Ezgo RXV 646285 Owner'S Manual Download

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GENERAL SPECIFICATIONS

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

MODEL: SHUTTLE™ 2+2 RXV
TYPE: ELECTRIC PERSONNEL CARRIER
MODEL YEAR: 2016

Part No:. 638546G01

Programmable AC Drive System:

Factory programmable to application

Solid State variable frequency AC speed controller

230 Amp AC Controller

Drive-by-wire electronic throttle control

Full torque, reduced speed reverse

Dash mounted direction selector switch (Forward-Neutral-Reverse)

Sealed Hall effect throttle sensor

Descent speed control and automatic hill hold

Full diagnostic capability (Hand held diagnostic unit)

Full-time regenerative braking

Six field selectable speeds with hand held diagnostic unit

Motor:

Battery Charger:

SC - 48V Charger. UL1564, CSA 107.2

Electrical System:

48 Volt DC, four, 12 volt deep cycle storage batteries (60 minute minimum, 140 amp-hour @ 20 hr. discharge rate)

Drive Train:

Direct motor shaft connected to transaxle pinion shaft

Transaxle:

Differential with reverse helical gears

Brakes:

Induction motor. Electro-magnetic parking brake is applied automatically

Body Protection:

360° energy transfer bumpers maximize vehicle protection from minor impact

Dimensions

Performance

Overall Length

105.5 in (268 cm)

Seating Capacity

4 Person

Overall Width

47.0 in (119 cm)

Dry Weight

645 lb (295 kg) (Without Batteries)

Overall Height (No Canopy)

45.7 in (116 cm)

Curb Weight

1000 lb (455 kg)

Overall Height (With Canopy)

74.0 in (188 cm)

Vehicle load capacity

720 lb (325 kg)

Wheel Base

65.7 in (167 cm)

Outside Clearance Circle

19.2 ft (5.8 m)

Front Wheel Track

35.5 in (90 cm)

Intersecting Aisle Clearance

N/A

Rear Wheel Track

38.0 in (97 cm)

Speed (Level Ground)

8-15 mph (13 - 24 kph) Programmable

Gnd Clearance @ Differential

4.5 in (11 cm)

Towing Capacity

N/A

Vehicle Power

Steering & Suspension

Power Source

48 Volts DC

Steering

Double Ended Rack & Pinion

Motor Type

48 Volt AC

Front Suspension

Independent A-Arm Coil Over Shock

Horsepower (kW)

4.4 hp (3.3 kW) Continuous

Rear Suspension

Mono-Leaf Spring With Hydraulic Shocks

Electrical System

48 Volt

Service Brake

Induction Motor

Batteries (Qty, Type)

Four, 12 Volt Deep Cycle

Parking Brake

Automatic Electro-Magnetic

Key or Pedal Start

Pedal

Front Tires

18 x 8.50 - 8 (4 Ply Rated)

Speed Controller

235 Amp AC Controller

Rear Tires

18 x 8.50 - 8 (4 Ply Rated)

Drive Train

Motor Shaft Direct Drive

Body & Chassis

Transaxle

Limited Slip Differential

Frame

Welded Steel with DuraShield™ powder coat

Gear Selection

Dash Mounted Forward-Neutral-Reverse

Body & Finish

Injection molded TPO

Rear Axle Ratio

16.99:1

Standard Color

Forest Green

CE Noise, Vibration & Harshness

Noise

Sound pressure: continued A-weighted equal to 68 db (A)

Vibration, WBV

The highest RMS value of weighted acceleration is: 1.15 m/s

Vibration, HAV

The highest RMS value of weighted acceleration is: less than 2.5 m/s². The uncetainty of measurement is 0.2 m/s

Some items shown may be optional equipment

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

48 Volt AC induction motor, solid copper windings. 4.4 hp (3.3 kW) Continuous. AC system reads motor speed for accurate speed control in all
conditions. Regenerative braking for maximum economy

PRODUCT OVERVIEW

Summary of Contents for RXV 646285

Page 1: ...OWNER S GUIDE 646285 RXV ELECTRIC POWERED VEHICLE REVISED AUGUST 2015 ISSUED MAY 2015 ...

