GLOBAL INDUSTRIAL 615162 4 Seat Electric Utility Vehicle User Manual

615162 4 Seat Electric Utility Vehicle

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Specifications

• Brand: Global IndustrialTM
• Model: 615162
• Type: 4-Seat Electric Utility Vehicle

Product Information

The Global IndustrialTM 4-Seat Electric Utility Vehicle is
designed for various utility and transportation needs. It provides
a comfortable and efficient way to move people or cargo in
industrial settings.

Product Usage Instructions

Receiving and Unpacking Vehicle

Before operating the vehicle, carefully read the manual
provided. Ensure the vehicle is in a safe working condition upon
delivery and conduct regular inspections thereafter. Visit the
following link for model no. 615162 unpacking and assembly
instructions:
Unpacking and Assembly Instructions.

Vehicle Identification

The vehicle serial number can be found on a name plate located
directly below the steering wheel column for identification
purposes.

FAQ

Q: What should I do if I encounter a hazardous situation while

operating the vehicle?

A: If you encounter a hazardous situation, immediately stop the
vehicle, follow safety protocols as outlined in the manual, and
seek assistance if needed.

Q: How often should battery maintenance be performed?

A: Regular battery maintenance should be performed as per the
guidelines provided in the manual. It is recommended to inspect and
clean the batteries periodically to ensure optimal performance.

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User’s manual
Customer Service US: 1-800-645-2986

Manual del usuario
Servicio de atención al Cliente US: 1-800-645-2986

Manuel de l’utilisateur
Service à la clientèle Canada: 888-645-2986

Global IndustrialTM 4-Seat Electric Utility Vehicle
Model: 615162

Operator’s Manual

Electric Utility Vehicle

User Manual

MANUAL AND CONVENTIONS
· Please read the manual carefully before operating vehicle. Keep this manual with the vehicle at all times.
· This manual serves as a guide for the electric utility vehicle. The manual is subject to change without notice. In case of any discrepancies, consider the actual vehicle as correct and use this manual for reference purposes only. Global Industrial is not liable for errors in this manual or any consequential damage that results from the use of this manual.
· For the most up-to-date version of the manual, please refer to the Global Industrial website.
· Throughout the manual, important safety information will be presented with the following headers. Please pay special attention to this information.
Indicates a hazardous situation that, if not avoided, will result in death or serious injury. Indicates a hazardous situation that, if not avoided, could result in death or serious injury. Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. Indicates information considered important but not hazard related.

RESPONSIBILITIES
The “owner” refers to individuals or legal entities directly using or entrusting others to use the vehicle, as described in this manual.
The owner is responsible for operator training, maintenance and repairs of the vehicle, and adherence to safety guidelines.
The owner must ensure that all operators thoroughly read and understand the manual.
The owner must provide a copy of the manual with vehicle at all times in cases it is rented, loaned, or transferred to another party.

