Ezgo RXV ELECTRIC Service & Repair Manual
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Ezgo RXV ELECTRIC Service & Repair Manual

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See also: Owner's Manual & Service Book , Owner's Manual
RXV ELECTRIC SERVICE & REPAIR
605975
ISSUED JANUARY 2008
REVISED APRIL 2009

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Questions and answers

Ron Lewis
January 23, 2025

There is a white wire that comes out of the wiring harness under the driver seat. I believe it was connected to a negative terminal on the old 48v lead acid batteries. What is this wire for and should it be reconnected to the negative terminal on a new lithium battery?

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Pat Stripp
February 13, 2025

Cart bucks and feels like brake is being engaged when accelerator is engaged stopping cart 2012 RXV ezgo

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1 comments:
Mr. Anderson
February 13, 2025

A 2012 Ezgo RXV electric cart may buck and feel like the brake is engaged when the accelerator is pressed due to issues with the motor brake. The motor brake is controlled by the speed control unit and service brake pedal. If the brake is overheating or failing, it can cause the cart to lock up or resist movement. Additionally, a faulty run plug connection or an issue with the accelerator pedal sensor could contribute to the problem. Checking the motor brake, wiring connections, and ensuring the accelerator pedal is functioning correctly may help resolve the issue.

This answer is automatically generated

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Robert W Kingston
February 24, 2025

should the spindle be tight or loose after tightening

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Anthony Morris Sr
March 18, 2025

Where is the “voltage reducer” located on my 2014 RXV? My lights, signals, horn and auxiliary usb/12 volt plug stop functioning after I run my cart, turn off the key and restart to go again. Everything works fine again after I recharge the batteries. I’ve checked all fuses and replaced the RHOX light/signal box. Thanks

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Anthony Morris Sr
March 18, 2025

My RXV lights, signals, horn and auxiliary usb/12 volt plug stop functioning after I run my cart, turn off the key and restart to go again. Everything works fine again after I recharge the batteries. I’ve checked all fuses and replaced the RHOX light/signal box. Would a faulty DC Converter cause this? Thanks

0
1 comments:
Mr. Anderson
March 18, 2025

Yes, a faulty DC to DC converter could cause the lights, signals, horn, and auxiliary USB/12-volt plug to stop functioning on an EZGO RXV electric cart. The converter is responsible for adjusting the voltage from the key switch to the required level for accessories. If it fails, these components may lose power, leading to their malfunction.

This answer is automatically generated

0
Marc Martinovic
April 8, 2025

Where small poll wires on solenoid go to on 2011 RXV EZ GO Golf cart. When Run/Tow switch is turn in to Run position ignition key is on but there is no click out of solenoid. Solenoid is good, checked out and even replaced with new one. I looks like solenoid is not getting power to small terminals and there for is not engaging big terminal and sending power to controller. Please help!

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1 comments:
Mr. Anderson
April 9, 2025

The small pole wires on the solenoid for a 2011 EZGO RXV Golf Cart connect to the controller and the Run/Tow switch circuit. Specifically, one small terminal connects to the controller output, and the other connects to the key switch or Run/Tow switch circuit to activate the solenoid coil.

This answer is automatically generated

0
John Rotle
April 21, 2025

Can I install a new solenoid intended for a TXT 48v in an RXV model?

0

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Summary of Contents for Ezgo RXV ELECTRIC

  • Page 1 RXV ELECTRIC SERVICE & REPAIR 605975 ISSUED JANUARY 2008 REVISED APRIL 2009...

  • Page 2: Safety

    S A FE TY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & 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: SALES PHONE: 001-706-798-4311, FAX: 001-706-771-4609 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852...

  • Page 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE SAFETY ........................Inside Covers MODELS ............................i GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C WHEELS AND TIRES ........................D ELECTRONIC SPEED CONTROL (AC MOTOR)................E FRONT SUSPENSION ........................
  • Page 6 TABLE OF CONTENTS Notes: Page iv Repair and Service Manual...

  • Page 7: Safety Information

    SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with proce- dures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 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.
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page viii Repair and Service Manual...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION .................. A - 1 TOWING ........................A - 2 SERVICING VEHICLE ....................A - 2 ROUTINE MAINTENANCE ..................A - 3 REAR AXLE ......................A - 3 TIRES........................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page A-ii Repair and Service Manual...