Page 2: ...tive hand tools If necessary contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule Repair or replacement parts are available from your E Z GO dealer or E Z GO Service Parts Department When you contact E Z GO about service or parts for your vehicle the information below is needed Vehicle Model _________________________________...

Page 3: ... materials in this Manual These are the original instructions as defined by 2006 42 EC CONTACT US E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 North America Technical Assistance and Warranty PHONE 1 800 774 3946 FAX 1 800 448 8124 Service Parts PHONE 1 888 GET EZGO 1 888 438 3946 FAX 1 800 752 6175 International PHONE 001 706 798 4311 FAX 001 706 771 4609 ...

Page 4: ... drain The battery charger can remain connected to the vehicle to keep a full charge on the batter ies while the charger is connected to an active electrical supply If the power to the electrical supply is disconnected or interrupted the battery charger will continuously check the charge on the battery pack A continuous check of the battery pack will pull power from the battery pack and drain the ...

Page 5: ...rection Selector 22 State of Charge Meter if equipped 23 Headlight Switch if equipped 23 Turn Signal Switch if equipped 23 Accelerator and Brake Pedals 23 Horn if equipped 23 Run Tow Switch 23 USB Port if equipped 24 12 Volt Power Outlet if equipped 24 Parking Brake 24 Front Seat 25 Front Hip Restraint 25 Cup Holder 25 Steering Wheel 25 Rear Seat and Cargo Platform if equipped 25 Rear Hand Rail 25...

Page 6: ...uipped 33 Run Tow Switch Operation 33 Rear Seat and Cargo Platform Operation if equipped 34 Regenerative Braking 34 Pedal Up Braking 35 High Pedal Disable Feature 35 STARTING AND DRIVING 35 Starting Vehicle On A Hill 35 Coasting 35 LABELS AND PICTOGRAMS 35 SUN TOP AND WINDSHIELD IF EQUIPPED 36 MAINTENANCE VEHICLE CLEANING AND CARE 37 ENVIRONMENTAL CONCERNS 37 Battery Disposal 38 LIFTING THE VEHICL...

Page 7: ...TTERY CHARGING AND MAINTENANCE 46 Safety 46 Battery Disposal 47 Battery 47 Battery Maintenance 47 At Each Charging Cycle 47 Monthly 47 Electrolyte Level and Water 48 Battery Cleaning 49 Battery Removal and Installation 50 Prolonged Storage 53 Battery Charging 54 AC Voltage 54 Fault Diagnosis 54 Hydrometer 55 Using A Hydrometer 56 Battery Charger Maintenance 56 PERIODIC SERVICE SCHEDULE PERIODIC SE...

Page 8: ...vi TABLE OF CONTENTS Notes Owner s Guide ...

Page 9: ...loss of vehicle control is abusive and will not be covered under the warranty Use caution when you tow the vehicle Towing the vehicle above the recommended speed can cause personal injury or damage to the vehicle and other property If the vehicle is used in a commercial environment signs must be in position to inform of possible conditions that can be dangerous Examples are shown below NOTICES CAU...

Page 10: ...omers must obey this SAFETY RULE Information on FMVSS 571 500 is found at Title 49 of the Code of Federal Regulations section 571 500 For information online go to www ecfr gov Vehicles are used for different purposes so it is not possible to know and inform of every possible occurrence Be careful when you drive to prevent avoidable personal injury or damage to the vehicle All users must read and o...

Page 11: ...tion selector is in the correct position before you press the accelerator pedal Decrease speed before and during turns Make sure you completely stop the vehicle before you move the direction selector See GENERAL SPECIFICATIONS for the vehicle load and seat capacity Read the following text and warnings before you service the vehicle Normal use wear or abuse can cause some components on the vehicle ...

Page 12: ...hen you operate the vehicle around people MAINTENANCE ALWAYS Replace damaged or missing warning caution or information labels Service the vehicle according to the periodic service schedule in this manual Make sure that approved and qualified personnel do all repairs Follow the manufacturer s maintenance procedures Use insulated tools within the battery area to prevent sparks or battery explosion U...