Electric Utility Vehicle
TABLE OF CONTENTS
1. GENERAL SAFETY INFORMATION……………………………………………………………………………………………………………….4 1.1. Safety Warning Labels …………………………………………………………………………………………………………………….4
2. RECEIVING AND UNPACKING VEHICLE………………………………………………………………………………………………………..5 3. VEHICLE IDENTIFICATION ………………………………………………………………………………………………………………………….6
3.1. Serial Number………………………………………………………………………………………………………………………………..6 3.2. Chassis Number ……………………………………………………………………………………………………………………………..6 3.3. VIN and ID Number…………………………………………………………………………………………………………………………6 4. VEHICLE SPECIFICATIONS ………………………………………………………………………………………………………………………….7 4.1. Dimensions ……………………………………………………………………………………………………………………………………7 4.2. Performance ………………………………………………………………………………………………………………………………….7 4.3. Tires & Wheels……………………………………………………………………………………………………………………………….7 4.4. Suspension & Brakes……………………………………………………………………………………………………………………….7 4.5. Capacities………………………………………………………………………………………………………………………………………8 4.6. Noise…………………………………………………………………………………………………………………………………………….8 4.7. Vehicle Weight & Load Capacities …………………………………………………………………………………………………….8 5. VEHICLE CONTROLS………………………………………………………………………………………………………………………………….9 6. VEHICLE OPERATION ………………………………………………………………………………………………………………………………16 6.1. Before Operating Vehicle……………………………………………………………………………………………………………….17 6.2. Operating Vehicle …………………………………………………………………………………………………………………………18 6.3. After Operating Vehicle …………………………………………………………………………………………………………………19 6.4. Charging the Vehicle……………………………………………………………………………………………………………………..19
6.4.1. Charging Indication Lights ………………………………………………………………………………………………………20 7. BATTERY MAINTENANCE…………………………………………………………………………………………………………………………21
7.1. Disconnecting the Battery from Main Terminal ………………………………………………………………………………..21 7.2. Cleaning the Batteries …………………………………………………………………………………………………………………..22
7.2.1. Cleaning the Exterior……………………………………………………………………………………………………………..22 7.2.2. Cleaning the Terminals …………………………………………………………………………………………………………..22 7.3. Inspecting the Batteries…………………………………………………………………………………………………………………22 7.3.1. Inspecting the Terminals ………………………………………………………………………………………………………..22 7.4. Reconnecting the Batteries ……………………………………………………………………………………………………………22 7.5. Installing the Batteries…………………………………………………………………………………………………………………..22 7.6. Open-Circuit Voltage Test ……………………………………………………………………………………………………………..22 8. CHARGER SPECIFICATIONS AND MAINTENANCE ……………………………………………………………………………………….23 8.1. Charger Troubleshooting and Error Codes ……………………………………………………………………………………….25 9. DRIVE MOTOR MAINTENANCE ………………………………………………………………………………………………………………..26 9.1. Cleaning the Drive Motor ………………………………………………………………………………………………………………26 9.2. Drive Motor Faults and Possible Cause ……………………………………………………………………………………………26 10. SPEED CONTROLLER MAINTENANCE ………………………………………………………………………………………………………27 10.1. Cleaning the Speed Controller………………………………………………………………………………………………………27 11. REAR AXLE MAINTENANCE ……………………………………………………………………………………………………………………27 11.1. Rear Axle Troubleshooting……………………………………………………………………………………………………………28 12. LIFTING THE VEHICLE…………………………………………………………………………………………………………………………….29 13. REPLACING THE TIRES …………………………………………………………………………………………………………………………..29 13.1. Inspecting the Tires …………………………………………………………………………………………………………………….28 14. CHECKING THE BRAKES …………………………………………………………………………………………………………………………29 15. LUBRICATING THE VEHICLE……………………………………………………………………………………………………………………30 16. MAINTENANCE SCHEDULE …………………………………………………………………………………………………………………….31 17. LOCATION OF FUSES……………………………………………………………………………………………………………………………..33 18. WIRE DIAGRAM……………………………………………………………………………………………………………………………………34 19. STORING THE VEHICLE ………………………………………………………………………………………………………………………….34

Electric Utility Vehicle
GENERAL SAFETY INFORMATION
Safety Warning Labels

1. Operating Instructions Label

2. Off-Road Use Only Label

3. Grade Maximum Label

Electric Utility Vehicle

User Manual

4. Pinch Point Warning Label

5. Pinch Point Warning Label

6. Rear Cargo and Seat Warning Label
RECEIVING AND UNPACKING VEHICLE
Inspect the vehicle immediately after delivery and unpacking. If any damage should occur to the packaging, make note of it. After unpacking the vehicle, ensure to charge it for approximately 8 hours before operating. Examine the contents of all packages and accessories that may have come in separate packages along with the vehicle and ensure everything listed on the packing slip is there. Unassembled versions of model no. 615162 include a packing slip listing all assembly hardware and components and assembly instructions. All versions of model no. 615162 include an on-board charging cable. Refer to “Before Operating Vehicle” section of this manual to check that the vehicle is in correct operating condition.
Please read the manual carefully before operating vehicle. Ensure the vehicle is in a safe working condition upon delivery and conduct regular inspections thereafter. Refer to below QR code or link for model no. 615162 unpacking and assembly instructions (if applicable): https://www.globalindustrial.com/p/4 -seat-electric-utility-vehicle

Electric Utility Vehicle

User Manual

VEHICLE IDENTIFICATION
Serial Number
The vehicle serial number is on a name plate located directly below the steering wheel column.

Chassis Number
The vehicle chassis number is located above the rear right tire.

VIN and ID Number
The VIN and ID number are located above the rear left tire.

Electric Utility Vehicle

User Manual

VEHICLE SPECIFICATIONS
Dimensions
Length Width Height Ground Clearance Wheel Base Wheel Track
Performance
Forward Speed Turning Radius Hill Climb Side Park

115 in 46.5 in 80 in 4.6 in 66 in Front: 37″ Rear: 38.6″
13 mph – maximum 118 in 20% 20%

Tires & Wheels
Tires Wheels

205/50-10 4PR 10 x 6 aluminum

Suspension & Brakes
Brake System Front Suspension Rear Suspension

4-wheel hydraulic brake, hand-activated parking brake
Independent suspension
Leaf spring suspension Taper leaf spring & cylinder hydraulic shock absorber

