Ezgo ST 400 48V User manual

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

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
SAFETY
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”.
Vehicles equipped with Precision Drive System™ (PDS) must be towed with the Run-Tow/Maintenance switch, located
under the passenger seat, in the ‘Tow/Maintenance’ position.
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.
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˚
Throughout this guide NOTE, CAUTION and WARNING
will be used.
A NOTE indicates a condition that should be observed.
A CAUTION indicates a condition that may result in
damage to the vehicle.
A WARNING indicates a hazardous condition
that could result in severe injury or death.
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.
Battery posts, terminals and related accesso-
ries contain lead and lead compounds. Wash
hands after handling.

Page i
Owner’s Manual and Service Guide
OWNER’S MANUAL
AND SERVICE GUIDE
ELECTRIC POWERED
UTILITY VEHICLES
ST 400 E
Starting Model Year 2009
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 INCIDEN-
TAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [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.
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).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain. The battery charger and the controller are both sources of
electrical drain. Unplug the battery charger DC plug from the vehicle receptacle.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.

Page iii
TABLE OF CONTENTS
Owner’s Manual and Service Guide
SAFETY ................................................................................................................ Inside covers
GENERAL INFORMATION .......................................................................................................ii
SAFETY INFORMATION ........................................................................................................... v
GENERAL ................................................................................................................................. ix
BEFORE INITIAL USE ..............................................................................................................1
Fig. 1 Initial Service Chart .........................................................................................................1
PORTABLE CHARGER INSTALLATION ............................................................................................................1
Fig. 2 Proper Charger Installation .............................................................................................2
Fig. 3 Charger Receptacle Location .........................................................................................2
CONTROLS AND INDICATORS ............................................................................................... 2
KEY/LIGHT SWITCH ...........................................................................................................................................2
Fig. 4 Key/Light Switch & State of Charge Meter .....................................................................3
DIRECTION SELECTOR .....................................................................................................................................3
Fig. 5 Direction Selector Types .................................................................................................3
STATE OF CHARGE METER .............................................................................................................................3
HOUR METER ..................................................................................................................................................... 3
ACCELERATOR PEDAL .....................................................................................................................................3
Fig. 6 Accelerator and Brake Controls ......................................................................................3
COMBINATION SERVICE BRAKE AND PARK BRAKE PEDAL ........................................................................4
RUN - TOW/MAINTENANCE SWITCH (PDS VEHICLES ONLY) .............................................4
Fig. 7 Run-Tow/Maintenance Switch ........................................................................................4
PLASTIC LOADBED .................................................................................................................4
MANUAL LIFT BED OPERATION .......................................................................................................................5
Fig. 8 Manual Bed Latch ...........................................................................................................5
TAILGATE OPERATION .....................................................................................................................................5
OPERATING THE VEHICLE ..................................................................................................... 5
PRECISION DRIVE SYSTEM™ ..........................................................................................................................6
Regenerative Braking .............................................................................................................................6
Pedal-Up Braking ....................................................................................................................................6
Walk-Away Feature ................................................................................................................................7
Anti-Roll Back Feature ............................................................................................................................7
Anti-Stall Feature ....................................................................................................................................7
High Pedal Disable Feature ....................................................................................................................7
Default Mode Feature .............................................................................................................................7
STARTING AND DRIVING ..................................................................................................................................7
STARTING VEHICLE ON A HILL ........................................................................................................................8
COASTING ..........................................................................................................................................................8
LABELS AND PICTOGRAMS .............................................................................................................................8
SUN TOP AND WINDSHIELD .............................................................................................................................8
TOWING A TRAILER ..........................................................................................................................................8
VEHICLE CLEANING AND CARE ............................................................................................9
VEHICLE CLEANING ..........................................................................................................................................9
REPAIR ......................................................................................................................................9
LIFTING THE VEHICLE ......................................................................................................................................9
Fig. 9 Lifting the Vehicle .........................................................................................................10
WHEELS AND TIRES ......................................................................................................................................10
Tire Repair ............................................................................................................................................10
Wheel Installation .................................................................................................................................11
Fig. 10 Wheel Installation .......................................................................................................11
LIGHT BULB REPLACEMENT ..........................................................................................................................11
Fig. 11 Headlight and Turn Signal Bulb Replacement ............................................................11
Fig. 12 Tail and Brake Light Bulb Replacement .....................................................................11
FUSE REPLACEMENT .....................................................................................................................................11
TRANSPORTING VEHICLE ....................................................................................................12
TOWING ............................................................................................................................................................12

