E-Z-GO TXT - Electric Owner Manual - Page 34

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.

B

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 Replacement

Before any electrical service is performed on TruCourse

echnology model vehicles, the Run-Tow/Maintenance/

Storage switch must be placed in the ‘Tow/Maintenance/

Storage’ position.

If a power wire (battery, motor or controller) is disconnect-

ed for any reason, the Run-Tow/Maintenance/Storage

switch must be left in the ‘Tow/Maintenance/Storage’

position for at least 30 seconds after the circuit is

restored.

Remove battery hold downs and cables. Lift out batteries

with a commercially available lifting device.

If the batteries have been cleaned and any acid in the

battery rack area neutralized as recommended, no corro-

sion to the battery racks or surrounding area should be

present. Any corrosion found should be immediately

removed with a putty knife and a wire brush. The area

should be washed with a solution of sodium bicarbonate

(baking soda) and water and thoroughly dried before

priming and painting with a corrosion resistant paint.

The batteries should be placed into the battery racks and

the battery hold downs tightened to 45 - 55 in. lbs. (5 - 6

Nm) torque, to prevent movement but not tight enough to

cause distortion of the battery cases.

Inspect all wires and terminals. Clean any corrosion from

the battery terminals or the wire terminals with a solution

of sodium bicarbonate (baking soda) and brush clean if

required.

To prevent battery explosion that could result

in severe personal injury or death, extreme

care must be used with aerosol containers of

battery terminal protectant. Insulate the metal

container to prevent the metal can from con-

tacting battery terminals which could result in

an explosion.

Use care to connect the battery wires as shown (Ref. Fig.

19). Tighten the battery post hardware to 90 - 100 in. lbs.

(6 -8 Nm) torque

.

Do not over-torque the terminal stud

nut, this will cause a “mushroom” effect on the battery

post which will prevent the terminal nut from being prop-

erly tightened.

Fig. 19

Battery Connections

Protect the battery terminals and battery wire terminals

with a commercially available coating.

Prolonged Storage

Battery charger, controller and other electronic devices

need to be disconnected since they will contribute to

the premature discharge of batteries.

The ’RUN-TOW/MAINTENANCE/STORAGE’ switch,

located

under the passenger seat is set to ‘TOW/MAINTENANCE/

STORAGE’ position for long term storage of

the vehicle to

avoid draining of the batteries.

During periods of storage, the batteries will need atten-

tion to keep them maintained and prevent discharge.