  • Page 13: Serial Number Location

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings. Thank you for purchasing this vehicle. This repair manu- Serial Number al contains information that will assist you in repairing and maintaining this vehicle.
  • Page 14 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings. TOWING sure that the ’Run/Tow’ switch in ’TOW’. Do not ride on a vehicle being towed. Tow bars are designed to tow only one vehicle at a maximum speed of 12 mph (19 kph) and up to three vehicles at a maximum speed of 5 mph (8 kph).

  • Page 15: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings. ROUTINE MAINTENANCE Removal of oil, tar, asphalt, shoe polish, etc., requires the use of a commercially available vinyl/rubber cleaner. This vehicle will give years of satisfactory service pro- The painted surfaces of the vehicle provide attractive viding it receives regular maintenance.

  • Page 16: Hardware

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings. porting. Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identi- Maximum speed with sun top installed is 50 fied by 6 marks on the head.

  • Page 17: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings. PERIODIC SERVICE SCHEDULE ✓ - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS ✓...
  • Page 18 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page A-6 Repair and Service Manual...
  • Page 19 SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTES, CAUTIONS AND WARNINGS ..............B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE ................B - 1 GENERAL MAINTENANCE ..................B - 1 BEFORE SERVICING THE VEHICLE ............... B - 1 Additional Warnings ..................
  • Page 20 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page B-ii Repair and Service Manual...

  • Page 21: General Maintenance

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES, CAUTIONS AND WARNINGS Throughout this manual, the following NOTES, CAU- Changes to the weight distribution or the cen- TIONS AND WARNINGS are used.

  • Page 22: Additional Warnings

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. If repairs are to be made that will require Any electrolyte spills should be neutralized welding or cutting, the batteries must be with a solution of 1/4 cup (60 ml) sodium removed.

  • Page 23: Safety

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Accessories connected to this vehicle that do not use amount required by the accessory. A DC to DC convert- the accessory harness must be connected across the er is available through E-Z-GO Service Parts.
  • Page 24 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. metal surfaces that have been cleaned must be primed and painted with a corrosion resistant paint. The following text, there are references to removing/installing 9.

  • Page 25: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. LIFTING THE VEHICLE Hex Nut Washer Tool List Qty. Battery Strap Floor Jack ..............1 Jack Stands ..............4 Wheel Chocks..............4 Some servicing operations may require the front, rear or Battery Hold Down the entire vehicle to be raised.
  • Page 26 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. To raise only the front or rear of the vehicle, place the wheel chocks in front and behind the rear wheels. The jack may be left under the center front of the frame while the front end of the vehicle is on the jack stands.
  • Page 27 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Repair and Service Manual Page B-7...
  • Page 28 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page B-8 Repair and Service Manual...

  • Page 29: Body

    BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY ........................C - 1 General ......................C - 1 BODY COMPONENT REPLACEMENT ..............C - 2 Front Bumper ....................C - 2 Rocker Panels....................C - 2 Floor Mat......................C - 2 Cowl and Instrument Panel ................
  • Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page C-ii Repair and Service Manual...

  • Page 31: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. INSTRUMENT PANEL INSTRUMENT PANEL TRIM SEAT BACK COWL SWEATER BASKET ASSEMBLY FLOOR MAT REAR BODY BUMPER UPPER ROCKER PANEL BAG WELL LOWER ROCKER PANEL STRUT COVER...

  • Page 32: Body Component Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. BODY COMPONENT REPLACE- Rocker Panels (Ref. Fig. 4) MENT Tool List Qty. Torx bit, T-45IP.............1 The body components can be replaced by removing the Ratchet ................1 securing hardware, replacing the component and install- ing hardware in the same orientation as it was removed.

  • Page 33: Cowl And Instrument Panel

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Using an insulated wrench, disconnect the bat- tery cable at the negative (-), BL-, battery ter- minal. If the vehicle is equipped with a sun top and windshield; remove these items before proceeding.

  • Page 34: Front Splash Guard

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 5. Remove three self threading nuts (20) securing the Front Splash Guard (Ref. Fig. 9) cup holder assembly (15) to the instrument panel. Remove the cup holder and disconnect the turn signal ITEM TORQUE SPECIFICATION...

