Operating

· Sit on the center of the seat and keep both feet within the foot platform perimeter. Clean foot platform if dirty, and remove any debris from around foot controls.

· Check for debris or refuse in the battery storage compartment, especially around brake linkage which attaches to axle housing on each side of the transaxle.

· Always use both hands for steering.

· Know location of controls and how and what they operate.

· Never operate utility vehicle while standing.

· Never operate utility vehicle with the cargo box raised.

· Check brake action before beginning vehicle operation. If necessary, have the brakes adjusted or serviced by a trained technician.

· To provide adequate braking ability and traction, DO NOT tow any attachment or loaded trailer unless the utility vehicle cargo box is loaded.

· Inspect vehicle before operating. Be sure hardware is tight. Repair or replace damaged, badly worn, or missing parts. Be sure guards and shields are in good condition and fastened in place. Make any necessary adjustments before operating.

· Keep people and pets out of the work area. Stop the vehicle if anyone enters the area. If an object is hit, stop and inspect the vehicle for damage. Make repairs before operating. Keep the vehicle properly maintained and in good working order.

· Keep headlight lenses clean.

· DO NOT leave vehicle unattended.

· Only operate during daylight or with good artificial light.

· Be careful of traffic when operating near or crossing roadways.

· This vehicle is NOT intended for use on highways or public roadways. It is to be used for off-road use only.

· Avoid sudden starts, stops, or turns.

· Always use a level turn-around area.

· DO NOT wear radio or music headphones while operating the vehicle. Safe operation requires your full attention.

· STAY ALERT: LOOK, LISTEN.

Park Safely

· Stop the vehicle on a level surface, not on a slope.

· Turn key switch to the OFF "0" position.

· Move directional control lever to the NEUTRAL "N" position.

· Engage park brake.

· Remove key.

Use Hand Holds

M78475

Hand Holds (A) are provided for passenger balance when driving over rough terrain. Use dash bar and side rails on seats for stability.

Check Wheel Bolts

· A serious accident could occur causing serious injury if wheel bolts are not tight.

· Check wheel bolt tightness after first 10 hours of vehicle operation and semi-annually thereafter.

Protect Children and Prevent Accidents

M78507

PROTECT CHILDREN:

· Never assume that children will remain where you last saw them. Stay alert to the presence of children.

· Never carry children in the cargo box area. DO NOT let children ride in the cargo box of the utility vehicle or any attachment. DO NOT tow children in a cart or trailer.

· Use extra care when coming to blind corners, shrubs, trees, or other objects that may block vision.

· DO NOT let children or an untrained person operate the vehicle.

· Before backing or turning, look behind and around the utility vehicle for children.

HELP PREVENT SERIOUS OR FATAL ACCIDENTS:

· Be alert at all times, drive forward and in reverse carefully. People, especially children, can move quickly into an area of operation.

· Back carefully. Look behind the vehicle, especially for children, before backing up.

· DO NOT operate vehicle if under the influence of alcohol or other drugs.

· Misuse and recreational riding can lead to accidents, severe bodily injury or death.

Avoid Tipping

W15212

Accidents resulting in serious injury or death can occur from tipping the utility vehicle. Observe the following practices to help prevent accidents:

· DO NOT misuse this utility vehicle. This utility vehicle is not designed for recreational riding.

· Never allow riders in the cargo box or other areas where seats are not provided.

· Drive very slowly when turning. Sharp turns could cause the utility vehicle to tip over.

· Reduce speed and exercise extreme caution on slopes or on rough ground.

· DO NOT overload vehicle and avoid shifting loads. Reduce load when operating over rough or hilly terrain.

· DO NOT stop or start suddenly when going uphill or downhill. Be especially cautious when changing direction on slopes.

· Stay alert for holes, rocks, and other hidden hazards in the terrain.

· Keep front wheels straight at crest of hill or going over bumps.

· When descending a hill, remove foot from accelerator and apply brakes to reduce speed and maintain control.

· DO NOT make changes or modifications to this utility vehicle.

· Use of a helmet and/or protective gear is recommended for certain operating conditions.

