Cushman COMMANDER 280 User manual

A Textron Company
GASOLINE POWERED UTILITY VEHICLES
ISSUED OCTOBER 2007 REVISED MARCH 2010
OWNER’S MANUAL
AND SERVICE GUIDE
606895

SAFETY
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
For any questions on material contained in this manual, contact an authorized representative for clarification.
Read and understand all labels located on the vehicle. Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-
vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed
on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.
Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.
Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.
Be sure that this manual remains as part of the permanent service record should the vehicle be sold. Throughout this
guide NOTE, CAUTION and WARNING will be used.
Observe these NOTES, CAUTIONS and WARNINGS; be aware that servicing a vehicle requires mechanical skill and
a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.
WASH HANDS
AFTER HANDLING!
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
BATTERY WARNING
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
BATTERIES
CONTAIN LEAD
AND RELATED PARTS
!
<
14
˚
25
%
DO NOT
DRIVE ACROSS
SLOPES IN
EXCESS OF 14˚
A NOTE indicates a condition that should be observed.
A CAUTION indicates a condition that may result in
damage to the vehicle.
A WARNING indicates a hazardous condition
that could result in severe injury or death.
Engine exhaust from this product contains
chemicals known, in certain quantities, to
cause cancer, birth defects, or other reproduc-
tive harm.
The exhaust emissions of this vehicles’ engine complies with
regulations set forth by the Environmental Protection Agency
(EPA) of the United States of America (USA) at time of manu-
facture. Significant fines could result from modifications or tam-
pering with the engine, fuel, ignition or air intake systems.
Battery posts, terminals and related accesso-
ries contain lead and lead compounds. Wash
hands after handling.
This spark ignition system meets all requirements of the Cana-
dian Interference-Causing Equipment Regulations.
C
e système d'allumage par étincelle de véhicule respecte
t
outes les exigences du Règlement sur le matériel brouilleu
r
d
u Canada.

Page i
Owner’s Manual and Service Guide
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED
UTILITY VEHICLES
COMMANDER™(280, 280CARB)
COMMANDER™(2200, 2200CARB)
Starting Model Year 2008
The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to
include these changes on units leased/sold previously.
The information contained in this Manual may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice.
The E-Z-GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
These are the orginal instructions as defined by 2006/42/EC.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]
INTERNATIONAL: PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page ii Owner’s Manual and Service Guide
GENERAL INFORMATION
This vehicle has been designed and manufactured in the United States of America (USA) as
a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in
the USA unless otherwise indicated.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling battery may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory
specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original
vehicle specifications in order to maintain the United States of America Federal and State
emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75°F (-60°C).

Page iii
Owner’s Manual and Service Guide
TABLE OF CONTENTS
SAFETY ................................................................................................................ inside covers
GENERAL INFORMATION .......................................................................................................ii
SAFETY INFORMATION ........................................................................................................... v
BEFORE INITIAL USE ..............................................................................................................1
Fig. 1 Initial Service Chart .......................................................................................................1
CONTROLS AND INDICATORS ............................................................................................... 1
KEY/LIGHT SWITCH ...........................................................................................................................................2
Fig. 2 Key/Light Switch ...........................................................................................................2
LOW OIL PRESSURE INDICATOR LIGHT .........................................................................................................2
FUEL GAUGE ......................................................................................................................................................2
DIRECTION SELECTOR .....................................................................................................................................2
Fig. 3 Direction Selector .........................................................................................................2
CHOKE ................................................................................................................................................................2
Fig. 4 Choke ...........................................................................................................................2
ACCELERATOR PEDAL .....................................................................................................................................3
Fig. 5 Accelerator, Brake and Horn Controls ..........................................................................3
COMBINATION BRAKE AND PARK BRAKE PEDAL .........................................................................................3
OPTIONAL FRONT DISC BRAKES.....................................................................................................................3
HORN...................................................................................................................................................................3
PLASTIC LOAD BED ................................................................................................................ 3
MANUAL LIFT BED OPERATION .......................................................................................................................4
Fig. 6 Manual Bed Latch .........................................................................................................4
Fig. 7 Gas Strut........................................................................................................................4
TAIL GATE OPERATION.....................................................................................................................................4
ELECTRIC LIFT BED OPERATION.....................................................................................................................4
Fig. 8 Electric Lift Switch..........................................................................................................4
OPERATING THE VEHICLE ..................................................................................................... 5
RUN-IN ................................................................................................................................................................5
Fig. 9 Check Oil Level on Dipstick ..........................................................................................5
Fig. 10 Clean Entire Dipstick .....................................................................................................6
COLD STARTING ................................................................................................................................................6
STARTING AND DRIVING ..................................................................................................................................6
STARTING THE VEHICLE ON A HILL ................................................................................................................6
COASTING ..........................................................................................................................................................6
FUEL ....................................................................................................................................................................7
Fig. 11 Fueling ..........................................................................................................................7
BATTERY ............................................................................................................................................................7
LABELS AND PICTOGRAMS .............................................................................................................................7
SUN TOP AND WINDSHIELD .............................................................................................................................7
12 VOLT POWER OUTLET..................................................................................................................................8
Fig. 12 12 Volt Power Outlet......................................................................................................8
TOWING A TRAILER ..........................................................................................................................................8
VEHICLE CLEANING AND CARE ............................................................................................ 8
VEHICLE CLEANING ..........................................................................................................................................8
REPAIR ..................................................................................................................................... 9
LIFTING THE VEHICLE ......................................................................................................................................9
Fig. 13 Lifting the Vehicle .........................................................................................................9
WHEELS AND TIRES .........................................................................................................................................9
WHEEL INSTALLATION ....................................................................................................................................10
Fig. 14 Wheel Installation .......................................................................................................10
LIGHT BULB REPLACEMENT ..........................................................................................................................10
Fig. 15 Headlight and Turn Signal Bulb Replacement ...........................................................11
Fig. 16 Tail and Brake Light Bulb Replacement ......................................................................11
FUSE REPLACEMENT .....................................................................................................................................11
VEHICLE WITH A DISCHARGED BATTERY ...................................................................................................11
TRANSPORTING VEHICLE ....................................................................................................11

