Home » E-Z-GO Manuals » Golf Carts » E-Z-GO RXV - Electric » Manual Viewer

E-Z-GO RXV - Electric Owner Manual

E-Z-GO RXV - Electric Manual

Get E-Z-GO RXV - Electric PDF manuals and user guides

View all E-Z-GO RXV - Electric manuals

Add to My Manuals
Save this manual to your list of manuals

E-Z-GO RXV - Electric manual content summary:

E-Z-GO RXV - Electric | Owner Manual - Page 1
ISSUED FEBRUARY 2009 REVISED JUNE 2012
E-Z-GO RXV - Electric | Owner Manual - Page 2
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 HANDS AFTER HANDLING! BATTERIES AND RELATED PARTS CONTAIN LEAD WASH HANDS AFTER HANDLING! WARNING
E-Z-GO RXV - Electric | Owner Manual - Page 3
OWNER'S GUIDE ELECTRIC POWERED FLEET & PERSONAL GOLF CARS RXV GOLF CAR RXV FREEDOM™ RXV SHUTTLE 2 + 2 STARTING MID-MODEL YEAR 2009 (MANUFACTURED BEGINNING FEBRUARY 23, 2009) E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual,
E-Z-GO RXV - Electric | Owner Manual - Page 4
Equipment Manufacturer (OEM) approved parts may void the warranty. Overfilling , fully charged and disconnected from any source of electrical drain. On all electric vehicles, set the key switch to 'OFF'. batteries. As with all electric vehicles, the batteries must be checked and recharged as required
E-Z-GO RXV - Electric | Owner Manual - Page 5
CODES 4 MAINTENANCE INSTRUCTIONS 4 CONTROLS AND INDICATORS BRAKING 7 PEDAL-UP BRAKING 8 HIGH PEDAL DISABLE FEATURE 8 STARTING AND DRIVING 8 STARTING VEHICLE ON A HILL 8 COASTING ...8 LABELS AND PICTOGRAMS 8 SUN TOP AND WINDSHIELD 8 VEHICLE CLEANING & CARE 8 VEHICLE CLEANING 8 REPAIR
E-Z-GO RXV - Electric | Owner Manual - Page 6
PROLONGED STORAGE 22 BATTERY CHARGING 23 TROUBLESHOOTING 23 HYDROMETER 23 USING A HYDROMETER 24 GENERAL SPECIFICATIONS 27 RXV ELECTRIC - FLEET VEHICLE SPECIFICATIONS 28 RXV ELECTRIC - FREEDOM VEHICLE SPECIFICATIONS 29 RXV ELECTRIC - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS 30 DECLARATION OF
E-Z-GO RXV - Electric | Owner Manual - Page 7
manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the B manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service Speed Vehicle (LSV) subject to the strictures and requirements of Federal Motor
E-Z-GO RXV - Electric | Owner Manual - Page 8
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
E-Z-GO RXV - Electric | Owner Manual - Page 9
manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair recommendations or applicable electrical code (whichever is higher). Owner's Guide Page vii
E-Z-GO RXV - Electric | Owner Manual - Page 10
SAFETY INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Notes: Page viii Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 11
B LABELS & PICTOGRAMS Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. B LABELS & PICTOGRAMS Owner's Guide Page ix
E-Z-GO RXV - Electric | Owner Manual - Page 12
selector to"FORWARD"and engage park brake. 608522 608522 FLEET VEHICLES OPERATING INSTRUCTIONS 608529 BEFORE OPERATING READ all warning labels and the owner's manual. Contact an authorized E-Z-GO dealer or visit www.ezgo.com for a replacement manual. This vehicle is equipped for personal
E-Z-GO RXV - Electric | Owner Manual - Page 13
as outlined in your repair manual. 609694 609694 DO NOT alter or tamper with this unit. Unauthorized modifications can result in SERIOUS INJURY or damage to the vehicle and will void the warranty. To disable electrical system, turn key switch to 'OFF' and remove battery wires. ALWAYS turn key to
E-Z-GO RXV - Electric | Owner Manual - Page 14
LABELS & PICTOGRAMS Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. B FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY. to remain properly seated and holding on. 608537 608537 Page xii Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 15
LABELS & PICTOGRAMS Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Notes: Owner's Guide Page xiii
E-Z-GO RXV - Electric | Owner Manual - Page 16
READ THE MANUAL OPERATE ACCORDING * TURN KEY TO 'OFF' * APPLY PARKING BRAKE MINIMUM HEIGHT TO OPERATE VEHICLE IS 150 CM I ON RN F O OFF ON RN F O OFF ELECTRIC VEHICLES FORWARD OPERATION * TURN KEY TO 'F' * MANUAL REPLACEMENT AVAILABLE AT www.ezgo.com WARNING: NEGATIVE GROUND ELECTRICAL