  • Page 35: Sweater Basket

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner Sweater Basket (Ref. Fig. 10) ITEM TORQUE SPECIFICATION Tool LIst...

  • Page 36: Fender Liner

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 6. Remove two torx screws (33) securing each hinge plate (32) along the front edge of the rear body then ITEM TORQUE SPECIFICATION remove both hinge plates.

  • Page 37: Rear Facing Seat & Foot Rest

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Installation is in the reverse order of removal. Replace any worn or damaged hardware with new as ITEM TORQUE SPECIFICATION required.
  • Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 3. Loosen the torx head bolts (23) and nuts (22) (Ref. Fig. 15) that secure the seat back mounting brackets and hip restraint to the seat back support (14).
  • Page 39 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. rear of the vehicle completely. Once the bolts are removed the foot rest assembly (29) may be removed ITEM TORQUE SPECIFICATION from the vehicle by sliding it backwards and off of the...

  • Page 40: Floorboard

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Floorboard Front Seat Support and Floorboard ITEM TORQUE SPECIFICATION Tool LIst Qty. 44, 46 13 - 16 ft. lbs. (18 - 22 Nm) Torx Bit, T-50 ...............

  • Page 41: Cleaning

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. BODY CARE MAINTENANCE 3-M 39009 Polishing Pad Glaze (for dark colors) ...1 qt. 3-M 05995 Polishing Pad Glaze (for light colors) ...1 qt. Coarse Cut Foam Compound Pad for Buffer....1 Cleaning Fine Cut Polish Pad for Buffer ........1...

  • Page 42: Larger Scratches

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Sandpaper, 1500 Grit wet or dry........1 the can for a minimum of one minute to mix the paint and achieve the best color match.
  • Page 43 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Repair and Service Manual Page C-13...
  • Page 44 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page C-14 Repair and Service Manual...

  • Page 45: Wheels And Tires

    WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ................... D - 1 Tire Repair ....................... D - 1 Wheel Installation..................... D - 2 LIST OF ILLUSTRATIONS Fig. 1 Tire Mounting & Cross Sequence for Tightening ......... D - 2 Repair and Service Manual Page D-i...
  • Page 46 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page D-ii Repair and Service Manual...
  • Page 47 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. WHEEL AND TIRE SERVICE tire inflation pressure should be in the higher allowable range, but under no condition should inflation pressure Tools List Qty.

  • Page 48: Wheel Installation

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Wheel Installation the tapered end is against the wheel rim; and tighten in a ‘cross sequence’ pattern; then, tighten lug nuts to specified torque in 20 ft.
  • Page 49 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Repair and Service Manual Page D-3...
  • Page 50 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page D-4 Repair and Service Manual...
  • Page 51 ELECTRONIC SPEED CONTORL (AC MOTOR) TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL......................... E - 1 Accelerator Pedal Assembly ................E - 2 Solenoid Replacement ..................E - 3 Controller ......................E - 4 LIST OF ILLUSTRATIONS Fig.

  • Page 52: Electronic Speed Control (Ac Motor)

    ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page E-ii Repair and Service Manual...
  • Page 53 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Controller Reverse Warning Indicator Run/Tow Switch Accelerator Pedal Pedal Cover Fig. 1 Electronic Speed Control GENERAL The recommended method for Christmas Tree...
  • Page 54 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Pedal Cover Christmas Tree Rivet Fig. 3 Pedal Cover Accelerator Pedal Assembly 2. Remove pedal cover. Tool List Qty.
  • Page 55 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Solenoid Replacement (Ref Fig. 5) Notched Pry Bar ............1 Ratchet ................1 Torque Wrench, in. lbs..........1 Torx Bit, T-27 IP ............1 Wire Cutters..............1 Wire Stripper ..............1...
  • Page 56 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ness to the upper terminal of the solenoid, secure in place with a hex nut (6). ITEM TORQUE SPECIFICATION 10.
  • Page 57 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Drain the stored energy from the controller. controller feet; and slide it to the back aligning the slot Make sure that the Run/Tow switch is in the under the head of the hex head bolt (10).
  • Page 58 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page E-6 Repair and Service Manual...