Operator Training Required

M78508

Study Operating section of this manual before operating the vehicle.

· Operate vehicle in an open, unobstructed area under the direction of an experienced operator.

· Learn the use of all controls.

· Operator experience is required to learn the moving, stopping, turning and other operating characteristics of the vehicle.

· Young drivers may not have the strength or experience to control the utility vehicle. This increases the chances of rolling the vehicle over resulting in severe bodily injury or death.

· The utility vehicle should NOT be operated by anyone under the age of 16 years.

Keep Riders Off Vehicle

M78507

· Seating is provided for operator and one passenger. No riders are allowed in cargo box or anywhere else on vehicle.

· Riders on vehicle are subject to injury such as being struck by foreign objects or being thrown off of the vehicle and severely injured or killed.

· Riders affect the operators ability to control the vehicle as well as its center of gravity. Also, riders could obstruct the operator's view resulting in the vehicle being operated in an unsafe manner.

Wear Appropriate Clothing

TS206TRA

· Wear close fitting clothing and safety equipment appropriate for the job.

· Loud noise can cause impairment or loss of hearing, wear a suitable protective device such as earplugs.

Driving On Rough Or Hilly Terrain

W15212

c CAUTION: Avoid injury! Help prevent severe bodily injury or death due to loss of control. Reduce load when operating over rough or hilly terrain.

Reduce speed when turning or when operating around obstacles or rough terrain.

Check the terrain and know the operational capability of the vehicle. Choose places to operate carefully.

· Always use the brakes when going down slopes. The utility vehicle can speed-up when carrying a load. Make sure loads are dispersed evenly and secured. Braking could shift the load and affect vehicle stability.

· Use existing trails. Avoid terrain such as dangerous slopes and impassable swamps. Watch carefully for sharp bumps, holes, ruts, or obstacles.

· Look ahead at terrain. Know what is coming and be prepared to react. Be alert for hazards.

· Keep front wheels straight at crest of hill or going over bumps.

· Adjust speed according to trail, terrain, and visibility conditions.

· Use of a helmet and or protective gear is recommended for certain operating conditions.

Driving Across Slopes

c CAUTION: Avoid injury! Help prevent severe bodily injury or death due to tipping or loss of control. Reduce speed and exercise extreme caution on slopes and in sharp turns. Be especially cautious when changing direction on slopes.

W15212

· Sit on center of seat and keep both feet within foot platform perimeter.

· Stay alert for holes, rocks and other hidden hazards in the terrain.

· When riding on soft terrain, turn front wheels slightly uphill to keep utility vehicle on a straight line across the hill.

· If utility vehicle begins to tip, turn front wheel downhill to gain control before proceeding.

· Use of a helmet or protective gear is recommended for certain operating conditions.

Climbing Or Descending A Hill

c CAUTION: Avoid injury! Help prevent severe bodily injury or death due to loss of control. Reduce load when operating over rough terrain.

Reduce speed when turning or when operating around obstacles or on rough ground.

W15212

· Sit on center of seat and keep both feet within foot platform.

· Never drive past the limit of visibility. Slow down near crest of hill until getting a clear view of the other side.

· Keep front wheels straight at crest of hill or going over bumps.

· DO NOT stop or start suddenly when going uphill or downhill. Be especially cautious when changing direction on slopes.

· If vehicle stops or loses power going up a hill, apply park brake to hold vehicle on slope. Maintain direction of travel and release brake slowly. Back straight down hill slowly while maintaining control. DO NOT turn vehicle sideways. Vehicle is more stable in a straight forward or rearward position.

· When descending a hill, remove foot from accelerator and apply brakes to reduce speed and maintain control.

· Use of a helmet and/or protective gear is recommended for certain operating conditions.

Riding Through Water

c CAUTION: Avoid injury! Help prevent serious bodily injury or death due to loss of vehicle control.

· Avoid water whenever possible.

· Sit on center of seat and keep both feet within foot platform perimeter.


IMPORTANT: Avoid damage! Help avoid potential damage to the electrical components of this vehicle. Cross a body of water at a reduced speed without creating a wake.