E-Z-GO RXV - Electric | Owner Manual - Page 17
ACCORDING TO LOCAL LAWS AND REGULATIONS MAINTAIN ACCORDING TO SERVICE & REPAIR MANUAL AVAILABLE AT www.ezgo.com MINIMUM HEIGHT TO OPERATE VEHICLE IS 150 CM DO NOT OPERATE VEHICLE WHEN LIGHTNING IS IN THE AREA ELECTRIC VEHICLES FORWARD OPERATION REVERSE OPERATION * TURN KEY TO 'F' * TURN
E-Z-GO RXV - Electric | Owner Manual - Page 18
TOW MORE THAN 3 VEHICLES * 12 mph (19 kph) MAX SPEED TOWING 1 VEHICLE * DO NOT DRIVE IN REVERSE WHEN TOWING VEHICLES MANUAL REPLACEMENT AVAILABLE AT www.ezgo.com TO REDUCE POSSIBILITY OF BATTERY EXPLOSION TURN KEY TO 'OFF' BEFORE DISCONNECTING OR CONNECTING BATTERY WIRES WARNING READ THE MANUAL
E-Z-GO RXV - Electric | Owner Manual - Page 19
B LABELS & PICTOGRAMS Read all of manual to become familiar with this vehicle. Pay attention to all IN FRONT OF OR BEHIND VEHICLE READ THE MANUAL REPLACEMENT AVAILABLE AT www.ezgo.com WARNING OPERATE ACCORDING TO LOCAL LAWS AND REGULATIONS www.ezgo.com : CHILDREN MUST BE ACCOMPANIED BY AN
E-Z-GO RXV - Electric | Owner Manual - Page 20
LABELS & PICTOGRAMS Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Notes: Page xviii Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 21
service procedures in this guide can be accomplished using common automotive hand tools. Contact your service representative on servicing the vehicle in accordance with the Periodic Service Schedule. Service Parts Manuals as well as Repair and Service Manuals frame rail at the rear of the vehicle (
E-Z-GO RXV - Electric | Owner Manual - Page 22
braking distance required to stop the vehicle for future brake service . ITEM SERVICE OPERATION Batteries Charge batteries Seats Remove protective plastic covering Brakes of electric electric shock way - refer all repair work to qualified personnel manual electrical code and charger
E-Z-GO RXV - Electric | Owner Manual - Page 23
SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Hanging Holes (7.893c.1m" ) Mounting Holes B To prevent a physical hazard that could result in an electrical GO charger, refer to the instructions Guide Page 3
E-Z-GO RXV - Electric | Owner Manual - Page 24
SERVICE INFORMATION Read all of manual problem with the battery pack or that the charger output current was severely reduced due to high parts. Check the charger harness for chaffing and rubbing. Inspect all wiring GO charger, refer to the instructions supplied with the charger. Page 4 Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 25
SERVICE INFORMATION Read all of manual 7. Service Brake Pedal 8. Run/Tow Switch l ONN F R OOFF 608769 Fig. 8 Operator Controls & Gauges KEY SWITCH/DIRECTION SELECTOR Located on the dash panel, the key switch/direction selector (1) enables the electrical on the electric vehicle shows
E-Z-GO RXV - Electric | Owner Manual - Page 26
SERVICE INFORMATION Read all of manual GO Service Parts motor brake; when the accelerator pedal is released, the motor will stop. To stop the vehicle more quickly , depress the service brake pedal (7)(Ref. Fig. 8). RUN/TOW SWITCH ALL accessories that do NOT use the accessory wiring or motor. NOTICE
E-Z-GO RXV - Electric | Owner Manual - Page 27
B OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. PARKING BRAKE This vehicle is equipped with an automatic parking brake; when the vehicle is stopped the parking brake is automatically set.
E-Z-GO RXV - Electric | Owner Manual - Page 28
SERVICE INFORMATION Read all of manual is in motion. REGENERATIVE BRAKING To reduce the possibility of Maintain a safe speed when driving down hill. Use the service brake to reduce speed when traveling use service brake to reduce speed. This vehicle is equipped with a regenerative motor control
E-Z-GO RXV - Electric | Owner Manual - Page 29
with this model. However, this is not a substitute for the service brake which should be used to slow the speed of the vehicle quickly. . NOTICE This model is equipped with a feature (pedal-up braking) that slows the vehicle's speed when the accelerator pedal is released until the vehicle stops
E-Z-GO RXV - Electric | Owner Manual - Page 30