Electric Utility Vehicle

Capacities
Motor Type Motor Horsepower Rating Battery Type Battery Quantity

36V DC motor 4 hp (3kW) 6V no-maintenance AGM gel batteries 6

Noise

Noise

68

Vehicle Weight & Load Capacities

Vehicle Dry Weight (w/o batteries) 926 lbs

Vehicle Curb Weight (w/ batteries) 1257 lbs

Load Capacity

595 lbs

Cargo Deck Capacity

220 lbs

User Manual

Electric Utility Vehicle
VEHICLE CONTROLS

User Manual

Electric Utility Vehicle

User Manual

Electric Utility Vehicle

1. Key Switch 2. Parking Brake Indicator Light Switch 3. Headlight Switch 4. Forward / Neutral / Reverse Control 5. Battery Level Indicator 6. USB Port 7. Turn Signal Lever 8. Horn Lever 9. Accelerator Pedal

10. Brake Pedal 11. Parking Brake 12. On-Board Charge Port 13. Charging Indicator Lights 14. Emergency Stop Button 15. Fixed Seat 16. Fold-Down Rear Seat 17. Hinged Windshield

1. Key Switch

Do not attempt to pull out key when key is in the ON position. This will damage vehicle/key.

The key switch is used to power the vehicle on or off. Turn key to “OFF” to turn off vehicle and remove key.

Turn key to “ON” to turn on vehicle.

Position

Function

OFF

Vehicle off. Not in use.

ON

Vehicle on. Vehicle in use.

2. Parking Brake Indicator Light
The parking brake light indicates when the parking brake is activated.

Electric Utility Vehicle

3. Headlight Switch

The headlight switch controls the headlights.

Position

Function

Up

High beam light

Down

Low beam light

4. Forward / Neutral / Reverse Switch
Failure to fully stop the vehicle before switching the forward / neutral / reverse control (FNR) can cause property damage and serious personal injury. Fully stop the vehicle before switching direction using the FNR.
Vehicle backup alarm will sound when the reverse direction is selected.

Position Up
Center Down

Function Forward Neutral Reverse

5. Battery Level Indicator
The battery level indicator has 10 tick marks that indicate battery level of the vehicle. As the battery level declines, the tick marks will move downwards. A flashing red light indicates that the battery is low and needs to be recharged.

6. USB Port
Vehicle is equipped with 5V, 2.4A USB receptacle for power and charge portable devices. When the USB receptacle is not in use, remove USB cord to prevent unintended battery discharge.

7. Turn Signal Lever

Position

Function

Down

Left

Center

Off

Up

Right

Electric Utility Vehicle

8. Horn Lever
Position Lift up (towards driver)

Function Horn

Neutral

–

9. Accelerator Pedal
Used to control speed. To increase the speed of the vehicle, gradually step on the pedal. Maximum speed to reached when pedal is fully depressed. The vehicle will slow down upon releasing the pedal.
If the accelerator pedal is stepped on before the vehicle is switched on, the vehicle will not run. In this case, you should release the accelerator pedal before turning the key to the “ON” position, then step down on accelerator pedal again to drive.
10. Brake Pedal
To decrease the speed of the vehicle, step on the brake pedal or bring vehicle to a full stop.
11. Parking Brake
Failure to engage the parking brake can cause property damage and serious personal injury. Engage the parking brake until it is fully engaged and prevents the vehicle from moving.
Always engage parking brake after parking vehicle or leaving the vehicle unattended.
Always disengage parking brake before driving vehicle. Failure to do so can cause serious damage to the vehicle.
The parking brake ensures the vehicle does not move while parked. It prevents unintended movement. Pull the parking brake up firmly to engage the parking brake. To disengage the parking brake, push and hold the button and push the parking brake downwards.
12.On-Board Charge Port
The on-board charge port enables easy vehicle charging. To charge vehicle, plug in charger into port.

Electric Utility Vehicle
13. Charging Indicator Lights

Indication Light Red light flashing Yellow light flashing Green light flashing

Battery Level <80% >80% 100%

NOTE: Lights flash in 1s intervals. If alternating colored lights are flashing, please refer to the `Charger Troubleshooting’ section in this manual.

14. Emergency Stop Button

Reset emergency stop button only when hazard has been cleared, and it is safe to operate the vehicle.

The emergency stop button is to be reserved to be used in case of emergencies ONLY. Do not use emergency stop button like a parking brake. Doing so can cause damage or malfunction to the vehicle.

The emergency stop button is used to cut-off all power on vehicle in case of emergencies.

Position Push Pull

Function Emergency button activates
Reset emergency button

Electric Utility Vehicle
15. Fixed Rear Seat
Ensure all passengers are seated and using handholds before operating vehicle. The rear seat supports a maximum of two passengers. Be wary of any pinch points when converting the cargo deck into a rear seat. In this configuration, the rear seat can accommodate two additional passengers.
16. Fold-Down Rear Seat
Be wary of any pinch points when converting the rear seat into a cargo deck. The rear seat can convert to a cargo deck to carry cargo.
17. Hinged Windshield
The windshield is a split hinged windshield that can be folded down depending on operator’s use case. The top panel of the windshield can be snapped off from the front roof struts of the vehicle and carefully placed down.