Page iv Owner’s Manual and Service Guide
TABLE OF CONTENTS
TOWING ............................................................................................................................................................11
NEUTRAL LOCK ...............................................................................................................................................11
Fig. 17 Neutral Lock ................................................................................................................12
HAULING ...........................................................................................................................................................12
SERVICE AND MAINTENANCE ..............................................................................................13
SERIAL NUMBER PLATE AND LOCATION .....................................................................................................13
Fig. 18 Serial Number Plate & Location...................................................................................14
PERIODIC SERVICE SCHEDULE ...................................................................................................................15
Fig. 19 Periodic Service Schedule ..........................................................................................15
TIRE INSPECTION ............................................................................................................................................16
FOUR CYCLE ENGINE.............................................................................................................17
ENGINE SPECIFICATIONS...............................................................................................................................17
ENGINE DESCRIPTION.....................................................................................................................................17
CHECKING OIL LEVEL......................................................................................................................................17
Fig. 20 Clean Entire Dipstick....................................................................................................17
Fig. 21 Check Oil Level on Dipstick .........................................................................................17
CHANGING THE OIL..........................................................................................................................................17
Fig. 22 Oil Viscosity Chart........................................................................................................18
Fig. 23 Cleaning Top of Engine ...............................................................................................18
Fig. 24 Remove Oil Filter .........................................................................................................18
Fig. 25 Inspect Oil Filter...........................................................................................................18
Fig. 26 Oil Drain Plug...............................................................................................................19
Fig. 27 Add Engine Oil.............................................................................................................19
Fig. 28 Check Belt Tension with Guage...................................................................................19
STARTER/GENERATOR BELT TENSION ........................................................................................................19
Fig. 29 Check Belt Tension Manually.......................................................................................20
Fig. 30 Adjust Belt Tension......................................................................................................20
ADJUSTING THE BELT .....................................................................................................................................20
BATTERY CLEANING........................................................................................................................................20
Fig. 31 Preparing Acid Neutralizing Solution............................................................................21
Fig. 32 Typical Brake Performance Test..................................................................................21
BRAKES .............................................................................................................................................................21
PERIODIC BRAKE TEST FOR MECHANICAL BRAKES ..................................................................................22
AIR INTAKE AND COOLING FINS.....................................................................................................................22
Fig. 33 Cleaning Cooling System with Air................................................................................22
REAR AXLE........................................................................................................................................................22
CHECKING THE LUBRICANT LEVEL...............................................................................................................22
Fig. 34 Add, Check and Drain Rear Axle Lubricant .................................................................23
AIR CLEANER INSPECTION AND REPLACEMENT ........................................................................................23
Fig. 35 Air Cleaner...................................................................................................................23
LUBRICATION....................................................................................................................................................23
SPARK PLUGS...................................................................................................................................................23
Fig. 36 Lubrication Points ........................................................................................................24
Fig. 37 Gapping the Spark Plug...............................................................................................24
PROLONGED STORAGE ..................................................................................................................................24
CAPACITIES AND REPLACEMENT PARTS.....................................................................................................25
Fig. 38 Capacities and Replacement Parts..............................................................................25
HARDWARE.......................................................................................................................................................25
Fig. 39 Torque Specifications and Bolt Grades........................................................................26
GENERAL SPECIFICATIONS ..................................................................................................29
Fig. 40 Vehicle Dimensions......................................................................................................32
Fig. 41 Vehicle Incline Specifications & Turning Clearance Diameter.....................................33
LABELS AND PICTOGRAMS ..................................................................................Appendix A
VEHICLE WARRANTIES..........................................................................................Appendix B
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT...................................................................B-3
FEDERAL EMISSION COMPONENT DEFECT WARRANTY .........................................................................B-5
DECLARATION OF CONFORMITY..........................................................................Appendix C

