Ezgo RXV Fleet Freedom Shuttle 2+2 Owner'S Manual Download Page 6

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SECTION TITLE

PAGE NO.

TABLE OF CONTENTS

Page iv

Owner’s Guide

TRANSPORTING THE VEHICLE ................................................................................. 12

TOWING.............................................................................................................. 12

HAULING............................................................................................................. 13

SERVICE AND MAINTENANCE .................................................................................. 13

ROUTINE MAINTENANCE.................................................................................. 14

TIRE INSPECTION.............................................................................................. 14

REAR AXLE ........................................................................................................ 14

HARDWARE........................................................................................................ 14

CAPACITIES AND REPLACEMENT PARTS....................................................... 15

PERIODIC SERVICE SCHEDULE....................................................................... 16

BATTERIES AND CHARGING..................................................................................... 17

SAFETY............................................................................................................... 17

BATTERY ............................................................................................................ 17

BATTERY MAINTENANCE.......................................................................................... 18

AT EACH CHARGING CYCLE ............................................................................ 18

MONTHLY ........................................................................................................... 18

ELECTROLYTE LEVEL AND WATER................................................................. 19

CLEANING BATTERIES

BATTERY REMOVAL & INSTALLATION.................................................................... 20

PROLONGED STORAGE ............................................................................................ 22

BATTERY CHARGING................................................................................................. 23

TROUBLESHOOTING.................................................................................................. 23

HYDROMETER ................................................................................................... 23

USING A HYDROMETER.................................................................................... 24

GENERAL SPECIFICATIONS...................................................................................... 27

RXV ELECTRIC - FLEET VEHICLE SPECIFICATIONS...................................... 28

RXV ELECTRIC - FREEDOM VEHICLE SPECIFICATIONS ............................... 29

RXV ELECTRIC - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS........................ 30

DECLARATION OF CONFORMITY (EUROPE ONLY) ................................................ 35

Summary of Contents for RXV Fleet Freedom Shuttle 2+2

Page 1: ...REVISED JULY 2014 ISSUED FEBRUARY 2009 ...

Page 2: ... vehicle is to be used in a commercial environment signs similar to the ones illustrated should be used to warn of sit uations that could result in an unsafe condition Observe these NOTICES CAUTIONS WARNINGS and DANGERS be aware that servicing a vehicle requires mechan ical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or ren der it uns...

Page 3: ...ivision and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and the E Z GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCI DENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual These are the original instructions as defined by 2006 42 EC TO CONTACT US NORTH AMERICA TECHNICAL ASSISTA...

Page 4: ... self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of electrical drain On all electric vehicles set the key switch to OFF Make sure that the RUN T...

Page 5: ...CTOR 5 SPEEDOMETER STATE OF CHARGE METER 5 HEADLIGHT SWITCH 6 TURN SIGNAL SWITCH 6 HORN 6 ACCELERATOR BRAKE PEDALS 6 PARKING BRAKE 6 RUN TOW SWITCH 6 OPERATING THE VEHICLE 7 REGENERATIVE BRAKING 7 PEDAL UP BRAKING 8 HIGH PEDAL DISABLE FEATURE 8 STARTING AND DRIVING 8 STARTING VEHICLE ON A HILL 8 COASTING 8 LABELS AND PICTOGRAMS 8 SUN TOP AND WINDSHIELD 8 VEHICLE CLEANING CARE 8 VEHICLE CLEANING 8 ...

Page 6: ...ND CHARGING 17 SAFETY 17 BATTERY 17 BATTERY MAINTENANCE 18 AT EACH CHARGING CYCLE 18 MONTHLY 18 ELECTROLYTE LEVEL AND WATER 19 CLEANING BATTERIES BATTERY REMOVAL INSTALLATION 20 PROLONGED STORAGE 22 BATTERY CHARGING 23 TROUBLESHOOTING 23 HYDROMETER 23 USING A HYDROMETER 24 GENERAL SPECIFICATIONS 27 RXV ELECTRIC FLEET VEHICLE SPECIFICATIONS 28 RXV ELECTRIC FREEDOM VEHICLE SPECIFICATIONS 29 RXV ELEC...

Page 7: ...connection with the use of all E Z GO products new and used the Distributor or Dealer has reason to believe may be operated in personal transportation applications Information on FMVSS 571 500 can be obtained at Title 49 of the Code of Federal Regulations section 571 500 or through the Internet at the website for the U S Department of Transportation at Dockets and Regulation then to Title 49 of th...