Electric Utility Vehicle
VEHICLE OPERATION
If any problems are found, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, severe personal injury, property damage or death.
This vehicle is not Federal or State DOT-approved and is not equipped to be operated on public roads, streets, or highways. This vehicle is only limited to indoor use with a hard and flat ground. Operation in inflammable, explosive, or corrosive environments can lead to severe bodily injury and/or property damage.
Vehicle is only limited to indoor use with a hard and flat ground.
Do not drive vehicle unless you are a qualified and trained operator and familiar with the vehicle operational controls. Any unauthorized repairs, modifications, or adjustments could lead to unsafe conditions resulting in severe bodily injury and/or property damage. Any modifications must be approved by the manufacturer. Global Industrial is not responsible for any consequences resulting from unauthorized repairs, modifications, and adjustments.
Do not operate vehicle under the influence of alcohol or drugs.
Keep all body parts (head, arms, legs) inside this vehicle while vehicle is in motion to prevent serious personal injury.
Wear closed toe low heel shoes when operating the vehicle. Avoid wearing any loose clothing that can get caught.
Operator must remain on vehicle while it is in motion.
Operating the vehicle while occupants are not fully seated can cause serious personal injury or death. Start/drive vehicle only when all occupants are fully seated and holding onto available hand holds.
No passengers are allowed to be transported in the cargo deck of the vehicle.
Do not overload the vehicle. Never exceed the rated capacity as specified on the vehicle name plate located below the steering wheel.
Do not allow more passengers than the vehicle is designated for.
Always observe surroundings, especially when driving vehicle in reverse.

Electric Utility Vehicle
Drive slowly when making a turn, especially on wet or inclined surfaces. Drive slowly up and down grades. Do not drive on steep hills or inclines. Do not drive on grades that exceed the vehicle’s gradeability. Do not park vehicle on incline/slope. Do not use accelerator to hold vehicle on an inclined surface. Refrain from starting or stopping vehicle abruptly. Operation in inflammable, explosive, or corrosive environments can lead to severe bodily injury and/or property damage. Turn the vehicle off and engage parking brake before loading and unloading. Untrained or unauthorized personnel should never attempt to operate or perform maintenance on this vehicle.

Before Operating Vehicle
If any of the following items malfunction or do not work as expected, do not operate vehicle until problem has been corrected.

Be wary of any pinch points when converting the rear seat to a cargo deck.

Daily Pre-Operation Checklist

Item Battery
Charger
Wheels/tires Headlight and blue safety light Turn signal lights

No. Check content

1 Fully or adequately charged

2 Charging cord is disconnected from port

3 All terminals and connections are secure and corrosion-free

4

No cracks, loose connections, and frayed wires. Plug is not overheating.

5 Contacts and terminals are clean.

6 Charger indicator lights are operating

7 Tires properly inflated and free of damage

8 No loose hardware

9 Blue safety light turns on when key switch is in “ON” position.

10 Headlight turns on when headlight rocker switch is set to `up’ position.

11

Turn signal lights flash according to direction activated on turn signal lever.

Electric Utility Vehicle

Horn Accelerator pedal
Brakes
Parking brake Steering FNR switch Reverse warning sound and reverse light Emergency stop Operator presence switch

12 Horn sounds when horn lever on combination switch is pulled. 13 Operates smoothly. Accelerates when pressure applied. 14 Brake pedal has firm pressure with minimal travel. 15 Brake light illuminates when brake pedal is depressed. 16 Sufficient brake oil 17 Parking brake lever engages and disengages properly. 18 Responsive and absent of excessive free play 19 Vehicle responds to and travels in respective direction settings

20

Reverse warning beeper sounds and reverse light illuminates when vehicle FNR rocker switch is set to the reverse direction.

21 Vehicle power is cutoff when emergency stop is pressed.

22 Vehicle not operable unless driver is seated in seat.

Operating Vehicle
Ensure nothing is pressing on the accelerator pedal prior to turning the key to “ON” position; otherwise, it can result in a sudden acceleration of vehicle upon start.
Decrease speed of the vehicle to less than 9 mph before making any turns. Do not attempt to hold the vehicle on a slope with the accelerator pedal. Use the brake pedal.
To avoid damage to the brake shoes, the parking brake should be placed in the “OFF” position before attempting to drive the vehicle.
The vehicle is equipped with a built-in protection against over-discharging the battery. As the battery approaches the need for recharging, the discharge current is gradually reduced, slowing down the vehicle. Upon continued usage without charging, the vehicle will eventually interrupt the current from the battery, preventing further operation until it is recharged.
Operator should monitor battery levels during operation and ensure they have enough charge to return to reach a charging station.