Page 13: ...key to ON select forward or reverse release the parking brake Gas vehicle only then slowly depress accelerator pedal Always bring the vehicle to a complete stop BEFORE shifting the direction selector Operate from the driver s seat ONLY PARKING ALWAYS fully engage the parking brake and remove the key BEFORE leaving the vehicle In an electric vehicle set the direction selector to neutral and in a ga...

Page 14: ...ual 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 609694 612594 This device is ONLY to be used for towing E Z GO vehicles NEVER tow other vehicles or equipment READ Owner s Manual before towing NO RIDERS in towed cars NEVER tow more than 3 vehicles at one time Max speed towing 2 or 3 v...

Page 15: ... Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 7 Owner s Guide 610631 MAX 4 in 10 cm MAX 14o 25 MAX 250 lbs 110 kg 610631 ...

Page 16: ...NOT OPERATE VEHICLE WHEN LIGHTNING IS IN THE AREA READ THE MANUAL OPERATE ACCORDING TO LOCAL LAWS AND REGULATIONS USE CAUTION IN BAD WEATHER FORWARD OPERATION TURN KEY TO ON MOVE DIRECTION SELECTOR TO F PRESS ACCELERATOR PEDAL GENTLY REVERSE OPERATION TURN KEY TO ON MOVE DIRECTION SELECTOR TO R PRESS ACCELERATOR PEDAL GENTLTY PARK VEHICLE MOVE DIRECTION SELECTOR TO F TURN KEY TO OFF APPLY PARKING ...

Page 17: ...ECTION SELECTOR TO R PRESS ACCELERATOR PEDAL GENTLTY PARK VEHICLE MOVE DIRECTION SELECTOR TO F TURN KEY TO OFF APPLY PARKING BRAKE GASOLINE VEHICLES FORWARD OPERATION TURN KEY TO F PRESS ACCELERATOR PEDAL GENTLY REVERSE OPERATION TURN KEY TO R PRESS ACCELERATOR PEDAL GENTLY PARK VEHICLE TURN KEY TO OFF ELECTRIC VEHICLES WARNING READ THE MANUAL REPLACEMENT IS AVAILABLE AT www ezgo com READ ALL LABE...

Page 18: ...CLE WILL NOT MOVE WARNING READ THE MANUAL WARNING DO NOT DRIVE FAST WARNING INSPECT TOW BAR SYSTEM EVERY 30 DAYS TOW BAR OPERATION PULL LOCKING COLLAR AWAY FROM LATCH AND PRESS ON LATCH TAB TO OPEN PLACE LATCH OVER FRONT TOWING BRACKET CLOSE LATCH AND MOVE LOCKING COLLAR UNDER LATCH TAB DO NOT TOW MORE THAN 3 VEHICLES 12 mph 19 kph MAX SPEED TOWING 1 VEHICLE DO NOT DRIVE IN REVERSE WHEN TOWING VEH...

Page 19: ...08820 www ezgo com READ THE MANUAL REPLACEMENT AVAILABLE AT www ezgo com WARNING OPERATE ACCORDING TO LOCAL LAWS AND REGULATIONS NO MORE THAN 2 OCCUPANTS IN EACH SEAT DO NOT STAND UP AND KEEP ENTIRE BODY INSIDE VEHICLE DO NOT STAND IN FRONT OF OR BEHIND VEHICLE CHILDREN MUST BE ACCOMPANIED BY AN ADULT DO NOT ALLOW CHILDREN TO RIDE ALONE DO NOT GET ON OR OFF A MOVING VEHICLE ...

Page 20: ...12 Owner s Guide SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes ...

Page 21: ... Vehicle load capacity 800 lb 360 kg Wheel Base 65 7 in 167 cm Outside Clearance Circle 19 2 ft 5 8 m Front Wheel Track 35 5 in 90 cm Intersecting Aisle Clearance N A Rear Wheel Track 38 0 in 97 cm Speed Level Ground 8 15 mph 13 24 kph Gnd Clearance Differential 4 5 in 11 cm Towing Capacity 3 E Z GO Golf Cars with approved tow bars Vehicle Power Steering Suspension Power Source 48 Volts DC Steerin...