  • Page 59: Front Suspension

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. MAINTENANCE ......................F - 1 Tire Wear Diagnosis..................F - 2 Wheel Alignment ....................F - 2 Hub Assembly ....................F - 3 Spindle Assembly..................... F - 3 Struts .......................
  • Page 60 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page F-ii Repair and Service Manual...

  • Page 61: Maintenance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. STEERING WHEEL STEERING COLUMN ASSEMBLY HUB ASSEMBLY INTERMEDIATE SHAFT PASSENGER SIDE SPINDLE ASSEMBLY TIE ROD END STRUT ASSEMBLY DRIVER’S SIDE SPINDLE ASSEMBLY A-ARM ASSEMBLY...

  • Page 62: Wheel Alignment

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. of the tread. Wear on either side of a correctly inflated the wheels in line with the body of the vehicle it will tire indicates a tire that is out of alignment.

  • Page 63: Hub Assembly

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 6. To adjust the wheel alignment, loosen the tie rod jam mended that locking nuts be replaced after a maxi- nut (1) and turn the tie rods and equal number of turns mum of 5 removals until the correct alignment is achieved.

  • Page 64: Struts

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Struts (Ref Fig. 5) Tool List Qty. Wrench, 15mm ............1 Socket, 15mm Deep-well..........1 Ratchet ................

  • Page 65: A-Arm Assembly

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Tie Rod End Tie Rod End Nut Fig. 5 Hub, Spindle, Strut and A-Arm Assemblies A-Arm Assembly 2.

  • Page 66: Clipboard And Steering Wheel

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ing a plastic faced hammer against the steering wheel retaining nut. Strike the plastic faced hammer sharply ITEM TORQUE SPECIFICATION with a ball peen hammer.
  • Page 67 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. clipboard with a new one. 11. Carefully press the top two tabs into the matching Steering Column slots in the steering wheel, then press the bottom two Assembly...

  • Page 68: Rod End / Ball Joint

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. yoke onto the shaft. Do not tighten the upper cross Inspect rod end or ball joint by grasping the end and bolt and nut.
  • Page 69 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 4. Repeat steps 3 through 5 for the remaining tie rod 9. Remove steering box from the driver’s side of the end.
  • Page 70 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page F-10 Repair and Service Manual...

  • Page 71: Motor & Motor Brake

    MOTOR & MOTOR BRAKE TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. GENERAL .........................G - 1 Motor........................ G - 1 Motor Brake ..................... G - 3 LIST OF ILLUSTRATIONS Fig. 1 Motor ......................G - 1 Fig. 2 Motor Connections ..................G - 2 Fig.
  • Page 72 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page G-ii Repair and Service Manual...
  • Page 73 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Wires to Controller Wires to Motor Motor Brake Harness Fig. 1 Motor GENERAL 4. Drain the stored energy from the controller. Place the Run/Tow switch in the Run position, turn the key The only serviceable items for the electric motor are the switch to reverse, wait for the reverse warning indica-...
  • Page 74 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. MOTOR Fig. 4 Motor Bolt Tightening Sequence Fig. 2 Motor Connections 14. Connect the wires from the main harness to the motor 10.
  • Page 75 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Motor Brake The motor brake may be removed with the motor still in the vehicle or the motor and motor brake can be removed from the vehicle as a unit.
  • Page 76 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page G-4 Repair and Service Manual...

  • Page 77: Batteries & Charging

    BATTERIES & CHARGING TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. SAFETY ........................H - 1 BATTERY........................H - 2 BATTERY MAINTENANCE ..................H - 2 At Each Charging Cycle ................... H - 2 Monthly ......................H - 2 Electrolyte Level and Water ................
  • Page 78 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page H-ii Repair and Service Manual...

  • Page 79: Safety

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. RESISTOR CONTROLLER CHARGER RECEPTACLE BATTERY STRAP BATTERY HOLD DOWN ACCESSORY HARNESS BATTERY TRAY Fig. 1 Batteries and Charging Receptacle SAFETY Never disconnect a circuit under load at a battery terminal.

  • Page 80: Battery

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. BATTERY MAINTENANCE Always wear a safety shield or approved Tool List Qty. safety goggles when adding water or Insulated Wrench, 9/16"..........1 charging batteries.