1. Sit on seat. If applicable, ensure all passengers are seated and holding onto handholds and any cargo loads are properly secured.
2. Insert key, press on brake pedal firmly, and turn key to “ON” position. 3. Switch the FNR switch to the desired direction of travel. 4. Disengage the parking brake. 5. Slowly press accelerator pedal to reach desired vehicle speed. 6. Move the steering wheel in desired direction. 7. To slow or stop vehicle, release the accelerator pedal and gradually press down on the brake pedal.

Electric Utility Vehicle
After Operating Vehicle
Never park the vehicle on incline
1. Straighten out steering wheel. 2. Allow or bring vehicle to a full stop by gradually pressing down on the brake pedal. 3. Turn key to “OFF” position and remove. 4. Engage hand-operated parking brake. 5. Set FNR switch to neutral center position. 6. If needed, charge vehicle.
CHARGING THE VEHICLE
Batteries produce explosive hydrogen gas at all times, especially, during charging and discharging. Charge battery in well-ventilated area and avoid areas with open flames, sparks, or other sources of combustion.
Use of an extension cord is not recommended. Incorrect connection of the charger AC cord to an extension cord can result in a fire or electrical shock.
Do not disconnect the cord from the battery receptacle when the charger is on. This could cause an arc which can lead to an explosion. Always disconnect the AC charging cable from the AC power outlet first, and then disconnect the DC outlet plug from the vehicle receptacle.
Opening the housing of the charger is prohibited unless performed by a qualified electrician.
Avoid charging the batteries when it is too hot or too cold or subjected to extreme temperatures.
Do not use charger near any water.
Charger should be used between -10°C to +45°C.
The charger is located under the front passenger seat.
The charger automatically turns on when it is plugged into the wall outlet and automatically turns off when the batteries are fully charged.
Power is automatically cut off to the vehicle when the battery is being charged.

Electric Utility Vehicle
Charger has over-discharging protection to prevent the battery from overdischarging. The charger will automatically turn off when the battery is fully charged.
The charger will automatically stop charging if the voltage falls outside the 90-260V range. This will also be indicated by the charger indicator lights. Charging resumes once the voltage returns to a 90-260V range.
When the battery power of vehicle is low, vehicle automatically reduces the discharge current, resulting in a speed reduction. Current is automatically cut off when power reaches threshold until battery is charged.
Do not allow the battery to over-discharge, i.e. letting the battery go below 20% charge. Over-discharging reduces the life of the battery.
Charging the Battery
The vehicle’s batteries should be recharged fully every day in order to optimize the performance of the vehicle and batteries. The battery capacity is indicated by the battery indicator on the dashboard. To charge with the on- board charger:
1. Turn off vehicle. (Key switch is turned to `OFF’ position and keys are removed.) 2. Connect the cord to the on-board charging receptacle located below the front passenger seat. 3. Connect the cord to power source. 4. Once connected, the indicator lights on the charger should initially flash red then flash green to
indicate that charging is in progress. 5. Once charging is complete, unplug the AC charging cable from the wall out first, and then disconnect
he DC outlet plug from the vehicle receptacle.

Charging Indication Lights

LED Red flashing Yellow flashing Green

Indication Battery charging; battery capacity <80% Battery charging; battery capacity >80% Battery fully charged; battery capacity 100%

If any other lights are observed, please refer to the “Charger Troubleshooting and Error Codes” section of this manual.

Electric Utility Vehicle
BATTERY MAINTENANCE
Ensure vehicle is completely turned off, batteries are not charging, and all load is off the battery before servicing batteries.
Disconnect the battery from the main terminal before performing any maintenance.
Do not place any foreign objects or tools near or on the battery.
Before disconnecting cables from any of the battery terminals, disconnect the main battery cable from the controller.
Do not connect the positive poles to the negative poles, as this may cause a shortcircuit, production of sparks, or damage to the battery or injury to the operator.
At the end of the battery’s life, its capacity will decrease dramatically. When changing batteries, use batteries of the same brand, same model, same capacity, and similar voltage (difference of less than 0.02V).
Equalizing charge will automatically be performed upon the installation of new batteries. Equalizing charge takes approximately an hour once the vehicle is fully charged. It is also performed after the vehicle has been charged 30 times (fully or partially).
Check every week on whether any battery cable terminals or nuts are damaged or has become loose.
Disconnecting the Battery from Main Terminal
Disconnect both main positive and negative terminals for the batteries from the controller as demonstrated in the below diagram and pictures. Always do this before disconnecting any other battery cables.