Page 22: ... load capacity 800 lb 360 kg Wheel Base 65 7 in 167 cm Outside Clearance Circle 19 2 ft 5 8 m Front Wheel Track 35 5 in 90 cm Intersecting Aisle Clearance N A Rear Wheel Track 38 0 in 97 cm Speed Level Ground 17 5 19 5 mph 28 31 kph Gnd Clearance Differential 4 5 in 11 cm Towing Capacity 3 E Z GO Golf Cars with approved tow bars Vehicle Power Steering Suspension Power Source 48 Volts DC Steering D...

Page 23: ...in 188 cm Vehicle load capacity 720 lb 325 kg Wheel Base 65 7 in 167 cm Outside Clearance Circle 19 2 ft 5 8 m Front Wheel Track 35 5 in 90 cm Intersecting Aisle Clearance N A Rear Wheel Track 38 0 in 97 cm Speed Level Ground 8 15 mph 13 24 kph Programmable Gnd Clearance Differential 4 5 in 11 cm Towing Capacity N A Vehicle Power Steering Suspension Power Source 48 Volts DC Steering Double Ended R...

Page 24: ...Canopy 74 0 in 188 cm Vehicle load capacity 800 lb 364 kg Wheel Base 65 7 in 167 cm Outside Clearance Circle 19 2 ft 5 8 m Front Wheel Track 35 5 in 90 cm Intersecting Aisle Clearance N A Rear Wheel Track 38 0 in 97 cm Speed Level Ground 8 15 mph 13 24 kph Programmable Gnd Clearance Differential 4 5 in 11 cm Towing Capacity N A Vehicle Power Steering Suspension Power Source 48 Volts DC Steering Do...

Page 25: ...empting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 17 Owner s Guide APPROXIMATE VEHICLE DIMENSIONS Figure 1 Fleet and Freedom Vehicle Dimensions 35 5 90 cm 38 97 cm 45 7 116 cm 68 50 174 cm 47 119 cm 68 50 174 cm 65 7 167 cm 94 5 240 cm ...

Page 26: ... all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Figure 2 Shuttle 2 2 Vehicle Dimensions 65 7 167 cm 105 5 268 cm 47 119 cm 35 5 90 cm 38 97 cm 45 7 116 cm 74 188 cm ...

Page 27: ...ay particular attention to Notices Cautions Warnings and Dangers 19 Owner s Guide TURNING DIAMETER AND INCLINE INFORMATION Figure 3 Vehicle Incline Specifications and Turning Diameter 1 9 2 5 8 m RECOMMENDED MAX SIDE TILT 25 GRADE OR 14 MAX RECOMMENDED MAX RAMP 25 GRADE OR 14 MAX SIDE TILT 4 MAX ...

Page 28: ...20 Owner s Guide GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes ...

Page 29: ...ure 1 1 Key Switch and Direction Selector 2 State of Charge Meter if equipped 3 Head Light Switch if equipped 4 Turn Signal Switch if equipped 5 Horn Button if equipped 6 Center Compartment 7 Power Outlet 12V if equipped 8 USB Port if equipped 9 Accelerator Pedal 10 Brake Pedal 11 Run Tow Switch Figure 1 Vehicle controls features and indicators ST OR AG E 608 769 F R OF F O ON N 11 11 European Veh...

Page 30: ...unt A DC to DC converter is available for purchase from E Z GO Service Parts The Operational Performance Guarantee of 2 rounds per day is void if non factory accessories that use more than 1 Amp Hour of energy per round are installed on the vehicle Key Switch and Direction Selector To decrease the risk of component damage stop the vehicle before you move the key switch or the direction selector To...

Page 31: ...is equipped with motor brake when the accelerator pedal is released the motor will stop To stop the vehicle quickly press the brake pedal 11 Figure 1 Horn if equipped The horn button is located on the driver side of the floorboard Press the button to activate the horn Run Tow Switch Before you attempt to tow the vehicle turn the key switch to N and move the Run Tow switch to the TOW position Failu...