injury or vehicle damage, read all instructions supplied by the manufacturer of the pressure washer. REPAIR LIFTING THE VEHICLE Tool List Qty. Floor Jack 1 Jack Stands 4 Wheel Chocks 4 Some servicing operations may require the front wheels, the rear wheels, or the entire vehicle be raised
E-Z-GO RXV - Electric | Owner Manual - Page 31
SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. of the frame while the front end of the vehicle is on the jack stands. Lower the vehicle by reversing the lifting sequence. WHEELS AND TIRES B TIRE REPAIR
E-Z-GO RXV - Electric | Owner Manual - Page 32
SERVICE INFORMATION Read all of manual most cost effective way to repair a puncture in the tread is are available at most automotive parts outlets and have the in accordance with manufacturer's instructions . Tire style may vary the backside of the light assembly. 1. Disconnect the accessory harness
E-Z-GO RXV - Electric | Owner Manual - Page 33
SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. . B TAILLIGHT/BRAKE the back of the headlight assembly. 4. Turn the bulb (3) assembly. Fig. 17 Tail and Brake speeds in excess of 12 mph (19 kph).
E-Z-GO RXV - Electric | Owner Manual - Page 34
SERVICE INFORMATION Read all of manual damage to the electric motor and controller. Do not tow a single vehicle at speeds in excess of Tow bars are available from the E-Z-GO Service Parts Department. Tow bars are not intended un- der PARKING BRAKE. See "PARKING BRAKE" on page 7. To Guide
E-Z-GO RXV - Electric | Owner Manual - Page 35
notes, cautions and warnings in this manual. Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with both drive wheels raised and vehicle properly supported on jack stands. To reduce the possibility of motor damage, never operate vehicle at full
E-Z-GO RXV - Electric | Owner Manual - Page 36
and refer to the Technician's Repair and Service Manual for specific torque values. Generally 2. CAPACITIES AND REPLACEMENT PARTS FLUID Rear Axle Lubricant Mobilube 85W - 140 PART NUMBER 613175 Friction Modifier E-Z-GO 611242 Fig. 18 Torque Specifications and Bolt Grades Page 16 Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 37
INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. PERIODIC SERVICE SCHEDULE B - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE before each use DAILY 20 rnds/20 hrs 100 miles/160 kms 60 rnds/60 hrs 300 miles
E-Z-GO RXV - Electric | Owner Manual - Page 38
OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with this vehicle. hydrogen gas is explosive. Be sure that the key switch is off and all electrical accessories are turned off before starting work on the vehicle. Never disconnect a circuit the battery. Page 18 Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 39
SERVICE INFORMATION Read all of manual If the battery electrolyte level is too high, the electrolyte will block the vent tube Vent MONTHLY • Inspect all wiring for fraying, loose terminations, plates exposed to air will be ruined beyond repair. Also avoid filling with too much water, Guide Page 19
E-Z-GO RXV - Electric | Owner Manual - Page 40
OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. B NOTICE The watering components adjacent to the batteries, these should also be sprayed with the baking soda solution. Page 20 Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 41
SERVICE INFORMATION Read all of manual wrench, disconnect and remove all other wires connected to the batteries. 5. Remove front of the vehicle just enough to clear the rear body and using the portable lifting device lift removed with a putty knife and a wire brush (for metal surfaces) or a
E-Z-GO RXV - Electric | Owner Manual - Page 42
SERVICE INFORMATION Read all of manual position the battery hold-down and the battery strap, guiding the J-bolts between the batteries (it may be wire terminals with a solution of baking soda and water, using a wire brush to completely remove corrosion if required. 13. Carefully replace the wires
E-Z-GO RXV - Electric | Owner Manual - Page 43
SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. . BL+ Red Wire from Solenoid Black Wire from Charger Receptacle B BL- Black Wire from Controller Red and Grey Wires . In high temperatures the Guide Page 23
