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E-Z-GO RXV - Electric Owner Manual - Page 27

This Procedure Should Only Be Per, Formed By Qualified Trained Per, Sonnel.

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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. PARKING BRAKE This vehicle is equipped with an automatic parking brake; when the vehicle is stopped the parking brake is automatically set. The parking brake is released when the key switch/direction selector is in forward ('F') or reverse ('R') and the accelerator is depressed. The parking brake is also released when the run/tow switch is placed in the 'TOW' or (on European Models) position with the key switch turned to neutral ('N'). In the event that the vehicle will not move in forward or reverse, the parking brake can be released using the instructions located on the controller splash shield beneath the seat on the passenger side of the vehicle. To move the vehicle, turn the key switch to 'N', flip the RUN-TOW switch to the 'TOW' position, move the vehicle to a safe location on level ground, chock the tires, and turn the key to 'OFF'. In case of total power loss and the RUN-TOW switch does not release the parking brake the instructions below the controller splash shield must be used. Chock the tires to prevent the vehicle moving when the brake is released. To access the instructions remove three re-usable plastic rivets securing the controller splash shield to the body and the controller. To remove the reusable rivets, press the center of the rivet with the vehicle key. When the center pin snaps into place the rivet can be removed. Repeat the process for each remaining rivet. Turn the splash shield over to reveal the instructions for releasing the parking brake. THIS PROCEDURE SHOULD ONLY BE PERFORMED BY QUALIFIED TRAINED PERSONNEL. Make sure that the key is in the 'OFF' position and the tires are chocked to prevent the vehicle moving; then perform the following: 1. Locate the 'Auxiliary Power' line (3) and remove the weather pack seal (4) from the connector. 2. Locate the 'Primary Power' line connector (1) and disconnect it from line (2). 3. Connect the 'Auxiliary Power' line (3) to the 'Primary Power' line (1) which will release the brake. If the tires B are not chocked and the vehicle is not on flat ground the vehicle will move immediately. 4. Move the vehicle to desired, safe location and chock the tires immediately. 5. Disconnect the 'Auxiliary Power' line (3) from the 'Pri- mary Power' line (1). 6. Connect the 'Primary Power' line (1) to line (2). 7. Replace the weather pack seal (4) on the 'Auxiliary Power' line connector (3). pRrAoDeNMccICeSDoCoAIdnCvdoITuUIdneTenOnrOeeOSunnevNCTncrteNEseAHinattNfcLhiVysfIftTtYSoEtyhieOhctH'leChBAPllOteoIehEeDRYTuWfweitgOxTV'Qo'iBPeiAnon'ClEAUiaArtdigUaEtaiAHutiemTrDhloXaxLysITPenUaCliIIillFELoPrrirRLakeSIywIRoPEEAeErdaewyPDYayRSfrlTecoeoPTHYtLDOktworcRoyOoF'RaPSewAstlUaMgithArsOneIieiLuN'oeOlIeaArDWliuNnEid'l'Vnn(OrD.lOeE(a3dieEe4nlFNn)RPiT)en(tFIdLEt1'hMoetoY'(ARo)eps3pMf'SBNca'Pt)ooaRhOoEErDraslskuenNilDTnimnotnRoNiAOidIt-oweauAtEEuponcCrrtTLxCyelwrttiLoEiaonhml'OEPipnreLaSeAooNeYddarwsvRwyrNnei'lieItcynedFPVEchirthEonoyChdN'oHnowseDilcTOsiIutnkeOlCcWrerT'e'roPELuvtrelnESi(OReceir1nanetlpFINN)etieMsgaRhoOwcriL(eAOtnrTot3ohErRMumst)iRhVPcpnYaceAaehrEadnalenNePc,LlwdnvuiakOncUesiaGplhreNSnelWleeR.ortSe(TrsecE2OiAfahunklo)RelFeU.alrta(Et'mdBiN4rs(ivAer)1nDearesR,fek.rrt,DE2qehotIeA)uEemMTniFAoArbMtetOTNMrhmdEaHDReookDsvBecvoSeIeoeA.ErrATnvmTTSPFhinHEceEEeEeeLInRRTScVYtFIte.YoOOWhriRU.cILMlSeLE:IDNJURY 609694 Fig. 11 Splash Shield and Parking Brake Release To reinstall the controller splash shield, position the splash shield by aligning the mounting holes with the holes in the body, push the center pin of each rivet upward so that the top of the pin is above the rivet head. Place a rivet in each mounting hole of the controller splash shield and push down on the center pin until the top of the pin is flush with the rivet head. Owner's Guide Page 7