Page iv Owner’s Manual and Service Guide
TABLE OF CONTENTS
HAULING .......................................................................................................................................................... 12
SERVICE AND MAINTENANCE ..............................................................................................12
SERIAL NUMBER PLATE AND LOCATION .................................................................................................... 13
Fig. 13 Serial Number Plate and Location ............................................................................. 13
PERIODIC SERVICE SCHEDULE .................................................................................................................. 14
Fig. 14 Periodic Service Schedule ......................................................................................... 14
TIRE INSPECTION ........................................................................................................................................... 15
BRAKES ........................................................................................................................................................... 15
Periodic Brake Test for Mechanical Brakes ......................................................................................... 15
Fig. 15 Typical Brake Performance Test ................................................................................ 16
REAR AXLE ...................................................................................................................................................... 16
Checking the Lubricant Level ............................................................................................................... 16
LUBRICATION .................................................................................................................................................. 16
Fig. 16 Add, Check and Drain Axle Lubricant ........................................................................ 17
Fig. 17 Lubrication Points ....................................................................................................... 17
PDS SYSTEM TEST ......................................................................................................................................... 17
HARDWARE ..................................................................................................................................................... 17
CAPACITIES AND REPLACEMENT PARTS ................................................................................................... 17
Fig. 18 Capacities and Replacement Parts ............................................................................ 17
BATTERIES AND CHARGING ................................................................................................17
SAFETY ............................................................................................................................................................ 17
Fig. 19 Torque Specifications and Bolt Grades ....................................................................... 18
BATTERY ......................................................................................................................................................... 18
BATTERY MAINTENANCE .............................................................................................................................. 19
At Each Charging Cycle ....................................................................................................................... 19
Monthly ................................................................................................................................................. 19
Electrolyte Level and Water ................................................................................................................. 19
Fig. 20 Correct Electrolyte Level ............................................................................................ 19
Fig. 21 Water Purity Table ..................................................................................................... 20
Fig. 22 Automatic Watering Gun ............................................................................................ 20
Battery Cleaning ................................................................................................................................... 20
Battery Replacement ............................................................................................................................ 21
Fig. 23 Preparing Acid Neutralizing Solution .......................................................................... 21
Fig. 24 36V Battery Connections ........................................................................................... 21
Prolonged Storage ............................................................................................................................... 21
BATTERY CHARGING ..................................................................................................................................... 22
Fig. 25 Freezing Point of Electrolyte ...................................................................................... 22
AC Voltage ........................................................................................................................................... 23
TROUBLESHOOTING ...................................................................................................................................... 23
Hydrometer .......................................................................................................................................... 23
Fig. 26 Hydrometer ................................................................................................................ 24
Using A Hydrometer ............................................................................................................................. 24
Fig. 27 Hydrometer Temperature Correction ......................................................................... 24
GENERAL SPECIFICATIONS .................................................................................................27
ST 400 E ........................................................................................................................................................... 28
Fig. 28 Vehicle Dimensions ....................................................................................................29
Fig. 29 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter ........... 30
LIMITED WARRANTIES ..........................................................................................................31
(U.S. AND CANADA) ........................................................................................................................................ 32
LABELS AND PICTOGRAMS ............................................................................Appendix A - 1
DECLARATION OF CONFORMITY (EUROPE ONLY) ......................................Appendix B - 1

Owner’s Manual and Service Guide Page v
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.
This vehicle conforms to the current applicable standard(s) for safety and performance requirements.

Page vi
SAFETY INFORMATION
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.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
Never use the chassis or body as a ground connection.
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.
GENERAL OPERATION
Always:
• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
• Read and observe all warnings and operation instruction labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being operated.
• Reduce speed to compensate for poor terrain or conditions.
• Apply service brake to control speed on steep grades.
• Maintain adequate distance between vehicles.
• Reduce speed in wet areas.
• Use extreme caution when approaching sharp or blind turns.
• Use extreme caution when driving over loose terrain.
• Use extreme caution in areas where pedestrians are present.
MAINTENANCE
Always:
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.
• Ensure that repairs are performed by those that are trained and qualified to do so.
• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing
any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

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.
• Check the polarity of each battery terminal and be sure to rewire the batteries correctly.
• 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.
• 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
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because
hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air
exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the recepta-
cle when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable
electrical code (whichever is higher).

Owner’s Manual and Service Guide Page ix
SAFETY INFORMATION
GENERAL
The following text is provided as recommended by part II of ANSI/ITSDF B56.8 - 2006. The manufacturer strongly
endorses the contents of this specification.
6 GENERAL SAFETY PRACTICES
6.1 Introduction
6.1.1 Like other machines, carriers can cause injury if improperly used or maintained. 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 could 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 user may arrange for a modification or alteration to a carrier, provided however, the controlling party
shall: