, etc.).
Be sure no loose clothing or hair can contact mov-
ing parts.
Use care not to touch hot objects.
Raise rear of vehicle and support on jack stands
before running or adjusting powertrain.
Wear eye protection when working on or around the
vehicle. In particular, use care when working around
batteries, using solvents, or compressed air.
Hydrogen gas forms when charging batteries. Do not charge batteries without adequate ventilation.
Do no permit open flame or smokers in an area being used for charging batteries. A concentration of 4% hydrogen gas or more is explosive.
666384 -
1
To locate your nearest dealer,
call 1-888-438-3946 or
visit www.textronoffroad.com
Textron Specialized Vehicles, Inc.
1451 Marvin Griffin Rd.
Augusta, GA 30906 USA
666384 A
Printed in USA
666384 A
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