Electric Utility Vehicle
Cleaning the Batteries
The battery’s exterior, cables, terminals, and fasteners should always be kept clean and dry. It is recommended to perform cleaning on a weekly basis.
Cleaning the Exterior Clean the top of the battery with a cloth or brush and solution of baking soda and water (1 cup of baking soda to 1 gallon of water). Ensure that no cleaning solution or other foreign substances enter the batteries. This procedure should be completed weekly.
Cleaning the Terminals Clean the battery terminals and cable clamps using a terminal post and clamp cleaner. Reconnect clamps to the terminals and apply a thin layer of petroleum jelly to prevent corrosion. Clean terminals have a metallic shine. Once cleaning is complete, reconnect the clamps to the terminals and thinly coat them in petroleum jelly. Perform this step as required.
Inspecting the Batteries
Inspecting the Terminals Weekly inspection should be completed on the terminals to prevent risk of sparking and furthering any ongoing damage to terminals. Check that the battery cables are undamaged and in good condition and are securely fastened to the batteries by the terminal nuts. If any damage is found to the battery contact technical support.
Reconnecting the Batteries
Follow the wiring diagram and reconnect the batteries carefully, differentiating between positive and negative poles to avoid shorting.
Installing the Batteries
The vehicle comes with batteries already installed. At the end of the battery’s life, its capacity will decrease dramatically. When changing batteries, use batteries of the same brand, same model, same capacity, and similar voltage (difference of less than 0.02V).

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Open-Circuit Voltage Test
Do not place any wrenches or any metal objects across battery terminals. This could cause an arc which can lead to an explosion or severe injuries.

For accurate voltage readings, batteries must remain idle (no charging or discharging) for at least 6 hours, preferably 24 hours.

1. Disconnect all loads from the batteries. 2. Measure the voltage using a DC voltmeter. 3. Refer to the state of charge in below table. 4. Charge the battery if it registers between 0% to 70% charged. 5. If the voltage is lower than the voltage shown on the table, the following conditions may exist:
a. The battery was left in a state of discharge for too long. b. The battery has a bad cell. Batteries in any of above stated conditions should be taken to a specialist for further evaluation or retired from service.

Percentage

of Charge

6V

100

6.37

90

6.31

80

6.25

70

6.19

60

6.12

50

6.05

40

5.98

30

5.91

20

5.83

10

5.75

Open-Circuit Voltage

8V

12V

24V

36V

8.49

12.73 25.46 38.20

8.41

12.62 25.24 37.85

8.33

12.50 25.00 37.49

8.25

12.37 24.74 37.12

8.16

12.24 24.48 36.72

8.07

12.10 24.20 36.31

7.97

11.96 23.92 35.87

7.88

11.81 23.63 35.44

7.77

11.66 23.32 34.97

7.67

11.51 23.02 34.52

48V 50.93 50.47 49.99 49.49 48.96 48.41 47.83 47.26 46.63 46.03

Electric Utility Vehicle
CHARGER SPECIFICATIONS AND MAINTENANCE

Manufacturer Information
Manufacturer Model Number
Dimension and Weight
Dimension (LxWxH) Weight

Tonsload WT3625ZG
13.18″ x 7.56″ x 4″ 9 lbs

Operational Temperature
Temperature Range

-22°F ­ 149°F

AC Input
Voltage Current Frequency

100 ­ 240 VAC 12A 45 ­ 65 Hz

DC Output
Voltage Current

Rated 36 VDC; 49 VDC maximum 25A maximum

Electric Utility Vehicle

Operational Temperature
Temperature Range

-22°F ­ 149°F

AC Input
Voltage
Current
Frequency

100 ­ 240 VAC 12A 45 ­ 65 Hz

DC Output
Voltage
Current

Rated 36 VDC; 49 VDC maximum 25A maximum

Charger Troubleshooting and Error Codes

LED Green, red
Red, green, red, 3s pause
Red, green, red, green, 2s pause
Green, red, 4s pause
Red, green, 4s pause Red, green, red, green, red, 1s pause Green, red, green, 4s pause

Indication Empty load
Overvoltage/overcurrent Ambient temperature is too high or too low
Charger overheating Output undervoltage Input AC anomaly Integrated fault

Diagnosis / Potential Solution Battery or charger connections are loose. The battery is reversed. The battery voltage is too low. Restart vehicle and if error light sustains, contact support. Check whether if ambient temperature is too high or if ventilation is good. Check the position of battery temperature sensor. Check whether if ambient temperature is too high or if ventilation is good. Contact support. Check the input voltage and whether the plug has good contact. Restart vehicle and match fault with above faults.