Owner’s Manual and Service Guide Page v
SAFETY INFORMATION
SAFETY INFORMATION
This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the
manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the
product. To reduce the chance of personal injury or property damage, the following must be carefully observed:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z-
GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured
vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER FED-
ERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Fed-
eral Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer
MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for
LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the
requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in the
places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final
Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPER-
ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE
REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-Z-
GO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this
SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has rea-
son to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or
through the Internet at the website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
GENERAL
Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. The manufacturer strongly suggests that all users and maintenance personnel read this
entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein.
If you have any questions regarding this vehicle, contact your closest representative or write to the address on the back
cover of this publication, Attention: Product Service Department.
The manufacturer reserves the right to make design changes without obligation to make these changes on units previ-
ously sold and the information contained in this manual is subject to change without notice.
The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result from the
use of the material in this manual.

Owner’s Manual and Service Guide
Page vi
SAFETY INFORMATION
This vehicle conforms to the current applicable standard(s) for safety and performance requirements.
These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety
Standards of the United States of America (USA) and are not equipped for operation on public streets. Some commu-
nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi-
nances.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and
disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the
vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when
used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,
terrain and common sense.
Operation of the vehicle is limited to persons above the height of 59 in. (150 cm)
GENERAL OPERATION
Always:
• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
• Read and observe all warnings and operation instruction labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being operated.
• Leave the vehicle when there is a risk of lightning.
• Reduce speed to compensate for poor terrain or conditions.
• Apply service brake to control speed on steep grades.
• Maintain adequate distance between vehicles.
• Reduce speed in wet areas.
• Use extreme caution when approaching sharp or blind turns.
• Use extreme caution when driving over loose terrain.
• Use extreme caution in areas where pedestrians are present.
MAINTENANCE
Always:
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.
• Ensure that repairs are performed by those that are trained and qualified to do so.
• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing
any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

Owner’s Manual and Service Guide Page vii
SAFETY INFORMATION
• Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the
battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material.
• Use specified replacement parts. Never use replacement parts of lesser quality.
• Use recommended tools.
• Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the
safety of personnel nor jeopardize the safe operation of the vehicle.
• Support the vehicle using wheel chocks and jack stands. Never get under a vehicle that is supported by a jack. Lift
the vehicle in accordance with the manufacturer’s instructions.
• Empty the fuel tank or plug fuel hoses to prevent fuel leakage.
• Maintain the vehicle in an area away from exposed flame or persons who are smoking.
• Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
• Test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both
vehicular and pedestrian traffic.
• Replace damaged or missing warning, caution or information labels.
• Keep complete records of the maintenance history of the vehicle.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that could result in severe
personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury,
refer the repair or maintenance to a qualified mechanic.
VENTILATION
Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.
Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water
heaters and furnaces.
Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon
monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

Owner’s Manual and Service Guide
Page viii
SAFETY INFORMATION
NOTES:

Owner’s Manual and Service Guide Page ix
SAFETY INFORMATION
The following text is pr ovided as recommended by part II of ANSI/ITSDF B5 6.8 - 2005. The manufacturer strongly
endorses the contents of this specification.
6 GENERAL SAFETY PRACTICES
6.1 Introduction
6.1.1 Like other machines, carriers can cause injury if improperly used or maintained. Part II contains broad safety
practices applicable to carrier operation. Before operation, the user shall establish such additional specific safety prac-
tices as may reasonably be required for safe operation.
6.1.2 Premise review — The user shall periodically review their premises, and as conditions warrant, identify areas
where carriers should not be operated and to identify possible hazards such as the following examples:
a) Steep Grade — In areas where steep grades exist, carrier operation should be restricted to the designated vehi-
cle’s pathways where possible, and shall be identified with a suitable warning giving the following information:
“Warning, steep grade.”
b) Wet Areas — Wet areas could cause a carrier to lose traction and could affect steering, stability and braking.
c) Sharp Turns, Blind Spots, Bridge Approaches — Sharp turns, blind spots, bridge approaches, and other poten-
tially hazardous areas shall be identified with a suitable warning to the operator of the nature of the hazard and
stating the proper precautions to be taken to avoid the hazard.
d) Loose Terrain — Loose terrain could cause a carrier to lose traction and c ould affect steering, stability, and
braking.
6.2 Operation
Experience has shown that carriers, which comply with the provisions, stated in paragraph 9.3.9 are stable when
properly operated and when operated in accordance with specific safety rules and practices established to meet actual
operating terrain and conditions. However, improper operation, faulty maintenance, or poor housekeeping may contrib-
ute to a condition of instability and defeat the purpose of the standard. Some of the conditions which may affect stability
are failure of the user to follow safety practices; also, ground and floor conditions, grade, speed, loading, the operation
of the carrier with improper loads, battery weight, dynamic and static forces, and the judgment exercised by the carrier
operator.
a) The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard.
b) The user shall survey specific operating conditions and environment, and establish and train carrier operators to
comply with additional, specific safety practices.
6.3 Nameplates, Markings, Capacity, and Modifications
6.3.1 The user shall maintain in a legible condition all nameplates, warnings, and instructions, which are supplied by
the manufacturer.
6.3.2 Except as provided in 6.3.4, no modifications or alterations to a carrier, which may affect the capacity, stability,
or safe operation of the carrier, shall be made without the prior written approval of the original carrier manufacturer or a
successor thereof. When the carrier manufacturer or its successor approves a modification or alteration, appropriate
changes shall be made to capacity plates, decals, tags, and operation and maintenance manuals
6.3.3 As required under paragraphs 6.3.1 or 6.3.2, the manufacturer shall be contacted to secure new nameplates,
warnings, or instructions, which shall then be affixed in their proper place on the carrier.
6.3.4 In the event that the carrier manufacturer is no longer in business and there is no successor in interest to the
business, the us er may arrange for a modific ation or altera tion to a carrier, provided however, the controlling p arty
shall:
(1) Arrange for the modification or alteration to be designed, tested, and implemented by an engineer(s) expert in
carrier(s) and their safety;

Owner’s Manual and Service Guide
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SAFETY INFORMATION
(2) Maintain a permanent record of the design, test(s), and implementation of the modification or alteration;
(3) Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals;
(4) Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been mod-
ified or altered together with the date of the modification or alteration, and the name of the organization that
accomplished the tasks.
6.4 Fuel Handling and Storage
6.4.1 The user shall supervise the storage and handling of liquid fuels (when used) to be certain that it is in accor-
dance with ANSI/NFPA 505 and ANSI/NFPA 30 or as required by local ordinance.
6.4.2 Storage and handing of liquefied petroleum gas fuels shall be in accordance with ANSI/NFPA 505 and ANSI/
NFPA 58 or as required by local ordinance. If such storage or handling is not in compliance with these standards, the
user shall prevent the carrier from being used until such storage and handling is in compliance with these standards.
6.43 Prevent fire and explosion caused by static electric discharge. Use on ly non-metal, portable fuel containers
approved by the Underwriter’s Laboratory (U.L.) or the American Society for Testing & Materials (ASTM). If using a fun-
nel, make sure it is plastic and has no screen or filter.
Static electric discharge can ignite gasoline vapors in an ungrounded fuel container. Remove the fuel container from
the bed of a c arrier or the trunk of a car ban place on the ground away from the carrier before filling. Keep nozzle in
contact with container opening while filling. When practical, remove equipment from trailers or truck beds and re -fuel
them on the ground. If this is not possible, use a portable, plastic fuel container to refuel equipment on a truck bed or
trailer.
6.5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers
6.5.1 The user shall require battery changing and charging facilities and procedures to be in accordance with ANSI/
NFPA 505 or as required by local ordinance.
6.5.2 The user shall periodically inspect fa cilities and review proc edures to be certain that ANSI/NFPA 505 or as
required by local ordinance, are strictly complied with, and shall familiarize carrier operators with it.
6.5.3 Maintenance and storage areas for carriers shall be properly ventilated to avoid fire hazards in accordance
with applicable fire codes and ordinances.
Ventilation for internal combustion engine powered carriers shall be provided to remove flammable vapors (gases),
fumes and other flammable materials. Consult applicable fire codes for specific levels of ventilation.
Ventilation for electric powered carriers shall be provided to remove the accumulation of flammable hydrogen gas
emitted during the battery charging process. The amount of hydrogen gas emitted depends upon a number of factors
such as the condition of the batteries, the output rate of the battery charger and the amount of time the batteries are on
charge. Because of the highly volatile nature of hydrogen gas and its propensity to accumulate in pockets, a minimum
number of air changes per hour is required during charging.
Consult applicable fire and safety codes for the specific ventilation levels required as well as the use of explosion
proof electrical apparatus. SAE J1718 can be followed to check for hydrogen gas levels.
6.6 Hazardous Locations
6.6.1 The user shall determine the hazard classification of the particular atmosphere or location in which the carrier
is to be use in the accordance with ANSI/NFPA 505.
6.6.2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI/NFPA
505.
6.7 Lighting for Operating Area
The user, in accordance with his responsibility to survey the environment and operating conditions, shall determine if

