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E-Z-GO RXV - Electric Owner Manual - Page 23

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B OPERATION AND 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 shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle. The power (AC) cord is equipped with a grounded plug. Do not attempt to pull out, cut or bend the ground post. The charging (DC) cord is equipped with a polarized connector that fits into a matching receptacle on the vehicle. The receptacle is located on the driver side of the vehicle just below the seat bottom. Fig. 6 Charger Mounting NOTICE Looping the DC cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging. The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away. An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution. USING THE CHARGER The charger may remain plugged into the AC outlet when not in use. To charge the vehicle refer to the instruction labels on the charger. Insert the polarized DC plug completely into the vehicle receptacle. The charger will automatically start a few seconds after the plug is in place. The charger will automatically stop when the batteries are fully charged and the DC plug can be removed to permit use of the vehicle. Fig. 7 Charger Receptacle NOTICE If vehicle is to be charged with a non E-Z-GO charger, refer to the instructions supplied with the charger. UNDERSTANDING THE CHARGER Plugging the charger into the vehicle's charger receptacle will lock the vehicle out of operation. When the charger is plugged into the vehicle's charger receptacle, the charger will automatically turn on and the charger's LED and the vehicle receptacle's LED will start flashing GREEN to indicate the batteries are charging. Once a minimum battery voltage of 2 volts per cell (Vpc) is reached, the charger's output current will change from a full current charge to the trickle rated charging current. The length of charge time will vary by how depleted the batteries are, the input AC voltage, and/or charger ambient temperatures. The charger's LED will give a SHORT flash if the charge is less than 80% and a LONG flash if the charge is greater than 80%. If the charger's LED is a steady GREEN the batteries are fully charged and the charger may be unplugged, although not necessary. The charger may be left plugged in for long periods of time to maintain the batteries charge level. If a fault occurred anytime during the charging the charger's LED will quickly flash RED. The specific fault is in- Owner's Guide Page 3

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

OPERATION AND SERVICE INFORMATION

Page 3

Owner’s Guide

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

Fig. 6

Charger Mounting

Looping the DC cord through the steering wheel when charg-

ing serves as a good reminder to store the cord out of the way

when finished with charging. The DC plug can be damaged by

driving over or catching the cord on the vehicle when driving

away.

An ungrounded electrical device may become

a physical hazard that could result in an elec-

trical shock or electrocution.

USING THE CHARGER

The charger may remain plugged into the AC outlet

when not in use. To charge the vehicle refer to the in-

struction labels on the charger. Insert the polarized DC

plug completely into the vehicle receptacle. The charger

will automatically start a few seconds after the plug is in

place. The charger will automatically stop when the bat-

teries are fully charged and the DC plug can be re-

moved to permit use of the vehicle.

To prevent a physical hazard that could result

in an electrical shock or electrocution, be sure

that the charger plug is not damaged and is

inserted into a grounded receptacle.

The power (AC) cord is equipped with a

grounded plug. Do not attempt to pull out, cut

or bend the ground post.

The charging (DC) cord is

equipped with a polarized

connector that fits into a

matching receptacle on the

vehicle. The receptacle is lo-

cated on the driver side of

the vehicle just below the

seat bottom.

Fig. 7

Charger Receptacle

If vehicle is to be charged with a non E-Z-GO charger, refer to

the instructions supplied with the charger.

UNDERSTANDING THE CHARGER

Plugging the charger into the vehicle’s charger recepta-

cle will lock the vehicle out of operation. When the char-

ger is plugged into the vehicle’s charger receptacle, the

charger will automatically turn on and the charger’s LED

and the vehicle receptacle’s LED will start flashing

GREEN to indicate the batteries are charging.

Once a minimum battery voltage of 2 volts per cell (Vpc)

is reached, the charger’s output current will change from

a full current charge to the trickle rated charging current.

The length of charge time will vary by how depleted the

batteries are, the input AC voltage, and/or charger am-

bient temperatures. The charger’s LED will give a

SHORT flash if the charge is less than 80% and a

LONG flash if the charge is greater than 80%. If the

charger’s LED is a steady GREEN the batteries are fully

charged and the charger may be unplugged, although

not necessary. The charger may be left plugged in for

long periods of time to maintain the batteries charge lev-

el.

If a fault occurred anytime during the charging the char-

ger’s LED will quickly flash RED. The specific fault is in-

Hanging Holes

Mounting Holes

3.1"

(7.89 cm)

NOTICE