Electric Utility Vehicle
DRIVE MOTOR MAINTENANCE
Ensure there are no explosive gas vapors in the working environment, Explosive gas vapors can interact with the sparks generated by the motor and lead to severe injury or damage to property.
Avoid Idling the motor as this can cause unnecessary wear.
Disconnect the positive terminal from the battery before performing any maintenance.
The carbon brush of the motor should be checked every 3 months for wear. Prolonging the use of the motor while brush is worn can cause serious damage to it.
Cleaning the Drive Motor
It is imperative to keep the drive motor clean to allow for efficient heat dissipation when it is running. The following steps should be performed periodically:
· Remove any debris from the motor. · Use low pressure air to remove debris off the carbon brush and commutator. · Check the contact between the carbon brush and commutator.

Drive Motor Faults and Possible Cause

Fault
Commutator surface evenly burnt throughout

Possible Cause The pressure of the brush is incorrect

Commutator alternating burnt surfaces / has a burn pattern Commutator scattered burn marks
Brush is worn out, discolored, or broken
Big sparks

Short circuit occurred between the commutator or within the armature coil. There is a disconnect between the commutator and armature coil.
The commutator is not centered or surface is not round.
The clearance between the motor brush and its holder is too big. The gap between the brush and commutator are too big. The mica between commutators extrudes. The motor is overloaded. The commutator is not clean. The brush is jammed in the brush holder. The brush holder is loose or vibrating.

Electric Utility Vehicle
SPEED CONTROLLER MAINTENANCE
Maintenance of the controller should only be performed by a qualified technician.
Disconnect the positive terminal from the battery before performing any maintenance.
There are no serviceable parts inside the controller. Do not attempt to open, repair, or otherwise modify the controller. Doing so may damage the controller and void the warranty.
Cleaning the Speed Controller
It is recommended that the controller be kept clean and dry. Its fault history file should be checked and cleared periodically. Note: This action can only be performed with a handheld programmer. To clean the controller:
1. Turn the key to the “OFF” position. 2. Cut off power by disconnecting the battery. (Follow the steps in “Disconnecting the Battery from
Main Terminal” section in this manual.) 3. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn)
across the controller’s B+ and B- terminals.
4. Remove any debris from the connector areas. The controller should be wiped clean with a moist rag. Ensure it is dry before reconnecting the battery. The controller should not be subjected to pressured water flow from either a standard hose or power washer.
5. Ensure all connections are secure (not loose or overtightened).
REAR AXLE MAINTENANCE
While using your vehicle, the rear axle should be maintained daily, periodically, and sporadically. · Clean any debris on the cover to maintain a clean axle. · Check that all connections are free of damage and if there is any stickiness or travel in the contact. · Check there is enough gear oil. If not, add gear oil. · Check if there is any link in the connection and transmission units or any unusual sounds within the axle. · Check the temperature and observe any smells of the brake drum. It should be adjusted and repaired if any issues are found. · Check the breather valve ventilation and that there is no oil leaking. · Check if there is any section of the parking brake cable that is broken or loosened. Replace with a new one if necessary.

Electric Utility Vehicle

Rear Axle Troubleshooting

Fault

Possible Cause

Potential Solution

The axle housing gear and bearing are damaged prematurely, and there is excessive noise on the final drive

1. The gear oil is insufficient or used improperly
2. The bearing is not assembled correctly
3. Adjust the brake shoe pin shim or the interval. 4. The gear between axle 1 and 2 do not have good contact. 5. The final drive is noisy:
– Check if there is any impurities or debris – Check if the gear is damaged

Add or replace oil
Contact Global Industrial for product support Adjust or replace brake shoe pin shim
Adjust correctly
Remove the impurities or replace the gear

6. Axle 1 damaged by collision or wear.

Adjust or replace rear axle

7. The rear axle is deformed. Check if it is overloaded.
1. There is a gap between the brake shoes and drum.
2. There is oil or debris on the brake shoes or drum.

Replace rear axle Adjust the interval Remove any impurities

Lack of braking force

3. There is air in brake pipe 4. The brake pipe leaks.

Dispel the air Repair the pipe

5. The brake shoes are worn out.

Replace brake shoe

6. The brake cable is too long or is blocked.

The brake is difficult to release completely

1. The brake pedal is not returning back smoothly after being depressed
2. The brake shoe is deformed
3. There is some blockage in the transmission.