Owner’s Manual and Service Guide Page xi
SAFETY INFORMATION
the carrier requires lights and, if so, shall equip the carrier with appropriate lights.
6.8 Control of Noxious Gases and Fumes
When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be main-
tained within limits specified in the American Conference of Governmental Industrial Hygienists publication,:Threshold
Limit Values for Chemical Substances and Physical Agents in the Workroom Environment.” This may be accomplished
by ventilation maintenance of emission control equipment recommended or provided by the manufacturer of the equip-
ment.
6.9 Warning Device(s)
6.9.1 The user shall make periodic inspections of the carrier to be certain that the sound-producing and/or visual
device(s) if so equipped are maintained in good operating condition.
6.9.2 The user shall determine if operating conditions require the carrier to be equipped with additional sound-pro-
ducing or visual devices or both and be responsible for providing and maintaining such devices, in accordance with the
manufacturer’s recommendations.
6.10 Safety Interlocks
The user shall make periodic inspections of the carrier to be certain that the safety interlock system, if so equipped,
is operating properly.
7 OPERATING SAFETY RULES AND PRACTICES
7.1 Personnel and Burden Carrier Operator Qualifications
Only persons whoa are trained in the proper operation of the carrier shall be authorized to operate the carrier. Oper-
ators shall be qualified as to visual, auditory, physical, and mental ability to safely operate the equipment according to
Section 7, all other applicable parts of this Standard and the operators’ manual.
7.2 Personnel and Burden Carrier Operators’ Training
7.2.1 The user shall conduct an operators’ training program.
7.2.2 Successful completion of the operators’ training program by the operator shall be required before operation of
the carrier. The program shall be presented in its entirely to all-new operators and not condensed for those claiming
previous experience.
7.2.3 The user shall include as a minimum in the operators’ training program the following.
a) Instructional material provided by the manufacturer including the operators; manual;
b) Emphasis on safety of passengers, material loads, carrier operator, and other person(s);
c) General safety rules contained within this Standard and the additional specific rules determined by the user in
accordance with this Standard, and why they were formulated;
d) Introduction of equipment, control locations of the environment which could affect carrier operation;
e) Operator competency evaluations.
7.3 Personnel and Burden Carrier Operator Responsibility
7.3.1 General Operator Responsibility
7.3.1.1 Read and follow operators’ manual
7.3.1.2 Do not operate carrier under the influence of drugs and alcohol.

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SAFETY INFORMATION
7.3.1.3 Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger
other persons.
7.3.1.4 Riding on the carrier by persons other than the operator is authorized only on personnel seat(s)
provided by the manufacturer. All parts of each person’s body shall remain within the plan view outline of the carrier.
7.3.1.5 When a carrier is to be left unattended, stop the carrier, apply the parking brake, stop the engine
or turn off power, turn off the control or ignition circuit, and remove the key if provided. Additionally, for the electric car-
riers, the forward and reverse directional controls, should be neutralized if a means is provided. Block the wheels if the
carrier is on a n incline.
7.3.1.6 A carrier is considered unattended when the operator is 7.6m (25 ft.) or more from the carrier
which remains in his view, or whenever the operator leaves the carrier and it is not within his view. When the operator
is dismounted and within 7.6m (25 ft.) of the carrier still in his view, he still must have controls neutralized, and the park-
ing brake(s) set to prevent movement.
7.3.1.7 Maintain a safe distance from potential hazards, such as edges of ramps and platforms.
7.3.1.8 Use only approved carriers in hazardous locations, as defined in the appropriate safety standards.
7.3.1.9 Report all accidents to the user.
7.3.1.10 Do not add to, or modify, the carrier.
7.3.1.11 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles, access
to stairways, or fire equipment.
7.3.1.12 Only operate carrier while within operator’s station.
7.3.2 Traveling
7.3.2.1 Observe all traffic regulations, including authorized speed limits. Under normal traffic conditions keep to the
right. Maintain a safe distance, based on speed of travel, from a carrier or vehicle ahead, and keep the carrier under control at all
times.
7.3.2.2 Yield the right of way to pedestrians, ambulances, fire trucks, or other carriers or vehicles in emergency sit-
uations.
7.3.2.3 Do not pass another carrier or vehicle traveling in the same direction at intersections, blind spots, or at other
dangerous locations.
7.3.2.4 Keep a clear view of the path of travel, observe other traffic and personnel, and maintain a safe clearance.
7.3.2.5 Slow down or stop, as conditions dictate, and activate the sound-producing warning device at cross aisles
and when visibility is obstructed at other locations.
7.3.2.6 Ascend or descend grades slowly.
7.3.2.7 Avoid turning, if possible, and use ca ution on grades, ramps, or inclines, normally travel straight up and
down.
7.3.2.8 Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop
in a safe manner.
7.3.2.9 Make starts, stops, turns, or direction reversals in a smooth manner so as no t to shift the load, endanger
passengers, or lose control of the carrier.
7.3.2.10 Do not operate carrier in a dangerous manner.
7.3.2.11 Slow down when approaching, or on, wet or slippery surfaces.
7.3.2.12 Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly,
and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power, and
set parking brakes. It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit.
7.3.2.13 Avoid running over loose objects, potholes, and bumps.
7.3.2.14 Reduce carrier speed to negotiate turns.
7.3.2.15 Avoid any action verbal or physical by an operator or passenger, which could cause the operator to be dis-
tracted.

Owner’s Manual and Service Guide Page xiii
SAFETY INFORMATION
7.3.3 Loading
7.3.3.1 Refer to operators’ manual for loading instruction.
7.3.3.2 Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered,
operate with extra caution.
7.3.3.3 Handle only loads within the capacity of each cargo area of the carrier as specified by the manufacturer.
7.3.3.4 Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manu-
facturer.
7.3.4 Operator Care of Personnel and Burden Carriers
7.3.4.1 Read and follow operators’ manual.
7.3.4.2 At the beginning of each shift during which the carrier will be used, the operator shall check the carrier con-
dition and inspect the tires, warning devices, lights, battery(s), speed and directional controllers, brakes, safety interlocks, and steer-
ing mechanism. If the carrier is found to be in need of repair, or in any way unsafe, the matter shall be reported immediately to the
user and the carrier shall not be operated until it has been restored to safe operating condition.
7.3.4.3 If during operation the carrier becomes unsafe in any way, the matter shall be reported immediately to the
user, and the carrier shall not be operated until it has been restored to safe operating condition.
7.3.4.4 Do not make repairs or adjustments unless specifically trained and authorized to do so.
7.3.4.5 Before refueling, the engine shall be stopped and allowed to cool. The operator and passengers shall leave
the carrier before refueling.
7.3.4.6 Spillage of hazardous materials shall be contained immediately and addressed via appropriate hazardous
materials regulations.
7.3.4.7 Do not operate a carrier with a leak in the fuel system or battery(s). Battery(s) shall be charged and serviced
per manufacturer’s instructions.
7.3.4.8 Do not use open flames for checking electrolyte level in storage battery(s) or liquid level in fuel tanks.
8 MAINTENANCE PRACTICES
8.1 Introduction
Carriers may become hazardous if maintenance is neglected. Maintenance facilities, trained personnel, and proce-
dures shall be provided. Such facilities may be on or off the premises.
8.2 Maintenance Procedures
Maintenance and inspection of all carriers shall be performed in conformance with the following practices
and should follow the manufacturer’s recommendations.
a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed.
b) Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect carriers.
c) Before undertaking maintenance or repair follow the manufacturer’s recommendations for immobilizing the car-
rier.
d) Chock wheels and support carrier, before working underneath it.
e) Before disconnecting any part of the engine fuel system, be sure the shutoff valve, if so equipped, is closed and
follow carrier manufacturer’s recommended practice.
f) Operation to check performance of the carrier shall be conducted in an authorized area where suitable condi-
tions exist, free of vehicular and pedestrian traffic.
g) Before returning carrier to service, follow the manufacturer’s instructions and recommended procedure.
h) Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to
check level or leakage of fuel, battery electrolyte, or coolant.
i) Properly ventilate the work area in accordance with applicable regulations or local ordinance.

Owner’s Manual and Service Guide
Page xiv
SAFETY INFORMATION
j) Handle fuel cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken
the tank and make it unsafe for use.
k) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors,
guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s rec-
ommendations.
l) Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure
that maintenance preserves the original approved safe operating features.
m) Fuel systems shall be checked for leaks and condition of parts. If a leak is found, action shall be taken to prevent
the use to the carrier until the cause of the leak has been repaired.
n) The carrier manufacturer’s capacity, operation, and maintenance instruction plated, tags, or decals shall be
maintained in legible condition.
o) Batteries, motors, speed and directional controllers, limit s witches, protective devices, ele ctrical conductors/
insulators, and connections shall be inspected and maintained per carrier manufacturer’s recommendation.
p) Carriers shall be kept in a clean co ndition to minimize hazards and facilitate detection of components needing
service.
q) Modifications and additions which affect capacity and safe carrier operation shall not be performed without man-
ufacturer’s prior written authorization; where authorized modifications have been made, the user shall ensure
that capacity, operation, warning, and maintenance instruction plates, tags, or safety labels are changed accord-
ingly.
r) Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a
quality at least equal to that provided in the original equipment.
s) Disconnect batteries, negative connection(s) first. When reconnecting, connect positive connection first.
t) Hydraulic systems, if so equipped, shall be checked for leaks, for condition of parts. Keep body and hands away
from pin-holes or nozzles that eject fluids under high pressure. Use paper or cardboard, not hands, to check for
leaks.
ANSI/ITSDF B56.8 - 2005