Page 8: ... grades maintain adequate distance between vehicles maintain adequate distance between vehicles reduce speed in wet areas use extreme caution when approaching sharp or blind turns use extreme caution when driving over loose terrain use extreme caution in areas where pedestrians are present MAINTENANCE ALWAYS replace damaged or missing warning caution or information labels maintain the vehicle in a...

Page 9: ...echanic VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement NEVER charge a vehicle in an area that is subject to flame or spark Pay particular atten...

Page 10: ...Page viii Owner s Guide Notes SAFETY INFORMATION Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS ...

Page 11: ...LABELS PICTOGRAMS Page ix Owner s Guide Read all of manual to become familiar with this vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS B B LABELS PICTOGRAMS ...

Page 12: ...LY when turning andAVOID sudden stops ALWAYS drive straight up and down slopes Do not coast use BRAKE when going down a slope NEVER drive this vehicle under the influence of drugs or alcohol This vehicle is NOT ATOY Drive responsibly NEVER leave children unattended or allow children to play on the vehicle NEVER leave the key in the vehicle when parked DO NOT OVERLOAD this vehicle NEVER carry more ...

Page 13: ...nual 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 ...

Page 14: ...E PERSONAL INJURY AVOID FALLS from the vehicle and other SERIOUS INJURIES Never attempt to enter or exit a moving vehicle KEEP feet legs hands and arms inside the vehicle at all times NEVER leave children unattended Children may need assistance to remain properly seated and holding on AVOID standing in front of or behind vehicle ONLY 2 occupants per seat Always remain PROPERLY SEATED and HOLDING O...

Page 15: ...Page xiii Owner s Guide Notes Read all of manual to become familiar with this vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS LABELS PICTOGRAMS ...

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: ...LOCAL LAWS AND REGULATIONS MAINTAIN ACCORDING TO SERVICE REPAIR MANUAL AVAILABLE AT www ezgo com 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 BRAKE GASOLINE VEHICLES FORWARD OPERATION TU...

Page 18: ...E VEHICLE IF THE VEHICLE 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 RE...

Page 19: ... 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 WARNING HOT SURFACE 608823 ...

Page 20: ...Page xviii Owner s Guide Notes LABELS PICTOGRAMS Read all of manual to become familiar with this vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS ...

Page 21: ... provide the vehicle model serial number and manufac ture date code SERIAL NUMBER LOCATION Three serial number and manufacture date code labels are on the vehicle One is placed on the steering column Ref Fig 1 the second is located on the frame mem ber under the front splash shield on the driver side Ref Fig 2 and the third is located on the passenger side frame rail at the rear of the vehicle Ref...

Page 22: ...he charger has received a sharp blow been dropped or otherwise damaged in any way refer all repair work to qualified per sonnel Not for use by children Portable chargers are shipped with the vehicles Prior to vehicle or charger operation the charger must be re moved and mounted on a platform or wall above the ground to permit maximum air flow around and under neath the charger A dedicated circuit ...

Page 23: ...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...

Page 24: ...cate a problem with the bat tery pack or that the charger output current was severely reduced due to high ambient tempera tures FOUR RED FLASHES Four flashes a pause and then again four flashes and a pause Battery Fault Charge time exceeded This indicates a problem with the battery pack voltage not reach ing the required nominal level within the maxi mum time allowed SIX RED FLASHES Six flashes a ...

Page 25: ...e direction selector for forward neutral or reverse To prevent inadvertent operation of the vehicle when left unattended the key should be turned to the OFF posi tion and removed To reduce the possibility of component damage the vehicle must be stopped before moving the key switch direction selector Fig 9 Run Tow Switch SPEEDOMETER STATE OF CHARGE SOC METER OPTIONAL EQUIPMENT If the vehicle is equ...

Page 26: ...A DC to DC converter is available through E Z GO Service Parts The Operational Performance Guarantee of 2 rounds per day shall be void if non factory accessories that use more than 1 Amp Hour of energy per round are installed on the vehicle ACCELERATOR BRAKE PEDALS With the key switch in the F or R position depressing the accelerator pedal 6 starts the motor and will move the vehicle in the direct...

Page 27: ...nd remove the weather pack seal 4 from the connector 2 Locate the Primary Power line connector 1 and dis connect 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 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...

Page 28: ...irection selector is in cor rect position before attempting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector Check the area behind the vehicle before operating in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehicle is in motion REGENERATIVE BRAKING To prevent the possibility of loss of control that co...