M78558

· Never cross any body of water where depth may be unknown to the operator. As an operational guideline, deep water is considered anything in excess of 152 mm (6 in.) in depth. Tires may float, making it difficult to maintain control.

· Choose a course within the waterway where both banks have a gradual incline. Cross at a point known to be safe.

· Proceed at a slow steady speed to avoid submerged obstacles and slippery rocks.

· Avoid water crossings where the operation of a utility vehicle may cause damage to waterway beds or erode waterway shoreline.

Operating Foot Brake and Accelerator Pedals

c CAUTION: Avoid injury! Help prevent bodily injury due to loss of control, load shifting and/or tipping. Reduce speed before braking, when turning, when hauling loads at higher speeds, when operating around obstacles, and when operating on any hazardous off-road conditions.

M97960

· Release accelerator pedal (A) and apply foot brake pedal (B) evenly and firmly to slow down or stop.

· Avoid hard braking applications.

· Push down the accelerator pedal slowly and smoothly when using.

· Before braking, remove foot from the accelerator pedal.

Using the Directional Control Lever

c CAUTION: Avoid injury! Help prevent the possibility of personal injury or damage to the vehicle. DO NOT move the directional control lever while the vehicle is in motion. Always bring the vehicle to a full stop before moving the directional control lever.

M97990 M97961

The directional control lever (A) is located on a console to the right and below the operator seat. There are three positions:

· FORWARD: Move the lever downward to position (B).

· NEUTRAL: Move lever to the middle position (C).

· REVERSE: Move the lever rearward to position (D).

Using the Charge Meter/Hour Meter (Optional)

Charge Meter

NOTE: Key switch must be turned to the ON "1" position to activate the charge meter LED display.

When activated and during normal operation the charge meter will continuously monitor the battery charge.

M97478 M97962

The charge meter (A) has a multicolored 10-bar LED that displays vehicle state of charge. Only one LED will illuminate at a time.

· A double flashing RED 2-bar LED signals "empty" at 80% of battery discharge. This signals to the operator that the battery charge is very low and the vehicle should return to an area where the battery set can be charged.

· A flashing YELLOW 3-bar LED signals "energy reserve" at 70% of battery discharge. This signals to the operator that the battery charge is getting low.

· A GREEN 5-bar LED signals that the vehicle "energy reserve" is between 50 and 100% of battery charge.

Hour Meter

· The hour meter (B) shows number of hours the vehicle has run.

· The service interval chart gives necessary service intervals. Use the hour meter and the service interval chart to determine when the vehicle will need service. (See Service Interval Chart section.)

Using the Service/Drive Switch

This utility vehicle is equipped with a two position service/drive toggle switch.

· Raise and tilt operator seat forward to locate switch.

Service Position

c CAUTION: Avoid injury! Help prevent serious personal injury or damage to the vehicle. When the service/drive switch is moved to the SERVICE position there is still electric battery voltage present in all vehicle electrical harnesses.

M98022 M98028

When the vehicle service/drive switch (A) is moved to the SERVICE position (B) the vehicle is disabled and prohibited from being driven.

The service/drive switch should be moved to the SERVICE position when:

· Performing any service function on the vehicle.

· The vehicle is not going to be in service for an extended period of time (one month or more).

· The vehicle is being towed.

Drive Position

When the vehicle service/drive switch (A) is moved to the DRIVE position (C) the vehicle controller is energized. When the key switch is turned to the ON "1" position, controls are energized and the vehicle is ready for normal operation.

Using Park Brake

c CAUTION: Avoid injury! Help prevent serious bodily injury due to loss of vehicle control. Always engage the park brake when the vehicle is left unattended.

This utility vehicle is equipped with a roll away alarm. An audible beeping alarm will sound if the park brake is not engaged and the vehicle should begin to roll downhill.

NOTE: Applying foot brake pedal while engaging and disengaging park brake decreases effort required to pull or push park brake lever.

To ENGAGE park brake:

M97961 M98020

· Pull up lever (A) and latch into position.

To DISENGAGE park brake:

· Pull up on lever (A).

· Depress button (B).

· Push lever (A) down.

