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

E-Z-GO RXV - Electric Owner Manual - Page 22

Portable Charger

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

Page 22 highlights

OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. BBefore a new vehicle is put into operation, the items shown in the INITIAL SERVICE CHART must be performed (Ref. Fig. 4). The vehicle batteries must be fully charged before initial use. Check for correct tire inflation. See GENERAL SPECIFICATIONS. Determine and record the braking distance required to stop the vehicle for future brake performance tests. Remove the protective clear plastic from the seat bottom and back rest before placing the vehicle in service . ITEM SERVICE OPERATION Batteries Charge batteries Seats Remove protective plastic covering Brakes Check operation Establish acceptable stopping distance Tires Check air pressure (see SPECIFICATIONS) Portable Charger Remove from vehicle and properly mount Fig. 4 Initial Service Chart PORTABLE CHARGER PORTABLE CHARGER INSTALLATION Use charger ONLY on 48 volt battery systems. Other usage may cause personal injury and damage. Lead acid batteries may generate explosive hydrogen gas during normal operation. Keep sparks, flames, and smoking materials away from batteries. Provide adequate ventilation during charging. Never charge a frozen battery. Study all battery manufacturers' specific precautions such as recommended rates of charge and removing or not removing cell caps while charging. DANGER Risk of electric shock. Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances. A grounded outlet is required to reduce risk of electric shock - do not use ground adapters or modify plug. Do not touch uninsulated portion of output connector or uninsulated battery terminal. Disconnect the DC supply before making or breaking the connections to the battery while charging. Do not open or disassemble charger. Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way - refer all repair work to qualified personnel. Not for use by children. Portable chargers are shipped with the vehicles. Prior to vehicle or charger operation, the charger must be removed and mounted on a platform or wall above the ground to permit maximum air flow around and underneath the charger. A dedicated circuit is required for the charger. Refer to the charger manual for appropriate circuit protection. For optimum performance and shortest charge times, place the charger in an area with adequate ventilation. The charger should also be placed in an area that will be relatively free of dirt, mud, or dust since accumulations within the fins of the charger will reduce their heat-dissipating qualities. Optimal cooling also occurs when the charger is placed on a horizontal surface with the fins vertical. More airflow from below the charger will help cool the fins, so placement above open areas or areas with cut-outs for airflow is desirable. If the charger is operated in an outdoor location, rain and sun protection must be provided. The charger may get hot during operation and must be placed such that risk of contact by people is reduced. The charger may be mounted on a wall or shelf using #10-M5 screws. The charger's status display must be visible to the user. Keep cooling fins clean and free of dirt and debris NEMA 15 - 5R Grounded AC Receptacle 110 - 120 VAC. Dedicated 15 AMP Circuit Locations outside the US and Canada: Reference appropriate local electrical code and charger manufacturer recommendations for AC power requirements Fig. 5 Charger Installation Page 2 Owner's Guide

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

Page 2

OPERATION AND SERVICE INFORMATION

Owner’s Guide

Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Before a new vehicle is put into operation, the items

shown in the

INITIAL SERVICE CHART

must be per-

formed (Ref. Fig. 4).

The vehicle batteries must be fully charged before initial

use.

Check for correct tire inflation. See GENERAL SPECIFI-

CATIONS.

Determine and record the braking distance required to

stop the vehicle for future brake performance tests.

Remove the protective clear plastic from the seat bot-

tom and back rest before placing the vehicle in service

Fig. 4

Initial Service Chart

PORTABLE CHARGER

PORTABLE CHARGER INSTALLATION

Use charger ONLY on 48 volt battery systems.

Other usage may cause personal injury and

damage. Lead acid batteries may generate

explosive hydrogen gas during normal opera-

tion. Keep sparks, flames, and smoking mate-

rials away from batteries. Provide adequate

ventilation during charging. Never charge a

frozen battery. Study all battery manufacturers’

specific precautions such as recommended

rates of charge and removing or not removing

cell caps while charging.

Risk of electric shock. Connect charger power

cord to an outlet that has been properly

installed and grounded in accordance with all

local codes and ordinances. A grounded outlet

is required to reduce risk of electric shock – do

not use ground adapters or modify plug. Do

not touch uninsulated portion of output con-

nector or uninsulated battery terminal. Discon-

nect the DC supply before making or breaking

the connections to the battery while charging.

Do not open or disassemble charger. Do not

operate charger if the AC supply cord is dam-

aged or if the charger has received a sharp

blow, been dropped, or otherwise damaged in

any way – refer all repair work to qualified per-

sonnel. Not for use by children.

Portable chargers are shipped with the vehicles. Prior to

vehicle or charger operation, the charger

must

be re-

moved and mounted on a platform or wall above the

ground to permit maximum air flow around and under-

neath the charger.

A dedicated circuit is required for

the charger.

Refer to the charger manual for appropri-

ate circuit protection. For optimum performance and

shortest charge times, place the charger in an area with

adequate ventilation. The charger should also be placed

in an area that will be relatively free of dirt, mud, or dust

since accumulations within the fins of the charger will

reduce their heat-dissipating qualities. Optimal cooling

also occurs when the charger is placed on a horizontal

surface with the fins vertical. More airflow from below

the charger will help cool the fins, so placement above

open areas or areas with cut-outs for airflow is desir-

able. If the charger is operated in an outdoor location,

rain and sun protection must be provided. The charger

may get hot during operation and must be placed such

that risk of contact by people is reduced. The charger

may be mounted on a wall or shelf

using #10-M5

screws. The charger’s status display must be visible to

the user.

Fig. 5

Charger Installation

ITEM

SERVICE OPERATION

Batteries

Charge batteries

Seats

Remove protective plastic covering

Brakes

Check operation

Establish acceptable stopping distance

Tires

Check air pressure (see SPECIFICATIONS)

Portable

Remove from vehicle and properly mount

Charger

DANGER

Keep cooling fins clean and free of dirt and debris

NEMA 15 - 5R Grounded AC Receptacle

110 - 120 VAC. Dedicated 15 AMP Circuit

Locations outside the US and Canada: Reference

appropriate local electrical code and charger manu-

facturer recommendations for AC power requirements