Page 32: ...ver to read the instructions This procedure must be performed by qualified trained personnel Make sure that the key switch is in the OFF position and chock the tires to prevent the vehicle from moving Then do the following Locate the Auxiliary Power line 7 and remove the weather pack seal 8 from the connector Figure 5 Locate the Primary Power line connector 5 and dis connect it from line 6 Connect...

Page 33: ...Wheel The steering wheel 12 controls the direction of vehicle travel Figure 6 Rear Seat and Cargo Platform if equipped Rear passengers must stay in the seat and hold both the hand rail and rear handle while the vehicle is in motion Do not allow passengers to ride on the cargo platform A sudden move or stop can cause severe injury or death to passengers on the cargo platform The vehicle has a featu...

Page 34: ...s Figure 7 Weather Enclosure if equipped A weather enclosure provides protection from strong weather conditions Rear View Mirror if equipped The rear view mirror is adjustable for use during the day or night DC to DC Converter The DC to DC Converter Supplies power to the power accessories Battery Compartment Lift the front seat to access the battery compartment for maintenance of the batteries and...

Page 35: ...nt splash shied on the driver side and the third is located on the passenger side frame rail at the rear of the vehicle Figure 1 Design changes occur on a continuous basis To get the correct components for the vehicle the PIN number manufac ture date code serial number or vehicle model must be supplied Figure 1 Serial Number Locations Improper use of the vehicle or the lack of proper maintenance m...

Page 36: ...sive hydrogen gas is created during the charge cycle of the batteries Good ventilation is necessary to remove gas from enclosed spaces The air must change every 12 minutes Never charge a battery near flammable materials open flame or sparks Never charge a vehicle near gas water heaters and furnaces Before a new vehicle is put into operation complete the items shown in the INITIAL SERVICE CHART POR...

Page 37: ...hicles Before vehicle or charger operation remove the charger from the vehi cle A dedicated circuit is necessary for the charger Refer to the charger manual for correct circuit protection For best performance and shortest charge times put the charger in an area with good ventilation The list below supplies points to keep the charger cool while in operation Put the charger in an area that is withou...

Page 38: ...than 80 The charger LED light will give a LONG flash if the charge is more than 80 SOLID GREEN indicates that the batteries are completely charged and you can dis connect the charger but it is not necessary The charger can stay connected to keep the batteries charged If a fault occurred during the charge cycle the charger LED will quickly flash RED The specified fault is indicated by the number of...

Page 39: ... the charger DC power cord and connect again If the fault is sensed after that take the charger to an approved service center To decrease the possibility of electrical shock or electrocution make sure that the charger plug is not damaged and is correctly connected to a grounded outlet The power AC cord has a plug with a ground post Do not remove cut or bend the ground post The charger DC cord has ...

Page 40: ...e vehicle turn the key to the OFF position and remove from the switch to prevent accidental operation To prevent accidental movement when the vehicle is to be left without an operator turn the key to the OFF position and remove the key Always stop the vehicle before moving the direction selector Do not take the vehicle out of gear while in motion move without power Check the area behind the vehicl...

Page 41: ...his vehicle is equipped with motor brake When the accelerator pedal is released the motor will stop To stop the vehicle quickly press the brake pedal 2 Figure 2 Horn if equipped If the vehicle is equipped with a horn the horn button 3 is located on the driver s side of the floorboard Pressing the button 3 will sound the vehicle s horn Figure 2 Run Tow Switch Operation Before you attempt to tow the...

Page 42: ...to the vehicle or cause the vehicle to tilt Put the load on the platform as far forward as possible Secure the loads on the platform to prevent movement The center of gravity of the load must be less than 4 inches 10 cm above the platform The load capacity of the cargo platform is a maximum of 250 lbs 115 kg Do not put more than the specified capac ity on the platform Increased loads can change th...

Page 43: ...les have an interlock system that disables the controller and prevents operation or tow of the vehicle while the charger is connected Remove the charger plug from the receptacle and correctly store the cable before you move the vehicle To operate the vehicle Put the key in the key switch and turn to the desired position Slowly press the accelerator pedal to start the motor When the accelerator ped...