NOTE: Make sure the park brake release button (B) is released. While the vehicle is in motion the park brake must be fully disengaged for the vehicle to operate properly.

Adjusting Seats

1. Lift and tip vehicle seat forward.

M78512

2. Loosen hardware (A).

3. Slide seat forward or backward to desired position.

4. Tighten hardware.

Starting the Vehicle

c CAUTION: Avoid injury! Help prevent possible injury or death. Remain alert for bystanders, especially children when choosing an area of vehicle operation. When the accelerator pedal is depressed, the vehicle will move. Direction of travel will be dictated by the position of the directional control lever.

Help prevent the possibility of personal injury or damage to the vehicle. DO NOT move the directional control lever while the vehicle is in motion. Always bring the vehicle to a full stop before moving the directional control lever.

NOTE: The charger DC cable plug must be removed from the vehicle receptacle before starting the vehicle.

NOTE: Sit on vehicle operator's seat.

M97963

5. Turn key switch to the ON "1" position (A).

NOTE: Reverse warning indicator will sound anytime the key switch is in the ON "1" position and the directional control lever is placed in the REVERSE position.

6. Select direction of travel.

M97990 M97961

· FORWARD: Move the directional control lever (B) downward to position (C).

· REVERSE: Move the directional control lever (B) rearward to position (D).

7. Depress the foot brake pedal and release the park brake (E).

M97960

8. Slowly depress accelerator pedal (F) to start vehicle movement.

Stopping and Parking the Vehicle

c CAUTION: Avoid injury! DO NOT turn the key switch to the OFF "0" position while the directional control lever is in forward or reverse and the vehicle is in motion. The vehicle will brake causing possible injury to the operator and/or occupant.

M97960

1. Release the accelerator pedal (A) fully and depress the foot brake pedal (B).

2. Allow vehicle to come to a complete stop.

M97963

3. Turn key switch to the OFF "0" position (C).

M97990 M97961

4. Move directional control lever (D) to the NEUTRAL "N" position (E).

5. Engage the park brake (F).

6. Remove key.

Raising and Lowering Cargo Box

c CAUTION: Avoid injury! Help prevent bodily injury from unintentional lowering of the cargo box. Be sure vehicle is on a level stable surface and parking brake is engaged before raising cargo box.

The cargo box can be very heavy, help prevent bodily injury such as back strain. A cargo box without a Power Lift option is not meant to be raised by hand when loaded.

NOTE: The manual lift and lower procedures should be implemented after cargo box is emptied.

Raising Cargo Box Manually

1. Release cargo box latch.

M97993

· Push latch (A) inward.

2. Raise cargo box manually with lift handle (B).

c CAUTION: Avoid injury!

Help prevent injury from an electrical shock. DO NOT touch battery terminals, connectors, or wires that are not insulated.

M98038a

3. Support rod (C) will slide along slotted channel (D) and lock into latch slot (E).

NOTE: Be sure support rod is locked before leaning into battery and axle area.

Lowering Cargo Box Manually

M98040

1. Raise cargo box slightly using handle (B), release support rod (C) from latch slot by pulling up on rod.

2. Slowly lower cargo box, support rod will slide along slotted channel.

3. When cargo box is fully lowered, rod will latch at front of cargo box.

Raising and Lowering Cargo Box with Power Lift (Optional)

NOTE: Support rod should be removed and discarded if Power-Lift option is installed.

M97963

1. Turn key switch to the ON "1" position (A).

c CAUTION: Avoid injury!

Help prevent injury from an electrical shock. DO NOT touch battery terminals, connectors, or wires that are not insulated.

NOTE: Noise that is heard when Power Lift reaches the end of either the retract or extend function, or when the lift capacity is exceeded, is the actuator's clutch slipping. Keep clutch slip to a minimum. Take care not to overload vehicle capacity.

2. Raise cargo box.

M78469

· Depress TOP of rocker switch (B) mounted on the left side of the vehicle dash.

M98048

· Power Lift actuator (C) is mounted under the right side of the cargo box.

3. Lower cargo box.

· Depress BOTTOM of rocker switch (B) mounted on the left side of the vehicle dash until cargo box is fully lowered.