Oil leaking

1. The oil seal is damaged 2. Too much oil

Adjust the brake cable Replace brake pedal Refit or replace Refit or replace Replace oil seal Adjust the oil levels

Electric Utility Vehicle
LIFTING THE VEHICLE
The vehicle may be lifted at the points identified below.
REPLACING THE TIRES
Before performing any maintenance or changes to the wheel and tire, ensure the key is turned to the “OFF”. Read the tire manufacturer’s instructions and make sure specifications match the vehicle conditions Wear proper PPE to protect face and eyes from escaping air from removing the valve core. Wear proper PPE to when mounting and unmounting the wheels and tires. To remove tire on the vehicle: 1. Chock the wheels then loosen the wheel nuts. 2. Using a jack, lift the vehicle and then remove the wheel nuts and the wheel. To install tire on the vehicle: 1. Use a jack to lift the vehicle and then place the wheel onto the wheel hub with lug nuts. (Refer to “LIFTING THE VEHICLE” section of the manual.) 2. Finger tighten the lug nuts, then torque lug nuts to 50-85 ft-lbs. (70-115 Nm) in 20 ft-lbs (30 Nm) increments following the `cross sequence’ pattern as demonstrated below.
3. Remove the jack.
Inspecting the Tires
If the tire is flat, remove the wheel and inflate the tire to its rated maximum pressure. Submerge the tire in water to locate and mark any leaks with chalk. Place tires plugs according to the manufacture’s specifications.

Electric Utility Vehicle

CHECKING THE BRAKES

If you experience any problems with the brakes, please contact trained technician or customer support. Brake failure can result in serious accidents or physical danger.

· The brakes on the vehicle are self-adjusted. · Before you operate the vehicle, press down on the brake pedal several times to ensure the brakes
are functioning properly. · Check and replace the brake shoes periodically.

LUBRICATING THE VEHICLE
Use 1L of 90GL hypoid gear oil for the rear of the vehicle. Lubrication Points
a) Spindle assembly (driver side) b) Spindle assembly (passenger side) c) Middle shaft d) Rear shaft

(a)

(b)

a)

(c) (d)

Electric Utility Vehicle

MAINTENANCE SCHEDULE
Before performing any maintenance or changes, ensure the key is turned to the “OFF”.
Ensure batteries are not charging and all load is off the battery before performing any maintenance.
Before disconnecting cables from any of the battery terminals, disconnect the main battery cable from the controller.
Disconnect the battery from the main terminal before performing any maintenance.

Item

Check content

Body and chassis

No loose hardware
Body and seat are clean and free of damage. Clean battery with baking soda and water solution Check tires are sufficiently inflated to air pressure spec.
Check tire wear
Check tires nuts are securely tightened Ensure shock absorbers are not leaking any oil or producing any excessive noises Ensure there are no oil leakages from the gearbox and the rear of the vehicle Add lubricant to the wheel hub and steering system. Recommended grease: Mobilgrease XHP 222 Check the toe angle at the front of the vehicle and adjust if needed

Weekly
· · · ·

Monthly

Quarterly

SemiAnnually

Annually

· ·
·

·

·

·

Electric Utility Vehicle

No frayed or broken cables

·

All terminals and connections are secure

·

Battery

Burnish any coarse surfaces on the battery

·

·

contacts with sandpaper

Clean the surface of the battery

·

Check carbon brush wear and if it needs any

·

replacing

Remove any debris that has accumulated on the

·

motor

Motor

Use low pressure air to remove debris off the

·

carbon brush and

commutator.

Check the contact between the carbon brush

·

and commutator

Check main circuit and ensure all connections are

·

secure. DO THIS ONLY

WHEN THE VEHICLE IS

OFF.

Check contactor for any defects and debris.

·

Replace immediately if

Controller

defects are found. Clean any debris with low

pressure air.

Discharge controller capacitors and clean any

·

debris off controller with a

moist rag

Check the solenoid contact points and that is

·

working properly

Clean surface of charger with clean, dry cloth.

·

Charger

Observe that the charging status is displayed when the vehicle is plugged in

·

to charge

Check the plug to ensure it is not getting too hot.

·

Brake system

Electric Utility Vehicle

Inspect the hose and tube to ensure there are no leakages Check that there is sufficient brake fluid inside the brake fluid reservoir Check brake drum and brake shoe wear and replace as needed.
Adjust brakes

· ·
· ·

LOCATION OF FUSES
When changing the fuse, make sure that the new fuse is appropriate for the rated current.
1. Blade fuses and fuse box All accessory fuses are installed in the fuse box located under the driver’s side’s seat.

2. Main fuse The main fuse is located on the controller mounting board under the front seat.

Electric Utility Vehicle
WIRE DIAGRAM
Wiring diagram for vehicle 36V with Curtis Controller
STORING THE VEHICLE
The battery should be fully recharged before storing the vehicle that is going to be kept unused for a long period of time. After that, the battery shall be recharged every month. Check the tire pressure to make sure it is at the recommended pressure, 30 psi. Remove and safely store vehicle key. Clean the exterior of the vehicle and apply rust inhibitor Cover the vehicles with a breathable cover and store it in a dry, safe, and well-ventilated place.

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