Page 29: ... automatically when the vehicle comes to a stop To start the vehicle on a hill de press the accelerator pedal and the parking brake will be released COASTING Uncontrolled coasting does not occur with this model However this is not a substitute for the service brake which should be used to slow the speed of the vehicle quickly This model is equipped with a feature pedal up braking that slows the ve...

Page 30: ...cle These materials will cause corrosion of underbody parts unless flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sedi ment packed in closed areas should be loosened to ease its removal taking care not to chip or otherwise damage paint REPAIR LIFTING THE VEHICLE Tool List Qty Floor Jack 1 Jack Stands 4 Wheel Chocks 4 Some servicing operations...

Page 31: ...n socket when removing wheels use only sockets designed for impact wrench use Use caution when inflating tires Overinflation could cause the tire to separate from the wheel or cause the tire to explode either of which could cause severe injury DO NOT use low inflation tires on any E Z GO vehicle DO NOT use any tire which has a rec ommended inflation pressure less than the inflation pressure recomm...

Page 32: ...tire is to be removed or mounted the tire changing machine manufacturer s recommendations must be fol lowed in order to reduce possibility of severe injury WHEEL INSTALLATION To reduce the possibility of component damage do not tighten lug nuts to more than 85 ft lbs 115 Nm torque It is important to follow the cross sequence pattern when installing lug nuts This will assure even seating of the whe...

Page 33: ... Push turn signal housing 9 into headlight assembly firmly making sure that it is seated completely 5 Turn the retaining collar 8 to secure the bulb housing and install the phillips head screw 7 to secure in place TAILLIGHT BRAKE LIGHT BULB REPLACE MENT Make sure that the vehicle key switch is in the OFF po sition and the key has been removed 1 Remove the two phillips head screws 10 that secure th...

Page 34: ...key switch is turned to OFF and the key removed Never use ropes or chains to tow vehicle s Tow bars are available from the E Z GO Service Parts Depart ment Tow bars are not intended for highway use Before tow ing place the direction selector in neutral N and make sure that the Run Tow switch in TOW or on Eu ropean Models Do not ride on a vehicle being towed Tow bars are designed to tow only one ve...

Page 35: ...extreme care Insulate metal container to reduce the pos sibility of can contacting battery terminals which could result in an explosion It is in the best interest of both vehicle owner and ser vice technician to carefully follow the procedures recom mended in this manual Preventative maintenance ap plied at recommended intervals is the best guarantee for keeping the vehicle both dependable and eco...

Page 36: ...ig 18 Capacities ITEM PART NUMBER Fuse ATC 10A E Z GO P N 35212G07 Headlight Bulb 894 E Z GO P N 74004G01 Turn Signal Bulb 912 NA E Z GO P N 74005G01 Tail Light Bulb 2057 E Z GO P N 604311 Fig 19 Replacement Part 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 4 7 8 1 Unless otherwise noted in text tighten all hardware in accordance with this chart This chart...

Page 37: ... state of charge condition loose terminals corro sion hold down hardware CL CL CL 17 Batteries check electrolyte level fill if required C A C A C A C A 18 Brakes smooth operation of pedal stopping distance Brakes aggressive stop test does brake hold on a hill Accelerator smooth operation Wiring loose connections broken or missing insulation Charger Receptacle clean connections CL CL CL CL Steering...

Page 38: ...onate baking soda dissolved in 1 1 2 gallons 6 liters of water and flushed with water Overfilling batteries may result in electrolyte being spilled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aerosol containers of battery terminal pro tectant must be used with extreme care Insulate metal container to prevent can from contacting...

Page 39: ...ry due to gassing and a decrease in volume of the electrolyte that results from the charging cycle DO NOT overfill batteries The charging cycle will expel electrolyte and result in component damage A battery being charged will gas with the majority of the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be ca...

Page 40: ... soda dissolved in 1 1 2 gal lons 6 liters of water and flushed with water CLEANING BATTERIES When cleaning the outside of the batteries and termi nals do not use a water hose without first spraying the batteries with a solution of baking soda sodium bicar bonate and water to neutralize any acid deposits Use of a water hose without first neutralizing the acid will move the acid from the top of the...

Page 41: ...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 nega tive BL battery cable 3 Using an ins...

Page 42: ...aces 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 metal surfaces that have been cleaned must be primed and painted with a corrosion resistant paint 9 4 12V Battery System Replace the batteries using the portable lifting device starting with the battery lo cated at the back of the battery tray 4 by making...