  • Page 81: Cleaning Batteries

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. The electrolyte level is important since any portion of the used with an approved water source. These watering plates exposed to air will be ruined beyond repair.
  • Page 82 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. metallic components adjacent to the batteries which lugs provided. Do not attempt to lift a battery with only one strap, this may break lifting lugs should also be sprayed with the baking soda solution.
  • Page 83 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 8. Check the area surrounding the battery tray for corro- Hex Nut sion. If any corrosion is found, it should be immedi- Washer ately removed with a putty knife and a wire brush (for metal surfaces) or a plastic bristle brush (for plastic...

  • Page 84: Prolonged Storage

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. BL+ Red Wire Black Wire from from Solenoid Charger Receptacle BL- Black Wire from Controller Black Wire from Harness Red and Grey Wires from Charger Receptacle...

  • Page 85: Battery Charging

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. injury that may result from personnel running over or tripping over the cord set. • The charger is automatically turned off during the connect/disconnect cycle and therefore no elec- trical arc is generated at the DC plug/receptacle contacts.

  • Page 86: Using A Hydrometer

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. lyte becomes. The higher the density, the higher the nal thermometer that will measure the temperature of the state of charge.
  • Page 87 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 12 Hydrometer Temperature Correction Repair and Service Manual Page H-9...
  • Page 88 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page H-10 Repair and Service Manual...

  • Page 89: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘I’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................I - 1 PORTABLE CHARGER INSTALLATION ..............I - 1 UNDERSTANDING THE CHARGER................I - 2 LED DISPLAY INFORMATION..................I - 2 LED Operation Codes ..................I - 2 LED Fault Codes....................I - 2 MAINTENANCE INSTRUCTIONS ................I - 2 LIST OF ILLUSTRATIONS Fig.
  • Page 90 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page I-ii Repair and Service Manual...

  • Page 91: Portable Charger Installation

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. CHARGER DESCRIPTION removed and mounted on a platform or wall above the ground to permit maximum air flow around and under- The Powerwise QE 48V charger is automatic and is neath the charger.

  • Page 92: Understanding The Charger

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. LED Fault Code: Looping the DC cord through the steering wheel when charg- ing serves as a good reminder to store the cord out of the way RED FLASH: Light turns on briefly, but does not flash after that - check for valid AC voltage.
  • Page 93 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Repair and Service Manual Page I-3...
  • Page 94 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page I-4 Repair and Service Manual...

  • Page 95: Brakes

    BRAKES TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL ........................J - 1 Brake Pedal Assembly ..................J - 1 LIST OF ILLUSTRATIONS Fig. 1 Brake Pedal....................J - 1 Fig. 2 Christmas Tree Rivet Removal ..............J - 1 Fig. 3 Pedal Cover....................J - 2 Fig.
  • Page 96 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page J-ii Repair and Service Manual...
  • Page 97 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Accelerator Pedal Brake Pedal Pedal Cover Fig. 1 Brake Pedal GENERAL The recommended method for Christmas Tree removing christmas tree rivets is Fastener For information on the Motor Brake see the Motor sec- to slide a notched pry bar under...
  • Page 98 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 6. Remove four socket head hex screws (6) securing the brake pedal assembly to the floorboard. (Ref Fig. 5) 7.
  • Page 99 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. (8) and to the brake switch (10). 13. Place pedal assembly (5) in position on the floorboard and secure with four socket head hex screws (6). 14.
  • Page 100 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page J-4 Repair and Service Manual...

  • Page 101: Electrical Components & Wiring

    ELECTRICAL COMPONENTS & WIRING TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. MAIN WIRING HARNESS ..................K - 1 Replacing the Main Wiring Harness ..............K - 1 REPLACING ELECTRICAL COMPONENTS............. K - 6 Run/Tow Switch ....................K - 6 Reverse Warning Indicator................

  • Page 102: Section Title

    ELECTRICAL COMPONENTS & WIRING TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO. Fig. 28 Trim Panel Hardware ................K - 15 Fig. 29 Fuel Gauge/State of Charge Meter............K - 15 Repair and Service Manual Page K-ii...

