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E-Z-GO RXV - Electric Owner Manual - Page 41

Battery Removal & Instal, Lation

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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. 1/4 Cup (60 ML) Baking Soda Non-Metalic Wand B Batteries are heavy. Use proper lifting techniques when moving them. Always lift the battery with a commercially available battery lifting device. Use care not to tip batteries when removing or installing them; spilled electrolyte can cause burns and damage. 1 1/2 GAL (6 Liters) Water 2 GAL (8 Liters) Gargen Sprayer (1 1/2 GAL (6 Liters) Baking Soda Solution Fig. 25 Preparing Acid Neutralizing Solution Allow the solution to set for at least three minutes; use a soft bristle brush or cloth to wipe the tops of the batteries in order to remove any residue that could cause the self-discharge of the battery. Rinse the entire area with low pressure clear water. All of the items required for complete battery cleaning and watering are contained in the Battery Maintenance Kit (P/N 25587-G01). Cleaning should take place once a month or more often under extreme conditions. After batteries are clean and dry, the terminals should be coated with a commercially available protectant. Aerosol containers of battery terminal protectant must be used with extreme care. Insulate the metal container to prevent the can from contacting the battery terminals. BATTERY REMOVAL & INSTALLATION Tool List Qty. Insulated Wrench, 9/16 1 Socket, 1/2" Deep-well 1 Socket, 9/16 1 Ratchet 1 Battery Carrier Strap 2 Torque Wrench, in. lbs 1 Portable Lifting Device 1 Torx Bit, 50 IP 1 NOTICE In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in its original position unless otherwise specified. Non-specified torques are as shown in the torque specifications (See Fig. 20). 1. Turn vehicle key to the off position and remove the key. 2. Using an insulated wrench, disconnect the main negative (-), BL-, battery cable. 3. Using an insulated wrench, disconnect the main positive (+), BL+, battery cable. 4. Using an insulated wrench, disconnect and remove all other wires connected to the batteries. 5. Remove the two Pan Head Torx screws, (one on each side) from the Battery Strap. 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 and unhooking the J-bolts from the battery tray. When removing the J-bolts from between the batteries it may help to tilt the battery to the outside of the car to release the pressure on the J-bolt. 7. Remove the batteries using commercially available battery carrier straps (2 per battery) and a portable lifting device. Remove the three front batteries (1, 2, & 3) one at a time; then using the carrier straps tilt the last battery (4) to the front of the vehicle just enough to clear the rear body and using the portable lifting device lift the battery up and out of the vehicle. 8. Check the area surrounding the battery tray for corrosion. If any corrosion is found, it should be immediately removed with a putty knife and a wire brush (for metal surfaces) or a plastic bristle brush (for plastic surfaces). The area should be washed with a solution of baking soda and water and dried thoroughly. All Owner's Guide Page 21

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 21

Owner’s Guide

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

Fig. 25

Preparing Acid Neutralizing Solution

Allow the solution to set for at least three minutes; use a

soft bristle brush or cloth to wipe the tops of the batter-

ies in order to remove any residue that could cause the

self-discharge of the battery. Rinse the entire area with

low pressure clear water. All of the items required for

complete battery cleaning and watering are contained in

the Battery Maintenance Kit (P/N 25587-G01).

Cleaning should take place once a month or more often

under extreme conditions. After batteries are clean and

dry, the terminals should be coated with a commercially

available protectant.

Aerosol containers of battery

terminal protectant must be used with extreme care.

Insulate the metal container to prevent the can from

contacting the battery terminals.

BATTERY REMOVAL & INSTAL-

LATION

Tool List

Qty.

Insulated Wrench, 9/16"

..............................................

Socket, 1/2" Deep-well

................................................

Socket, 9/16"

...............................................................

Ratchet

........................................................................

Battery Carrier Strap

...................................................

Torque Wrench, in. lbs

.................................................

Portable Lifting Device

................................................

Torx Bit, 50 IP

..............................................................

Batteries are heavy.

Use proper lifting tech-

niques when moving

them. Always lift the

battery with a commer-

cially available battery

lifting device. Use care

not to tip batteries when

removing or installing them; spilled electrolyte

can cause burns and damage.

In the following text, there are references to removing/installing

bolts, etc. Additional hardware (nuts, washers, etc.) that is

removed must always be installed in its original position unless

otherwise specified. Non-specified torques are as shown in the

torque specifications (See Fig. 20).

Turn vehicle key to the off position and remove the

key.

Using an insulated wrench, disconnect the main nega-

tive (-), BL-, battery cable.

Using an insulated wrench, disconnect the main posi-

tive (+), BL+, battery cable.

Using an insulated wrench, disconnect and remove all

other wires connected to the batteries.

Remove the two Pan Head Torx screws, (one on each

side) from the Battery Strap.

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 and unhooking the J-bolts from the

battery tray. When removing the J-bolts from between

the batteries it may help to tilt the battery to the out-

side of the car to release the pressure on the J-bolt.

Remove the batteries using commercially available

battery carrier straps (2 per battery) and a portable lift-

ing device. Remove the three front batteries (1, 2, & 3)

one at a time; then using the carrier straps tilt the last

battery (4) to the front of the vehicle just enough to

clear the rear body and using the portable lifting de-

vice lift the battery up and out of the vehicle.

Check the area surrounding the battery tray for corro-

sion. If any corrosion is found, it should be immedi-

ately removed with a putty knife and a wire brush (for

metal surfaces) or a plastic bristle brush (for plastic

surfaces). The area should be washed with a solution

of baking soda and water and dried thoroughly. All

1 1/2 GAL (6 Liters) Water

Non-Metalic Wand

1/4 Cup (60 ML)

Baking Soda

2 GAL (8 Liters)

Gargen Sprayer

(1 1/2 GAL (6 Liters)

Baking Soda Solution

NOTICE