E-Z-GO RXV - Electric | Owner Manual - Page 44
SERVICE INFORMATION Read all of manual the instructions electrical arc part of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the vehicle charging receptacle. TROUBLESHOOTING In general, troubleshooting that are the problem are identified, Guide
E-Z-GO RXV - Electric | Owner Manual - Page 45
SERVICE INFORMATION Read all of manual a new golf car battery battery must go through at indicates a problem with the low problem High adjust to the electrolyte temperature and note the reading. Examine the color of the electrolyte. A brown or gray coloration indicates a problem C). Adjust the reading
E-Z-GO RXV - Electric | Owner Manual - Page 46
OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Notes: Page 26 Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 47
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner's Guide Page 27
E-Z-GO RXV - Electric | Owner Manual - Page 48
GENERAL SPECIFICATIONS RXV ELECTRIC - FLEET VEHICLE SPECIFICATIONS BATTERIES SPEED CONTROLLER MOTOR Four 12 Volt deep cycle (70 minute minimum, 140 Amp-Hour discharge rate) Solid state, 230 Amp capacity 3 phase AC induction TRANSAXLE BRAKES PARKING BRAKE 16.99:1 Reverse helical geared with
E-Z-GO RXV - Electric | Owner Manual - Page 49
GENERAL SPECIFICATIONS RXV ELECTRIC - FREEDOM VEHICLE SPECIFICATIONS BATTERIES SPEED CONTROLLER MOTOR TRANSAXLE BRAKES PARKING BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING STEERING WHEEL SEATING SEATING CAPAPCITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS DASH PANEL TIRES TIRE
E-Z-GO RXV - Electric | Owner Manual - Page 50
GENERAL SPECIFICATIONS RXV ELECTRIC - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS BATTERIES SPEED CONTROLLER MOTOR TRANSAXLE BRAKES PARKING BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING STEERING WHEEL SEATING SEATING CAPAPCITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS DASH PANEL TIRES TIRE
E-Z-GO RXV - Electric | Owner Manual - Page 51
GENERAL SPECIFICATIONS 65.7" (16657.7c"m) (167 cm) 94.5" (240 cm) 94.5" (240 cm) 68.50" (174 cm) 68.50" (174 cm) 45.7" 45(1.71"6 cm) (116 cm) 35.5" (90 cm) 35.5" 3(89"0 cm) (97 cm) 38" (97 cm) 47" (119 cm) 47" (119 cm) Fig. 31 Fleet & Freedom Vehicle Dimensions Owner's Guide Page 31
E-Z-GO RXV - Electric | Owner Manual - Page 52
GENERAL SPECIFICATIONS Page 32 65.7" (167 cm) 105.5" (268 cm) 74" (188 cm) 45.7" (116 cm) 35.5" (90 cm) 38" (97 cm) 47" (119 cm) Fig. 31 Shuttle 2 + 2 Vehicle Dimensions Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 53
GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP 25% GRADE OR 14° MAX RECOMMENDED MAX SIDE TILT 25% GRADE OR 14° MAX 19('52."8m) Fig. 32 Vehicle Incline Specifications and Turning Diameter Owner's Guide Page 33
E-Z-GO RXV - Electric | Owner Manual - Page 54
GENERAL SPECIFICATIONS 1.8" (4.5 cm) 1.4" 3.5cm 11.4" (28.9 cm) 7.8" (19.8 cm) 6.3" (16 cm) 2.5" (6.3 cm) Page 34 10.5" (26.7 cm) 4.8" (12.2 cm) 5.4" 4.1" (13.7 cm) (10.4 cm) Fig. 33 Powerwise QE 48V Charger Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 55
DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner's Guide Page 35
E-Z-GO RXV - Electric | Owner Manual - Page 56
DECLARATION OF CONFORMITY Page 36 Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 57
DECLARATION OF CONFORMITY Owner's Guide Page 37
E-Z-GO RXV - Electric | Owner Manual - Page 58
DECLARATION OF CONFORMITY Notes: Page 38 Owner's Guide
E-Z-GO RXV - Electric | Owner Manual - Page 59
service brake to control speed when traveling down an incline. Use extra care and reduced speed repair highly corrosive, explosive or may produce high amperage or reach high parts. Use care not to touch hot objects. Raise rear of vehicle and support on jack stands before attempting to run or adjust
E-Z-GO RXV - Electric | Owner Manual - Page 60
Service Parts International: Phone: 1-800-774-3946, FAX: 1-800-448-8124 Phone: 1-888-GET-E-Z-GO (1-888-438-3946), FAX: 1-800-752-6175 Phone: 001-706-798-4311, FAX: 001-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO

Section	Page
C-1_Model_Info-3NOV08.pdf	4
E_Operation_Service_Inffo_28apr10.pdf	21
Fig. 1 Serial Number Location on Steering Column	21
Fig. 2 Serial Number on Front Frame	21
Fig. 3 Serial Number on Rear Frame	21
BEFORE INITIAL USE	21
.	22
Fig. 4 Initial Service Chart	22
PORTABLE CHARGER	22
Portable Charger Installation	22
Fig. 5 Charger Installation	22
Fig. 6 Charger Mounting	23
Using the Charger	23
Fig. 7 Charger Receptacle	23
UNDERSTANDING THE CHARGER	23
LED Operation Codes:	24
LED Fault Codes:	24
MAINTENANCE INSTRUCTIONS	24
1. For flooded lead-acid batteries, regularly check the water levels of each battery cell after charging and add distilled water...	24
2. Make sure the charger connections to the battery terminals are tight and clean. Check for any deformations or cracks in the p...	24
3. Keep the cooling fins free of dirt and debris, do not expose the charger to oil, dirt, mud or to direct heavy water spray when cleaning equipment.	24
4. Inspect the plug of the battery charger and the vehicle receptacle housing for dirt or debris. Clean the DC connector monthly or more often if needed.	24
CONTROLS AND INDICATORS	25
1. Key Switch / Direction Selector	25
2. State Of Charge Meter (optional)	25
3. Head Light Switch (optional)	25
4. Turn Signal Switch (optional)	25
5. Horn Button (optional)	25
6. Accelerator Pedal	25
7. Service Brake Pedal	25
8. Run/Tow Switch	25
l	25
Fig. 8 Operator Controls & Gauges	25
Key Switch/Direction Selector	25
Fig. 9 Run/Tow Switch	25
State Of Charge Meter (optional equipment)	25
Headlight Switch (optional equipment)	26
Turn Signal Switch (optional equipment)	26
Horn (optional equipment)	26
Fig. 10 Attach Accessory Wires to Battery Pack	26
Accelerator & Brake Pedals	26
Run/Tow Switch	26
PARKING BRAKE	27
1. Locate the ’Auxiliary Power’ line (3) and remove the weather pack seal (4) from the connector.	27
2. Locate the ’Primary Power’ line connector (1) and disconnect it from line (2).	27
3. Connect the ’Auxiliary Power’ line (3) to the ’Primary Power’ line (1) which will release the brake. If the tires are not chocked and the vehicle is not on flat ground the vehicle will move immediately.	27
4. Move the vehicle to desired, safe location and chock the tires immediately.	27
5. Disconnect the ’Auxiliary Power’ line (3) from the ’Primary Power’ line (1).	27
6. Connect the ’Primary Power’ line (1) to line (2).	27
7. Replace the weather pack seal (4) on the ’Auxiliary Power’ line connector (3).	27
Fig. 11 Splash Shield and Parking Brake Release	27
OPERATING THE VEHICLE	28
Regenerative Braking	28
a) the vehicle is being driven down a slope	28
b) the driver attempts to exceed the specified top speed with the accelerator pedal depressed or released	28
Pedal-Up Braking	28
a) the vehicle is being driven down a slope	28
b) the accelerator pedal is released	28
High Pedal Disable Feature	29
Starting And Driving	29
.	29
When the direction selector is in the reverse position, a warning signal will sound to indicate that the vehicle is ready to run in reverse.	29
Starting Vehicle On A Hill	29
Coasting	29
.	29
Labels and Pictograms	29
Sun Top And Windshield	29
VEHICLE CLEANING AND CARE	30
Vehicle Cleaning	30
REPAIR	30
Lifting The Vehicle	30
Fig. 12 Chock Wheels	31
T	31
Fig. 13 Lifting the Vehicle	31
WHEELS AND TIRES	31
Tire Repair	31
.	32
Wheel Installation	32
Fig. 14 Wheel Installation	32
LIGHT BULB REPLACEMENT	32
Head Light Bulb Replacement	32
1. Disconnect the accessory harness (5) from the light bulb.	32
2. Turn the headlight bulb (3) clockwise and pull to remove.	32
.	33
Fig. 15 Headlight Bulb Replacement	33
3. Align the bulb with the opening in the back of the headlight assembly.	33
4. Turn the bulb (3) counter clockwise until it stops.	33
5. Connect the accessory harness (5) to the light bulb (3).	33
Turn signal Bulb Replacement	33
1. Remove the phillips head screw (7) and turn the retaining collar (8) to align with the turn signal bulb housing (9).	33
2. Grip the turn signal bulb housing (9) and pull backward to remove housing from the headlight assembly.	33
Fig. 16 Turn Signal Bulb Replacement	33
3. Remove the bulb from the housing and replace with a new one.	33