M78469

M97963

4. Turn key switch to the OFF "0" position (C).

Operating the Cargo Box Tailgate

M97994 M97995

1. Push in and down on each tailgate latch rod (A).

M97996

2. Pull each latch rod out and down. Lower tailgate (B) onto latch rod ends.


IMPORTANT: Avoid damage! To avoid damage to the vehicle tailgate, DO NOT operate vehicle with the latch rods disengaged and the tailgate (B) fully lowered. Lugs on tires will catch on tailgate causing structural damage.

M97997

Removing Cargo Box Tailgate

M97996

1. Raise tailgate (A) slightly. Rotate latch rod ends (B) to disengage from slots in cargo box sides.

2. Remove latch rods from each side of tailgate.

M97998

3. Swing tailgate down, align slots (C) in cargo box bracket and tabs (D) on tailgate rod.

4. Slide tailgate right or left with the tailgate rod passing through slot (C) to the outside of the cargo box bracket.

5. With one side of tailgate detached, route tailgate in the opposite direction through cargo box bracket slot to complete removal.

6. To replace, reverse steps.

Replacing Cargo Box Tailgate Latch Rods

M78493

1. Identify right (A) and left (B) latch rods.

M98000

2. Route each latch rod through the bottom of tailgate slot (C).

3. Slide and rotate each latch rod within slots (C) and (D) until required position within tailgate and cargo box brackets is accomplished.

M97994

4. Raise tailgate and push in and up to engage latch rod in slot (E) in top rail.

Daily Operating Checklist

Maintain desirable operational standards and help ensure the safety of the operator by routinely checking the following on a daily basis:

· Test safety systems. (Roll Away Alarm and Charger Interlock)

· Check tires for damage or cracking.

· Check brakes.

· Check operation of accelerator pedal.

· Clean operator's station.

· Check steering and linkages for proper operation.

· Check and make sure all vehicle safety labels are properly installed.

· Check charger and vehicle battery receptacle for damage.

· Visually inspect condition of batteries.

· Charge battery set.

TESTING SAFETY SYSTEMS

Use the following checkout procedure to check for normal operation of the utility vehicle.

If there is a malfunction during one of these procedures, DO NOT operate the vehicle. (See a John Deere dealer for service.)

Perform these tests in a clear open area. Keep bystanders away.

Test 1 (ROLL-AWAY ALARM)

NOTE: Perform this test with the vehicle parked on a hard, level surface.

1. Move the service/drive switch to the DRIVE position.

2. Sit on the operator's seat.

3. Release park brake.

4. Turn the key switch to the ON "1" position.

5. Move the directional control lever to the FORWARD position.

6. Operator off the seat.

7. Roll vehicle forward and rearward slightly.

· The vehicle should resist movement and the roll away alarm should begin beeping.

8. Move the directional control lever to the NEUTRAL position.

9. Roll vehicle forward and rearward slightly.

· The vehicle should resist movement and the roll away alarm should begin beeping.

NOTE: The reverse warning indicator will sound.

10. Move the directional control lever to the REVERSE position.

11. Roll vehicle forward and rearward slightly.

· The vehicle should resist movement and the roll away alarm should begin beeping.

12. Turn the key switch to the OFF "0" position.

13. Repeat steps 6-11.

· The vehicle should resist movement and the roll away alarm should begin beeping.

Test 2 (CHARGER INTERLOCK)

1. Move the service/drive switch to the DRIVE position.

2. Engage park brake.

NOTE: It is not necessary to connect the charger AC input plug to an electrical outlet when performing this test.

3. Connect the battery charger DC cable plug to the vehicle battery receptacle located below the operator seat on the left side of the vehicle.

M98018

· Grasp DC plug handle (A) and push plug straight into receptacle to the full engagement mark (B).

4. Turn the key switch to the ON "1" position.

5. Move the directional control lever to the REVERSE position.

· The reverse warning alarm must not sound.

6. Disconnect the DC cable plug from the vehicle receptacle.

· The reverse warning alarm must sound.

Carrying and Distributing a Load

M78553

c CAUTION: Avoid injury! Help prevent bodily injury from loose or shiftable loads. Keep all shields in place. Be sure load guard is installed.