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 7

Owner’s Guide

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. The parking brake is released when

the key switch/direction selector is in forward (’F’) or

re-

verse (’R’) and the accelerator is depressed. The park-

ing brake is also released when the run/tow switch is

placed in the ’TOW’ or

(on European Models) posi-

tion with the key switch turned to neutral (’N’).

In the event that the vehicle will not move in forward or

reverse, the parking brake can be released using the in-

structions located on the controller splash shield be-

neath the seat on the passenger side of the vehicle. To

move the vehicle, turn the key switch to ’N’, flip the

RUN-TOW switch to the ’TOW’ position, move the vehi-

cle to a safe location on level ground, chock the tires,

and turn the key to ’OFF’.

In case of total power loss and the RUN-TOW switch

does not release the parking brake the instructions be-

low the controller splash shield must

be used. Chock the tires to prevent

the vehicle moving when the brake is

released.

To access the instructions remove

three re-usable plastic rivets securing

the controller splash shield to the body

and the controller. To remove the re-

usable rivets, press the center of the

rivet with the vehicle key. When the

center pin snaps into place the rivet can

be removed. Repeat the process for each

remaining rivet.

Turn the splash shield

over to reveal the instructions for releas-

ing the parking brake.

THIS PROCEDURE SHOULD ONLY BE PER-

FORMED BY QUALIFIED TRAINED PER-

SONNEL.

Make sure that the key is in the ’OFF’ position and the

tires are chocked to prevent the vehicle moving; then

perform the following:

Locate the ’Auxiliary Power’ line (3) and remove the

weather pack seal (4) from the connector.

Locate the ’Primary Power’ line connector (1) and dis-

connect it from line (2).

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.

Move the vehicle to desired, safe location and chock

the tires immediately.

Disconnect the ’Auxiliary Power’ line (3) from the ’Pri-

mary Power’ line (1).

Connect the ’Primary Power’ line (1) to line (2).

Replace the weather pack seal (4) on the ’Auxiliary

Power’ line connector (3).

Fig. 11

Splash Shield and Parking Brake Release

To reinstall the controller splash shield,

position the splash shield by aligning the

mounting holes with the holes in the

body, push the center pin of each rivet

upward so that the top of the pin is

above the rivet head. Place a rivet in

each mounting hole of the controller

splash shield and push down on the

center pin until the top of the pin is flush with the rivet

head.

609694

Failure to follow these instructions can result in DEATH or SERIOUS INJURY

THIS PROCEDURE SHOULD ONLY BE TO CLEAR VEHICLE FROM AN UNSAFE AREA AND BE PERFORMED

ONLY BY QUALIFIED TRAINED PERSONNEL

In Case Of Total Power Loss And The ‘Run-tow’ Switch DOES NOT Release The Brake To Move The Vehicle:

Turn the ignition key to the ‘OFF’ position and ‘chock’ tires to prevent inadvertent movement.

Connect ‘Auxiliary Power’ line (3) to ‘Primary Power’ line (1) which will release the brake. THIS WILL

CAUSE THE VEHICLE TO MOVE IMMEDIATELY IF NOT ON LEVEL GROUND.

Move vehicle to desired location and park it properly on level ground, chock tires, IMMEDIATELY

DISCONNECT ‘AUXILIARY POWER’ AND RECONNECT ‘PRIMARY POWER’ (1, 2) FOR SAFETY

AND TO AVOID BATTERY DRAIN.

Reconnect the Weather Pack Seal (4) to the Auxiliary Power line (3) and perform required service

procedures following all Safety guidelines as outlined in your repair manual.

Identify the ‘Auxiliary Power’ line (3) and remove the Weather Pack Seal (4) from the connector.

Identify the ‘Primary Power’ line (1) connector and disconnect the line (2).