4. Push turn signal housing (9) into headlight assembly firmly, making sure that it is seated completely.	33
5. Turn the retaining collar (8) to secure the bulb housing and install the phillips head screw (7) to secure in place.	33
Taillight/Brake Light Bulb Replacement	33
1. Remove the two phillips head screws (10) that secure the lens (11) to the taillight assembly.	33
2. Remove the light bulb.	33
3. Install the new light bulb.	33
4. Install the lens (11) and secure in place with the two phillips head screws. (10)	33
Fig. 17 Tail and Brake Light Bulb Replacement	33
TRANSPORTING VEHICLE	33
Towing	33
Hauling	34
SERVICE AND MAINTENANCE	35
ROUTINE MAINTENANCE	35
Tire Inspection	35
Rear Axle	35
HARDWARE	35
CAPACITIES AND REPLACEMENT PARTS	36
Fig. 18 Capacities	36
Fig. 19 Replacement Part	36
Fig. 20 Torque Specifications and Bolt Grades	36
PERIODIC SERVICE SCHEDULE	38
SAFETY	38
BATTERY	38
BATTERY MAINTENANCE	39
At Each Charging Cycle	39
Monthly	39
Electrolyte Level and Water	39
Fig. 22 Correct Electrolyte Level	39
Fig. 23 Water Purity Table	40
Fig. 24 Automatic Watering Gun	40
Cleaning Batteries	40
Fig. 25 Preparing Acid Neutralizing Solution	41
BATTERY REMOVAL & INSTALLATION	41
In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that is...	41
1. Turn vehicle key to the off position and remove the key.	41
2. Using an insulated wrench, disconnect the main negative (-), BL-, battery cable.	41
3. Using an insulated wrench, disconnect the main positive (+), BL+, battery cable.	41
4. Using an insulated wrench, disconnect and remove all other wires connected to the batteries.	41
5. Remove the two Pan Head Torx screws, (one on each side) from the Battery Strap.	41
6. Remove the battery hold down and the battery strap by loosening all three hex nuts until they are at the end of the J-bolt an...	41
7. Remove the batteries using commercially available battery carrier straps (2 per battery) and a portable lifting device. Remov...	41
8. Check the area surrounding the battery tray for corrosion. If any corrosion is found, it should be immediately removed with a...	41
.	42
Fig. 26 Battery Removal	42
9. Replace the batteries, using the portable lifting device, starting with the battery located at the back of the battery tray (4), making sure that it is positioned as shown.	42
Fig. 27 Battery Placement & Orientation	42
10. With the J-bolts in the battery hold-down and held in place by the hex nuts on the end of the threaded portion; carefully po...	42
11. Install the two Pan Head Torx drive screws through the ends of the battery strap into the holes on the vehicle frame and tighten them to 80 - 97 in. lbs. (9 - 11 Nm) torque.	42
Fig. 28 Battery Components	42
12. Inspect all wires and terminals and clean any corrosion from the battery terminals or wire terminals with a solution of baking soda and water, using a wire brush to completely remove corrosion if required.	42
13. Carefully replace the wires on the battery terminals as shown (Ref. Fig. 29). Make sure to reconnect the main negative (-) battery cable, BL-, from the controller last.	42
14. Tighten all battery terminal hardware to 98 - 105 in. lbs. (11 - 12 Nm) torque.	42
15. Protect the battery terminals and battery cable terminals with a commercially available protective coating.	42
.	43
Fig. 29 Battery Connections	43
PROLONGED STORAGE	43
Fig. 30 Freezing Point of Electrolyte	43
BATTERY CHARGING	44
TROUBLESHOOTING	44
Fig. 31 Hydrometer	44
Hydrometer	44
Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte.	45
Using A Hydrometer	45
1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and not...	45
2. Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder.	45
3. Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float.	45
4. Add or subtract four points (.004) to the reading for every 10° F (6° C) the electrolyte temperature is above or below 80° F ...	45
5. Test each cell and note the readings (corrected to 80° F or 27° C). A variation of fifty points between any two cell readings (example 1.250 - 1.200) indicates a problem with the low reading cell(s).	45
Fig. 32 Hydrometer Temperature Correction	45

Match case Limit results 1 per page

REVISED

JUNE 2012

ISSUED

FEBRUARY 2009