  • Page 103: Main Wiring Harness

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. DIAGNOSTIC PLUG WIRING HARNESS MOTOR CHARGER RECEPTACLE BATTERY BANK Fig. 1 Main Electrical Harness MAIN WIRING HARNESS The Main Electrical Harness for the vehicle is routed Using an insulated wrench, disconnect the bat- under the floormat, recessed into the floorboard, the for-...
  • Page 104 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. instrument panel through a slot in the cowl, squeeze that secure the lower edge of the rear body to the the legs of the tab together and push to the back of the floorboard.
  • Page 105 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 22. Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield. Splash Shield MOTOR Fig.
  • Page 106 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. e) Connect the wires to the brake pedal rotary posi- j) Connect the wire harness to the key switch. tion sensor (8) and the brake enable switch con- k) Route the two rear sections of the harness nector (9).
  • Page 107 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Resistor Heatsink MOTOR Controller Fig. 14 Motor Connections 18. Install the reverse warning indicator (11) onto the con- troller splash shield using two Torx head screws (10) Fig.

  • Page 108: Replacing Electrical Components

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 21. Replace the controller splash shield and secure it to switch (8). the body with two Torx head screws. 7.
  • Page 109 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 1. Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench. 2.

  • Page 110: Wiring Diagram

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 19 Main Wiring Harness Repair and Service Manual Page K-8...
  • Page 111 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 20 Accessory Wiring Harness Repair and Service Manual Page K-9...

  • Page 112: Accessory Wiring

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Headlight/Turnsignal Relay Fuse Holders Accessory Harness Horn Front Splash Shield Horn Button Brake Light/Turnsignal Rear Splash Shield Fig.
  • Page 113 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 4. Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder.

  • Page 114: Replacing Electrical Accessories

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REPLACING ELECTRICAL ACCESSO- remove. RIES 2. Disconnect the accessory harness from the light bulb. 3. Connect the accessory harness to the light bulb. 4.

  • Page 115: Turn Signal Switch Replacment

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ITEM TORQUE SPECIFICATION 6- 9 ft. lbs (8 - 127 Nm) Turn Signal Switch Replacement Make sure that the vehicle key switch is in the ’OFF’...

  • Page 116: Tail Light Assembly Replacement

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 2. Unplug the flasher unit from the turn signal wire har- lens to the tail light assembly. ness.
  • Page 117 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. the vehicle and secure in place with the hex head bolt. meter (20) and push the unit out of the trim panel (11). 4.
  • Page 118 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page K-16 Repair and Service Manual...

  • Page 119: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. GENERAL ........................L - 1 SHOCK ABSORBER ....................L - 1 REAR LEAF SPRING ....................L - 2 LIST OF ILLUSTRATIONS Fig. 1 Rear Suspension ..................L - 1 Fig. 2 Shock Absorber ..................L - 2 Fig.
  • Page 120 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page L-ii Repair and Service Manual...
  • Page 121 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Frame Shock Absorber Shackle Leaf Spring Leaf Spring bracket Rear Axle Fig. 1 Rear Suspension GENERAL SHOCK ABSORBER (Ref Fig.
  • Page 122 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. manual. Place wheel chocks in front and 6. Install the hex head bolt (1) and washer (2) for the behind the front wheels and check the stability upper shock mount, make sure that the shock (3) is of the vehicle on the jack stands before starting...
  • Page 123 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 5. Remove the hex head bolt (7) and nut (4) from the for- install the hex head bolt (15) and nut (11). ward leaf spring mounting bracket.
  • Page 124 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page L-4 Repair and Service Manual...

  • Page 125: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE..................M - 1 Checking Torque to Rotate ................M - 1 Replacing the Lubricant ...................M - 1 Fill Procedure For Axles Fitted With Fill Plugs ..........M - 2 REAR AXLE DISASSEMBLY ..................M - 2 Rear Hub......................M - 2 Axle Shaft, Bearing and Seal Removal and Disassembly ........M - 3...
  • Page 126 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page M-ii Repair and Service Manual...
  • Page 127 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Motor Motor Brake Axle Fig. 1 Rear Axle REAR AXLE MAINTENANCE clockwise motion. If the axle hub moves at 60 ft. lbs or less replace the differential.