Help prevent bodily injury from loss of control due to overloading or uneven loading.

When stopping and starting on a grade with a loaded cargo box, use of the foot brake is recommended to help manage vehicle speed.

· Reduce load and ground speed when operating over rough or hilly terrain.

· DO NOT overload utility vehicle. Limit loads to those that can be safely controlled.

· On level terrain, maximum cargo box payload capacity for this utility vehicle is 227kg (500 lb.).

· When loading objects into utility vehicle, be sure load is securely anchored and evenly distributed in cargo box. Shifting loads will affect stability.

· Avoid concentrated loads at rear or side of cargo box to prevent vehicle from tipping over.

· DO NOT carry loads above height of load guard.

Avoid Overloading

c CAUTION: Avoid injury! To help prevent bodily injury from loads shifting forward, DO NOT load above height of load guard.

Payload is more than just pounds carried, load density is more important for judging load. An example of load densities and volumes is listed using sand as a material.

M78556

NOTE: Because of the difference in weight between dry and wet sand, the only way of getting true weight of the load you are carrying is by using a weigh scale.

· For this vehicle, dry sand weighing 227 kg (500 lb) would be approximately 1/2 of cargo box volume.

· For other materials such as those that are bagged, weight is normally printed on the bag.

· The load carrying capacity of this vehicle for example is 227 kg (500 lb). Five bags of material weighing 45.5 kg (100 lb) would be a full load.

Dumping a Load

M78552

c CAUTION: Avoid injury! Help prevent serious personal injury or death due to tipping. When dumping loads, keep the rear of the vehicle a reasonable distance away from the edge of a loading dock or ravine.

· Back vehicle to area where load is desired.

· Engage parking brake and release tailgate latches.

c CAUTION: Avoid injury! The cargo box can be very heavy, help prevent bodily injury such as back strain. A cargo box equipped without a Power Lift option is not meant to be raised by hand when loaded.

· If vehicle is NOT equipped with Power Lift, empty box first before raising by hand.

· If vehicle is equipped with Power Lift, raise cargo box.

· When load is dumped, lower cargo box, DO NOT operate vehicle with cargo box in raised position.

Towing Loads

c CAUTION: Avoid injury! To help prevent personal injury due to loss of control or tipping, always tow a load slowly enough to maintain control.

To provide adequate braking ability and traction do not tow a load unless utility vehicle cargo box is loaded.

· Be sure to load cargo box of utility vehicle before towing a load.

· DO NOT tow a load with this vehicle that exceeds 272kg (600 lb.).

· DO NOT exceed a tongue weight of 45kg (100 lb).

· Never exceed 16 km/h (10 mph) when towing a load. Tow load at a speed slow enough to maintain control.


IMPORTANT: Avoid damage! Extreme angles (A) such as high railroad crossings can place high bending loads on hitch connection. If traversing terrain where these conditions exist, use of a ball or pintle type hitch is recommended.

M78554

· Always use hitch point provided on, and hitches approved for the utility vehicle. They are the approved hitch point and hitches, DO NOT modify in any way.

M78520

Towing the Utility Vehicle

c CAUTION: Avoid injury! Always remove any load from the vehicle cargo box before towing. Towing a loaded vehicle could cause either vehicle to lose control.


IMPORTANT: Avoid damage! DO NOT tow utility vehicle in excess of 15 mph (24 km/h) or motor may rupture or disintegrate.

NOTE: When the service/drive switch is moved to the SERVICE position the utility vehicle can be towed with the directional control lever in any position.

M98028

1. Move the service/drive switch to the SERVICE position (A) before towing the utility vehicle. (See Using the Service/Drive Switch in this section.)

2. Attach a tow line to the utility vehicle.

M98050 M98001

· If equipped with the optional front bumper, attach the tow line securely to the front bumper mounting assembly (B).

· If vehicle is not equipped with a front bumper, attach the tow line inside the front axle (C) in the position shown.

3. Disengage park brake.

4. Tow vehicle slowly and carefully to desired location.

Transporting the Utility Vehicle

· Use a heavy-duty trailer, full size pick-up or flatbed truck to transport the utility vehicle.