Page 44: ... provide protection from tree limbs or flying objects The sun top and windshield provide some protection from the elements however they will not keep the operator and passenger dry in heavy rain This vehicle is not equipped with seat belts and the sun top has not been designed to pro vide roll over protection In addition the sun top does not protect against falling objects nor does the windshield ...

Page 45: ...ailable vinyl and rubber cleaner to remove oil tar asphalt shoe polish etc Wash the vehicle frequently with cool water and mild detergent to protect the painted surfaces Apply wax that is for clear coat automotive finishes to improve the appearance and protection of the painted surfaces Do not apply wax to matte finish surfaces Occasional cleaning and waxing with non abrasive products designed for...

Page 46: ...le being lifted When you lift the vehicle put the jacks and jack stands at the areas indicated only Tool List Quantity Tool List Quantity Floor Jack 1 Jack Stands 4 Wheel Chocks 4 Remove payload from vehicle before lifting No person s should be in or on the vehicle while lifting How to lift the entire vehicle 1 Install wheel chocks in front and behind each front wheel 2 Center the jack under the b...

Page 47: ...ower the vehicle 1 Lift the vehicle enough to remove the jack stands 2 Carefully lower the vehicle to the ground with the jack WHEELS AND TIRES Recommended tire inflation pressure 18 22 psi To decrease the risk of tire explosion add small amounts of air to the tire at intervals to seat the tire beads Over inflation of small tires can occur in a few seconds Do not over inflate the tires Excess pres...

Page 48: ...ualities Always install the valve stem cap after you check or inflate the tires The vehicle has low pressure tubeless tires installed on one piece rims Use a tire plug to repair small holes in the tread part of the tire For large holes and cuts replace the tire Tire plug tools and plugs are available at automotive outlets The tires do not have to be removed from the wheel to install the tire plugs...

Page 49: ...ipped Make sure that the vehicle key switch is in the OFF position and the key has been removed Remove the phillips head screw 7 and turn the retaining collar 8 to align with the turn signal bulb housing 9 Figure 1 Grip the turn signal bulb housing 9 and pull backward to remove housing from the headlight assembly Remove the bulb from the housing and replace with a new one Push turn signal housing ...

Page 50: ...in excess of 15 mph the motor brake will engage and slow the vehicle down This vehicle is equipped with a Run Tow switch located underneath the seat on the passenger side The TOW or on European Models position with the key switch in the N position allows the vehicle to roll freely without activating the warning beeper and eliminating potential damage to controller or motor Check to see that vehicl...

Page 51: ...supported on jack stands before you do any service to the powertrain when the motor is in operation To decrease the risk of motor damage do not operate the vehicle at full throttle for more than 5 seconds with the drive wheels lifted off the ground Disconnect the negative battery cable before you service the vehicle to prevent accidental opera tion Wear eye protection when you service the vehicle ...

Page 52: ... than recommended in the Periodic Service Schedule For example high or low temperatures high dust and dirt conditions high use with maximum load To access the powertrain for normal maintenance lift or remove the seat and remove the rear access panel For major repairs refer to the applicable Technician s Repair and Service Manual Some service procedures make it necessary to lift the vehicle Refer t...

Page 53: ...cant is to be replaced the oil pan must be removed or the oil siphoned through the check fill hole CAPACITIES AND REPLACEMENT PARTS Figure 2 Capacities Figure 3 Replacement Parts HARDWARE Normally three classes of standard hardware and three classes of metric hardware are used in the vehicle Grade 5 hardware is identified by the three marks on the hexagonal head grade 8 hardware is identified by s...

Page 54: ...e batteries during removal or installation An electrolyte spill can cause burns and damage The electrolyte in a storage battery is an acid solution which can cause burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 ...

Page 55: ...als immersed in an acid If the acid is absent or if the metals are not dissimi lar a battery has not been created The batteries in this vehicle are lead acid A battery does not store electricity but it can produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy The chemical reaction occurs faster in warm conditions and slower ...