OPERATION AND SERVICE INFORMATION
Page 1
Owner’s Manual and Service Guide
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Thank you for purchasing this vehicle. Before driving the
vehicle, we ask you to spend some time reading this
Owner’s Manual and Service Guide. This guide contains
the information that will assist you in maint aining this
highly reliable v ehicle. Some illustrations may show
items that are optional for your vehicle. This guide covers
the operation of several vehicles; therefore, some picto-
rial views may not represent your vehicle. Physical differ-
ences in controls will be illustrated.
This vehicle has been designed and manufactured as a
‘World Vehicle’. Some countries have individual require-
ments to comply with their specifications; therefore,
some sections may not apply in your country.
Most of the service procedures in this guide can be
accomplished using common automotive hand tools.
Contact your service representative on ser vicing the
vehicle in accordance with the Periodic Service Sched-
ule.
Service Parts Manuals and Technician’s Repair and Ser-
vice Manuals are available from a local Distributor, an
authorized Branch or the Service Parts Department.
When ordering parts or requesting information for your
vehicle, provide vehicle model, serial number and manu-
facture code.
BEFORE INITIAL USE
Read, understand and follow the sa fety label on the
instrument panel. Be sure you understand how to oper-
ate the vehicle, its equipment and how to use it safely.
Maintaining good performance depends to a large extent
on the operator.
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.
Before a new vehicle is put into operation, the items
shown in the INITIAL SERVICE CHART must be per-
formed (Ref Fig. 1 on page 1).
Vehicle battery must be fully charged before initial use.
Check for correct tire inflation. See GENERAL SPECIFI-
CATIONS.
Check for oil or fuel leaks that could have developed in
shipment from the factory.
Determine and record braking distance required to stop
vehicle for future brake performance tests.
Remove the protective clear plastic, that protect the seat
bottom and back rest during shipping, before placing the
vehicle in service.
Fig. 1 Initial Service Chart
CONTROLS AND INDICATORS
Vehicle controls and indicators consist of:
•key/light switch
•direction selector
•choke
•fuel gauge
•low oil pressure indicator light
•accelerator pedal
•combination service and park brake pedal
•front disc brakes (optional)
•horn
ITEM SERVICE OPERATION
Battery Charge battery
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Check hydraulic brake fluid level if equipped
Establish acceptable stopping distance
Tires Check air pressure (see SPECIFICATIONS)
Fuel Fill tank with correct fuel
Engine Check oil level
Ref Isc 6

OPERATION AND SERVICE INFORMATION
Page 2 Owner’s Manual and Service Guide
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
KEY/LIGHT SWITCH
Located on the dash panel, this switch enables the basic
electrical system of the vehicle to be turned on and off by
turning the key. To prevent inadvertent operation of the
vehicle when left unattended, the key should be turned to
the ‘OFF’ position and removed (Ref Fig. 2 on page 2).
LOW OIL PRESSURE INDICATOR LIGHT
A low oil pressure indicator light is loca ted on the dash
panel (Ref Fig. 2 on page 2). The light illuminates when
the oil pres sure is low. Check oil level. If oil level is
between ADD and FULL mark on dipstick, a mechanical
problem exists within the engine and the vehicle must
not be driven. Contact a local distr ibutor or authorized
branch.
Fig. 2 Key / Light Switch
If the vehicle is equipped with lights, the key switch has a
position to operate them, indicated by the light icon.
FUEL GAUGE
The fuel gauge (if equipped) will either be located on the
dash panel (electric) (Ref Fig. 2 on page 2) or directly on
the fuel tank (mechanical).
If the vehicle is equipped with factory installed custom accesso-
ries, some accessories remain operational with the key switch
in the ‘OFF’ position.
DIRECTION SELECTOR
To reduce the possibility of component damage, the
vehicle must be completely stopped before moving the
direction selector.
Located on the seat support panel, this lever permits the
selection of either ‘F’ (forward) or ‘R’ (reverse) (Ref Fig. 3
on page 2). Vehicle should be left in ‘F’ when unattended.
Fig. 3 Direction Selector
CHOKE
The choke is used to aid cold starting (Ref. Fig. 4 on
page 2). See COLD ST ARTING section for operating
instructions.
Fig. 4 Choke
To prevent engine damage, do not operate engine
until oil pressure is corrected. Do not over fill engine.
Too much oil may cause smoking or allow oil to
enter the filter enclosure.
If oil level is below ADD mark on dipstick, add oil to bring
level to FULL mark. Drive Vehicle a short distance and
check oil pressure. If oil light does not come on, continue
to use vehicle.
OFF
OFF
ON
ON
FUEL
F
E
Low Oil Pressure
Indicator Light
Key/Light Switch Fuel
Gauge
R
ef Kes 2
Forward
Reverse
R
ef Dsl 2
Choke
Ref Chk 1