In high temperatures the chemical reaction is faster,

while low temperatures cause the chemical reaction to

slow down. A vehicle that is stored at 90° F (32° C) will

loose .002 of specific gravity each day. If a fully charged

battery has a specific gravity of 1.275, and the battery is

allowed to sit unused, it will become partially dis-

charged. When it reaches 1.240, which it will do in less

than twenty days, it should be recharged. If a battery is

left in a discharged state, sulfating takes place on and

+

-

+

-

+

-

+

-

+

-

+

-

Front of Vehicle

BL +

BL -

NOTICE

Section	Page
TXT_Operation_Service_Info1.pdf	17
.	17
Fig. 1 Initial Service Chart	17
Portable Charger Installation	17
Fig. 2 Charger Installation	18
Fig. 3 Charger Mounting	18
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.	18
Using the Charger	18
Fig. 4 Charger Receptacle	19
If vehicle is to be charged with a non E-Z-GO charger, refer to the instructions supplied with the charger.	19
Understanding the Charger	19
LED Operation Codes:	19
LED Fault Codes:	19
MAINTENANCE INSTRUCTIONS	19
1. For flooded lead-acid batteries, regularly check the water levels of each battery cell after charging and add distilled water...	19
2. Make sure the charger connections to the battery terminals are tight and clean. Check for any deformations or cracks in the p...	20
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.	20
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.	20
If vehicle is to be charged with a non E-Z-GO charger, refer to the instructions supplied with the charger.	20
CONTROLS AND INDICATORS	20
KEY/ STATE OF CHARGE METER	20
Fig. 5 Key & State of Charge Meter	20
STATE OF CHARGE METER	20
DIRECTION SELECTOR	20
Fig. 6 Direction Selector	20
ACCELERATOR PEDAL	20
Fig. 7 Accelerator and Brake Controls	21
Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure the longest service life of brake components.	21
COMBINATION BRAKE AND PARK BRAKE PEDAL	21
RUN - TOW/MAINTENANCE SWITCH	21
Fig. 8 Run-Tow Maintenance Switch	21
OPERATING THE VEHICLE	22
TRUCOURSE TECHNOLOGY SYSTEM™	22
TruCourse Technology vehicles operate only when the Run - Tow/Maintenance switch is in the ’RUN’ position.	22
Performance Options	22
Fig. 9 Performance Options	22
1. The All-Terrain performance option: The vehicle’s top speed is sensed and regulated directly by the controller.	22
2. The Steep Hill performance option: This option includes all of the driving features and top speed of All-Terrain plus pedal-up braking. This is the strongest of the two pedal-up braking options.	22
3. The Mild Hill performance option: This option includes all of the driving features of the Steep Hill option, except the pedal-up braking feel is milder and the top speed is slightly higher.	23
Regenerative Braking	23
a) the vehicle is being driven down a slope	23
b) the vehicle attempts to exceed the specified top speed with the accelerator pedal depressed or released	23
Pedal-Up Braking	23
a) the vehicle is being driven down a slope	23
b) the accelerator pedal is released for more than one second	23
Walk-Away Feature	23
a) the vehicle has been stopped for more than 1.5 seconds	23
b) the accelerator pedal has been released for more than one second	23
c) the vehicle begins to roll above 2 mph (3 kph)	23
Anti-Roll Back Feature	23
Anti-Stall Feature	23
a) the system senses that the accelerator pedal is depressed (power applied to motor)	23
b) the motor is stalled long enough that any more time may cause motor damage	23
a) the system senses that the accelerator pedal is depressed (power applied to motor)	23
b) the brake is engaged so as to prevent vehicle motion	23
High Pedal Disable Feature	24
Diagnostic Mode Feature	24
Starting And Driving	24
Starting Vehicle On A Hill	24
Coasting	24
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.	24
Labels and Pictograms	24
Sun Top And Windshield	24
VEHICLE CLEANING AND CARE	25
VEHICLE CLEANING	25
REPAIR	25
LIFTING THE VEHICLE	25
Fig. 10 Lifting the Vehicle	26
WHEELS AND TIRES	26
Tire Repair	26
Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel.	26
.	26
Wheel Installation	27
It is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will assure even seating of the wheel against the hub.	27
Fig. 11 Wheel Installation	27
TRANSPORTING VEHICLE	27
Towing	27
Hauling	27
SERVICE AND MAINTENANCE	28
SERIAL NUMBER PLATE & LOCATION	28
Fig. 12 Serial Number Plate & Location	28
ROUTINE MAINTENANCE	29
Tire Inspection	29
Rear Axle	29
HARDWARE	29
Fig. 13 Torque Specifications and Bolt Grades	29
PERIODIC SERVICE SCHEDULE	30
a - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE	30
Fig. 14 Periodic Service Schedule	30
BATTERIES AND CHARGING	31
SAFETY	31
Always observe the following warnings when working on or near batteries:	31
BATTERY	31
BATTERY MAINTENANCE	31
At Each Charging Cycle	32
Monthly	32
Electrolyte Level and Water	32
Fig. 15 Correct Electrolyte Level	32
Fig. 16 Water Purity Table	32
Fig. 17 Automatic Watering Gun	33
The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates.	33
Battery Cleaning	33
Fig. 18 Preparing Acid Neutralizing Solution	33
Battery Replacement	34
Fig. 19 Battery Connections	34
Prolonged Storage	34
Fig. 20 Freezing Point of Electrolyte	35
BATTERY CHARGING	35
In some portable chargers, there will be a rattle present in the body of the charger DC plug. This rattle is caused by an intern...	35
TROUBLESHOOTING	35
Fig. 21 Hydrometer	36
Hydrometer	36
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.	36
Using A Hydrometer	36
1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and not...	36
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.	36
3. Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float.	36
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 ...	36
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).	36
Fig. 22 Hydrometer Temperature Correction	37
Ltd_Warranty.pdf	43
DOMESTIC WARRANTY	44

E-Z-GO TXT - Electric Owner Manual - Page 34

Battery Replacement, Prolonged Storage

Page 34 highlights