M78557

NOTE: Space limitations may vary from one truck manufacturer to another. Short bed trucks do not have the necessary length requirement to accommodate the utility vehicle. Vehicle width to outside of tires is 1524 mm (60 in.).

· Turn key switch to the OFF "0" position.

· Move shift lever to the NEUTRAL "N" position.

· Engage park brake.

· Remove key.

· Fasten machine to trailer with heavy-duty straps, chains, or cables. Both front and rear straps must be directed down and outward from the vehicle.

· Trailer or truck must have all signs and lights required by law.

Use Care In Handling and Servicing Batteries

Prevent Battery Explosions

MIF

Batteries contain sulfuric acid and produce explosive mixtures of hydrogen. Because hydrogen gas is present even when the utility vehicle is not in operation, make sure batteries are stored and serviced in a well ventilated area.

· Always wear proper eye, face and hand protection.

· Keep sparks, lighted matches, and open flame away from the top of battery.

· Remove all jewelry (watches, rings, bracelets, etc.) before servicing the electrical system or batteries.

· Make sure work area is well ventilated.

· Never lean over battery while testing or charging.

· Keep removable vents tight and level except when servicing electrolyte.

c CAUTION: Avoid injury! Use extreme caution when using tools, wires or metal objects near batteries. A short circuit and/or spark could cause an explosion. Wrap tools with vinyl tape to prevent shorting out of batteries.

· Exercise caution while working with tools or conductors to prevent short circuits and sparks.

WRENCH

· Never check battery charge by placing a metal object across the posts. Use a battery tester, voltmeter or hydrometer.

· DO NOT charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Charging Safety

· Never attempt to charge a battery set without first reviewing the instructions provided with the charger

· Use only the battery charger provided with the utility vehicle. DO NOT use substitutes.

· Always wear proper eye, face and hand protection.

· Keep sparks, lighted matches, and open flame away from the top of battery.

· Make sure work area is well ventilated.

· Never lean over battery while testing or charging.

· Keep removable vents tight and level except when servicing electrolyte.

· To avoid dangerous sparks, make sure the charger AC plug is disconnected before disconnecting the DC plug to the vehicle receptacle.

· Never try to charge a visibly damaged or frozen battery.

· Be sure that the key switch and all electrical accessories are turned off.

· Make sure the charger leads are not broken, frayed or loose.

· If the battery becomes hot, or if violent gassing or spewing of electrolyte occurs, unplug the charger AC source first before removing the DC plug.

· If battery set is on charge, unplug the charger AC plug before disconnecting the charger DC cable plug to avoid dangerous sparks.

Using the Battery Charger

M95703

The battery charger is included with every GATOR® Electric Utility Vehicle. The charger is totally automatic and has no controls.

The charger monitors the battery set state of charge and contains an electronic timer that automatically turns the charger off as the batteries reach full charge.

The charger is a taper charge type which automatically decreases the rate of charge to provide good equalization of battery cells and reduce water usage.

Battery Charger Safety

c CAUTION: Avoid injury! Help reduce the risk of a fire, electrical shock or an explosion:

· Each charger should have its own (15 ampere maximum) branch circuit protection in accordance with National Electrical Code, ANSI/NFPA 70 and local codes and ordinances.

· Make sure AC and DC cords, plugs, and receptacles are in good condition. DO NOT use if cords, plug, or receptacles are damaged, loose, or feel hotter than normal. Replace worn or damaged parts immediately.

· DO NOT use charger near flammable materials or vapors such as fuels, grain dust or solvents.

· DO NOT use extension cords.

· Explosive mixtures of hydrogen gas are present within battery cells. DO NOT service or charge vehicle batteries in an area where open flames, sparks, cigarettes, or any other source of combustion are present.

· Use this charger only on 48 volt, 24 cell wet lead acid systems of 140 to 270 amp hours
(20 hour rate).

· DO NOT use a charger other than the type supplied with this vehicle.

· Make sure the charger is sufficiently elevated above the ground to permit maximum ventilation underneath and around the charger.