Page 56: ...his loss is minimum If the electrolyte level is high the elec trolyte will block the vent tube and the gas will push it out the vent tube and battery cap The water will dry but the sulphuric acid will stay and damage the vehicle components and the storage facility floor Sulphuric acid loss will weaken the amount of acid within the electrolyte and decrease the life of the battery Over the life of t...

Page 57: ...0 ml sodium bicarbonate baking soda mixed with 1 quart 1 liter of water Always wear a safety shield or approved safety goggles when you add water or charge the batteries Battery Cleaning To prevent battery damage make sure you correctly install all battery caps To decrease the risk of damage to vehicle or floor neutralize acid before you spray the battery with water To decrease the risk of damage ...

Page 58: ...ntainer with insulation to prevent an explosion Clean one time a month or more often in harsh conditions After the batteries are clean and dry apply a commercially available protectant to the terminals Battery Removal and Installation Tool List Quantity Tool List Quantity Insulated Wrench 9 16 1 Socket 1 2 Deep well 1 Socket 9 16 1 Ratchet 1 Battery Carrier Strap 1 Torque Wrench in lbs 1 Portable ...

Page 59: ...straps 2 per battery and a portable lifting device Figure 5 Remove the three front batteries 1 2 and 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 Figure 6 6 8V Battery System Remove the batteries using commercially available batter...

Page 60: ...n the J bolts 15 by making sure that the J bolts are securely hooked in the battery tray 16 Tighten the lock nuts 13 to a torque of 44 55 in lbs 5 6 2 Nm 11 4 12V Battery System Install the two screws 7 through the ends of the battery strap 9 into the holes on the vehicle frame and tighten the screws 7 to a torque of 80 97 in lbs 9 11 Nm 6 8V Battery System Install battery hold down 17 using two s...

Page 61: ... chemical reaction to slow A vehicle that is stored at 90 F 2 C will lose 002 of specific gravity each day If a completely charged bat tery has a specific gravity of 1 275 and the battery is not used it will become partially discharged When it reaches 1 240 which it will do in less than 20 days it must be charged again If a battery stays in a discharged state sulfating occurs on and within the pla...

Page 62: ...s that is made during the charge cycle A minimum of five air replacements for each hour is recommended The charger connector components must be in good condition and free from dirt and particles The charger connector must be completely installed in the vehicle receptacle The charger connector and cord set must be protected from damage The charger connector and cord set must be used in an area wher...

Page 63: ... 1 000 The concentration of sulfuric acid to water in a new golf car battery is 1 280 which means that the electrolyte weighs 1 280 times the weight of the same volume of water A fully charged battery will test at 1 275 1 280 while a discharged battery will read in the 1 140 range Do not perform a hydrometer test on a battery that has just been watered The battery must go through at least one char...

Page 64: ... 80 F or 27 C A variation of fifty points between any two cell read ings example 1 250 1 200 indicates a problem with the low reading cell s As a battery ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the battery providing all cells are within fifty points of each other Since the hydrometer test is in response to a vehicle exhibiting a per...

Page 65: ...rdware loose or missing Reverse Warning Indicator Overall Vehicle Condition Batteries state of charge condition loose terminals corrosion hold down and hardware CL CL CL Batteries check electrolyte level fill if required C A C A C A C A Brakes smooth operation of pedal stopping distance Brakes aggressive stop test does brake hold on a hill Accelerator smooth operation Wiring loose connections brok...

Page 66: ...58 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide ...

Page 67: ...APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers A Owner s Guide APPENDIX A DECLARATION OF CONFORMITY ...

Page 68: ...B APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Owner s Guide ...

Page 69: ...APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers C Owner s Guide ...

Page 70: ...Notes D APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Owner s Guide ...

Page 71: ...an cause some components on the vehicle to fail The manufacturer can not know all possi ble component failures or the methods that failures can occur A vehicle in need of repair does not operate correctly and can be dangerous Be careful when you service the vehicle Be aware of your safety and the safety of other people in the area Some components are heavy spring loaded corrosive explo sive can ca...

Page 72: ... 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine E Z GO Parts and Accessories Department or at www shopezgo com Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc T...

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