OPERATION AND SERVICE INFORMATION
Page 3
Owner’s Manual and Service Guide
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
ACCELERATOR PEDAL
Unintentional movement of the accelerator ped-
al will release the park brake and may cause
the vehicle to move which could result in
severe injury or death.
With the key switch ‘ON’, depressing the accele rator
pedal starts the engine. When the pedal is released, the
engine will stop (Ref Fig. 5 on page 3). To stop the vehi-
cle more quickly, depress the service brake.
Fig. 5 Accelerator, Brake and Horn Controls
If key switch is ‘ON’ and park brake is set, depressing the
accelerator inadvertently will release the park brake and
will cause the vehicle to move which could cause severe
injury or death.
Depressing the acc elerator pedal will release the p ark
brake if it is engaged. This is a feature to assure the vehi-
cle is not driven with the park brake engaged. Depress-
ing the accelerator pedal is not the preferred method of
releasing the park brake.
Depressing the lower section of the brake pedal is the pre-
ferred method of releasing the park brake to assure the longest
service life of brake components.
COMBINATION SERVICE AND PARK BRAKE
PEDAL
The brake pedal incorporates a park brake feature (Ref
Fig. 5 on page 3). To engage, push down on the upper
section of the pedal until it locks in place. The park brake
will release when the service brake pedal is depressed.
Use the lower section of the brake pedal to operate the
service brake system.
OPTIONAL FRONT DISC BRAKES
The front disc brakes activate as the brake pedal
reaches the ’park’ or ’latch’ p osition. Depressing the
brake pedal further will increase the effectiveness of the
front brakes
HORN
The horn is operated by pushing the horn button located
on the floor to the left of the brake pedal (Ref Fig. 5 on
page 3)
PLASTIC LOAD BED
The manual lift bed is the standard bed for the vehicle.
The bed may be equipped with a n optional electric lift
switch.
Failure to follow these instructions may result in
personal injury, damage the vehicle and/or
cause the vehicle to tip over. Operate the vehi-
cle with awareness of the load. Read, under-
stand and follow the Danger label affixed to the
front of the load bed.
Do not permit anyone to ride in the bed.
Before operating, check to ensure no one is
behind the vehicle.
A load bed warning label is affixed to the inside front of
the bed (see Appendix A). This label must be understood
and observed at all times for safe operation of the vehi-
cle. See the lo ad bed warning label for maximum load.
The load must be positioned in the bed as far forward as
possible, distributed in such a way that its center of grav-
ity must not be higher than height noted on label, and
securely fastened down. Failu re to follow these instruc -
tions may result in severe personal injury, damage the
vehicle and/or cause the vehicle to tip over. Operate the
vehicle with awareness of the load.
Do not permit anyone to ride in the bed.
Do not drive the vehicle with the load bed raised or with
the tailgate unsupported.
When using the electric lift, be sure to avoid backing up
to the edge of a drop off, such as a loading dock ravine.
A misjudgment of distance or an unstable surface could
result in the vehicle falling backwards.
Before operating, check to ensure no one is behind the
vehicle.
Park
Brake
Accelerator
PARK
Service
Brake
R
ef Abc 1
Horn

OPERATION AND SERVICE INFORMATION
Page 4 Owner’s Manual and Service Guide
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Never fill a gas can in the bed of a vehicle. Stat-
ic discharge could ignite gasoline vapor and
cause an explosion.
Always place a gas can on the ground before filling.
Never fill a gas can in the bed of the vehicle. Static elec-
tricity is built up during the fueling process and could dis-
charge causing the gasoline vapor to ignite.
MANUAL LIFT BED OPERATION
Exercise caution while operating the manual lift
bed to ensure the bed is not released during lift-
ing or lowering procedure. Severe injury could
result if bed is released and traps fingers or oth-
er body parts.
To lift the manual lift bed, pull up on th e latch release
handle immediately behind the driver seat (Ref Fig. 6 on
page 4). Raise the bed using the handle on the side of
the bed.
Fig. 6 Manual Bed Latch
The gas strut will assist in raising the empty loadbed and
will keep the bed raised (Ref Fig. 7 on page 4).
Gas Strut & Tether Cable are available only for cer tain
models.
Over time, the gas strut may allow the load bed to slowly lower.
If this condition is evident, replacement of gas strut is required.
To lower the ma nual lift bed, grasp the bed handle and
lower the bed to th e rest position. Be sure hands are
not trapped by the bed.
Fig. 7 Gas Strut
TAIL GATE OPERATION
To open the tail gate, lift tail gate straight up with a sharp
upward pull to lift out of the closed position and pivot out
for open position. To remove the tail gate, remove the
side cables from the loadbed and open tail gate until it is
straight down, move tail gate panel straight up to remove
from pins and remove from the load bed. Reassemble in
reverse order.
ELECTRIC LIFT BED OPERATION
Exercise caution while operating the electric lift
bed to ensure clothing is not snagged during
lifting or lowering procedure. Severe injury
could result if bed is lowered and traps fingers
or other body parts.
The electric lift toggle switch is located on the driver side
of the front seat panel (Ref Fig. 8 on page 4). Move the
toggle switch upward to raise the dump bed and down-
ward to lower the dump bed.
Fig. 8 Electric Lift Switch
Ref Mbl 3
F
ront of Vehicle
Manual Load Bed Latch
Pull Up to Release
Ref Gss 1
Tether Cable
Gas Strut
Raise
Lower
R
ef Lbs 1