· DO NOT touch portions of output connector or battery terminals that are not properly insulated.

· Connect only to properly grounded three wire outlets.

· DO NOT insert objects into charger housing ventilation slots.

· DO NOT use the charger outdoors. Charger and power cords must be kept dry and not exposed to any form of moisture.


IMPORTANT: Avoid damage! Help reduce the risk of injury or damage to the vehicle. Read and follow all safety warnings and operating instructions supplied with and inscribed on top of the charger.

M97970

Charging Procedure


IMPORTANT: Avoid damage! An improper battery charging procedure may shorten battery life. DO NOT use battery additives, the life of the batteries can be shortened.

· Become familiar with the operating instructions issued with the charger.

· Batteries are to be charged after each period of use.

· Charging for short intervals when the vehicle is not being used is permissible.

· In cold weather batteries should be taken off charge just prior to use.

· DO NOT charge the batteries if the utility vehicle is not used that day.

· DO NOT allow batteries to set in a state of discharge.

· Prior to using the utility vehicle each day, always make sure the batteries are fully charged.

M95703

1. With the battery charger DC output cable plug (A) disconnected from the vehicle, connect the AC input plug (B) to a properly grounded outlet.

c CAUTION: Avoid injury! DO NOT disconnect the DC output cord from the battery receptacle when the charger is on. The resulting arcing and burning will damage the connector and could cause the batteries to explode. Disconnect the AC power supply cord to turn the charger off before disconnecting the DC output plug.

NOTE: The vehicle battery set can be charged with the service/drive switch in the SERVICE or DRIVE position.

MIF M98017

2. Connect the DC output cable plug to the battery receptacle (C) located below the operator seat on the left side of the vehicle.

NOTE: This utility vehicle is equipped with a charger interlock feature. Electrical current to the ignition is locked out when the DC outlet plug is connected to the vehicle battery receptacle.

· Grasp the DC output plug handle (A) and push the plug straight into the receptacle to the full engagement mark (D).

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· The charger will turn on with an audible "click" and "hum" after a short 3-10 second delay.


IMPORTANT: Avoid damage! DO NOT allow the battery charger to operate more than 30 minutes with the charge rate over 25 amperes. This is misuse and will cause overheating and transformer burnout.

M95704 M98019

3. Monitor the ammeter (E) for the initial charge rate.

NOTE: If the batteries are heavily discharged, or the AC input line voltage is higher than nominal, the charge rate may exceed 25 amperes. Under normal conditions, the charge rate will taper to less than 25 amperes within 30 minutes.

· The initial charge rate will vary between 16 and 25 amperes depending upon the state of battery discharge and AC line voltage.

· The charge rate will decrease to 4-9 amperes for the last few hours of charge if all batteries are good.

· The charger turns off automatically when the batteries reach full charge.

· As batteries age, it is normal for the charge rate to increase above the 4 to 9 amp finish rate. The charger will still determine when the batteries are as charged as they can be and then turn off.

· The required charge time varies with the depth of the discharge. Under normal conditions, the typical charge time is 10-12 hours. This is the normal charge time for batteries which have been discharged to 80% of their capacity.

As much as four additional hours may be required to properly charge the batteries under the following conditions:

· Heavily discharged batteries (more than 80% discharged).

NOTE: When charging new or cold batteries, a higher than normal finishing charge voltage can be expected. This results in a low finish charge rate (2-5 amperes), and additional time is required to achieve equalization of all battery cells.

· Charging new batteries (batteries with less than 20 to 50 discharge/charge cycles).

· Charging cold batteries.

· Charging optional larger batteries.


IMPORTANT: Avoid damage! DO NOT leave the charger DC output cable plug connected while unattended for two or more days in a row. Severe overcharging and possible damage to the batteries will result if the charger electronic timer should fail and not turn off, or turn back on. Avoid damage to the output cord, plug and receptacle. DO NOT pull cord. DO NOT twist, bend, or pull output cable plug sideways.

4. Disconnect the DC output cable plug from the vehicle receptacle.

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· Grasp the DC output plug handle (A) and pull the plug straight out of the receptacle.