Page 43: ...28 Battery Components 12 Inspect all wires and terminals and clean any corro sion 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 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 14 Tighten ...

Page 44: ... plates This condition is not reversible and will cause permanent damage to the battery In order to pre vent damage the battery should be recharged A hy drometer P N 50900 G1 can be used to determine the specific gravity and therefore the state of charge of a battery In winter conditions the battery must be fully charged to prevent the possibility of freezing A fully charged bat tery will not free...

Page 45: ... of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the vehicle charging receptacle TROUBLESHOOTING In general troubleshooting will be done for two distinct reasons First a battery that performs poorly and is out side of the manufacturers specification should be identi fied in order to replace it under the terms of the manu facturer s warranty ...

Page 46: ...it the thermometer to adjust to the electrolyte temperature and note the reading Examine the color of the electrolyte A brown or gray coloration indicates a problem with the battery and is a sign that the bat tery is nearing the end of its life 2 Draw the minimum quantity of electrolyte into the hy drometer to permit the float to float freely without con tacting the top or bottom of the cylinder 3...

Page 47: ...Page 27 Owner s Guide GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS ...

Page 48: ...or 1 passenger TOTAL LOAD CAPACITY 800 lbs 360 kg including operator passenger accessories cargo SPEED 14 mph 23 kph in forward on flat ground CHASSIS Welded tubular steel powder coated DuraShield BODY Flexible Impact resistant Injection Molded TPO Thermoplastic Polyolefin with Base Coat Clear Coat STANDARD COLORS Ivory Forest Green DASH PANEL Scuff resistant plastic with 4 drink holders storage f...

Page 49: ...r TOTAL LOAD CAPACITY 800 lbs 360 kg including operator passenger accessories cargo SPEED 19 mph 31 kph in forward on flat ground CHASSIS Welded tubular steel powder coated DuraShield BODY Flexible Impact resistant Injection Molded TPO Thermoplastic Polyolefin with Base Coat Clear Coat STANDARD COLORS Ivory Forest Green DASH PANEL Scuff resistant plastic with 4 drink holders storage for balls tees...

Page 50: ...L LOAD CAPACITY 700 lbs 318 kg including operator passenger accessories cargo SPEED 14 17 5 mph 23 28 2 kph in forward on flat ground CHASSIS Welded tubular steel powder coated DuraShield BODY Flexible Impact resistant Injection Molded TPO Thermoplastic Polyolefin with Base Coat Clear Coat STANDARD COLORS Ivory Forest Green DASH PANEL Scuff resistant plastic with 4 drink holders storage for balls ...

Page 51: ...e GENERAL SPECIFICATIONS Fig 31 Fleet Freedom Vehicle Dimensions 65 7 167 cm 94 5 240 cm 35 5 90 cm 38 97 cm 45 7 116 cm 68 50 174 cm 47 119 cm 65 7 167 cm 94 5 240 cm 35 5 90 cm 38 97 cm 45 7 116 cm 68 50 174 cm 47 119 cm ...

Page 52: ...Page 32 Owner s Guide GENERAL SPECIFICATIONS Fig 31 Shuttle 2 2 Vehicle Dimensions 65 7 167 cm 105 5 268 cm 35 5 90 cm 38 97 cm 45 7 116 cm 74 188 cm 47 119 cm ...

Page 53: ...Page 33 Owner s Guide GENERAL SPECIFICATIONS Fig 32 Vehicle Incline Specifications and Turning Diameter RECOMMENDED MAX RAMP 25 GRADE OR 14 MAX RECOMMENDED MAX SIDE TILT 25 GRADE OR 14 MAX 1 9 2 5 8 m ...

Page 54: ...Page 34 Owner s Guide GENERAL SPECIFICATIONS Fig 33 Powerwise QE 48V Charger 4 5 cm 19 0 cm 21 0 cm 19 35 cm 3 0cm 21 5 cm 16 5 cm 14 0 3 cm 22 4 3 cm 10 6 1 cm 26 4 3 cm ...

Page 55: ...Page 35 Owner s Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY ...

Page 56: ...Page 36 Owner s Guide DECLARATION OF CONFORMITY ...

Page 57: ...Page 37 Owner s Guide DECLARATION OF CONFORMITY ...

Page 58: ...Page 38 Owner s Guide DECLARATION OF CONFORMITY Notes ...

Page 59: ...ly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing remov...

Page 60: ... whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department TO CONTACT US North America Technical Assistance Warranty Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 GET E Z GO 1 888 438 3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 ...

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