  • Page 128: Rear Axle

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. pump. Fill with 25 oz. of Mobile 424 lubricant slowly and replace the fill plug. To reduce the possibility of personal injury, fol- low the lifting procedure in Section B of this manual.

  • Page 129: Rear Hub

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. any repair procedure. Never work on a vehicle that is supported by a jack alone. ITEM TORQUE SPECIFICATION Rear Hub 70 ft.
  • Page 130 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 7. Install the inner snap ring. Bearing To prevent damage to the oil seal, lightly coat the axle Separator shaft with bearing grease and support the shaft during installation.
  • Page 131 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Repair and Service Manual Page M-5...
  • Page 132 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Repair and Service Manual Page M-6...

  • Page 133: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD ................... N - 1 WINDSHIELD ......................N - 2 GOLF CAR TOP......................N - 2 2 + 2 TOP........................N - 4 LIST OF ILLUSTRATIONS Fig.
  • Page 134 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page N-ii Repair and Service Manual...
  • Page 135 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Sun top Windshield Fig. 1 Top and Windshield TOP AND WINDSHIELD Trailering Personal injury to occupants of other highway vehicles may occur if vehicle and contents are The top does not provide protection from roll not adequately secured to the trailer.
  • Page 136 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. WINDSHIELD ITEM TORQUE SPECIFICATION Tool List Qty. Torx Bit, 50 IP .............. 1 124 - 142 in. lbs (14 - 16 Nm) Ratchet ................
  • Page 137 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. the matching holes in the sweater basket and seat back support, install the hex head bolts (5) and nuts (4) finger tight only.
  • Page 138 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 2 + 2 TOP If vehicle is equipped with a windshield remove it before working with the top. Tool List Qty.
  • Page 139 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 3. Lift the top (3) off of the struts and set it aside. 4. Remove the access cover (1) by sliding a flat screw- ITEM TORQUE SPECIFICATION driver under the edge of it and prying it away from the...
  • Page 140 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page N-6 Repair and Service Manual...
  • Page 141 TROUBLESHOOTING AND DIAGNOSTICS TABLE OF CONTENTS FOR SECTION ‘O’ SECTION TITLE PAGE NO. HOW TO USE THE HAND HELD DIAGNOSTIC UNIT..........O - 1 MENUS ........................O - 1 Diagnostics Report................... O - 1 Battery and Warranty ..................O - 3 Error Messages....................
  • Page 142 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page O-ii Repair and Service Manual...

  • Page 143: How To Use The Hand Held Diagnostic Unit

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. HOW TO USE THE HAND HELD DIAG- HIGHLIGHTED MENU ITEM MENU TITLE NOSTIC UNIT SERVICE MENU The E-Z-GO Hand Held Diagnostic Unit, P/N 606215 is DIAG REPORT used for troubleshooting, tuning, programming and the...
  • Page 144 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. motor by the pedal position. DIAG REPORT 9. MOTOR ACTUAL SPEED: displayed as VOLTAGE ’ACTSPEED’, the next line displays the actual motor 49.28 V speed in RPMs.

  • Page 145: Battery And Warranty

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 16. SOLENOID: displayed as ’SOLENOID’, the next line displays the solenoid state as ’ON’ or ’OFF STATUS SOC BATT ’...

  • Page 146: Error Messages

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ERROR MESSAGES SETTING TOP SPEED AND PERFORMANCE PROFILES (read and write) To change the speed, scroll down the list and highlight SERVICE MENU one of the vehicles;...

  • Page 147: Fault Codes

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Turn key to ’OFF’ and then back ’ON’. If car does not run proceed to step 2.
  • Page 148 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that all battery wires are securely fastened and have less than 0.1 ohms resis- tance between wire terminal and battery post.
  • Page 149 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Check both +5V and 5V GND to chassis, 1.
  • Page 150 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Turn key switch to ’OFF’ and unplug 23 pin connector from controller.
  • Page 151 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that all battery wires are securely fastened and have less than 0.1 ohms resis- tance between wire terminal and battery post.
  • Page 152 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Measured heat sink temper- 1. Allow time to cool. ature is greater than 85°C Heat Sink Temp (185°F) but less than 115°C...
  • Page 153 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. If this occurs with the key switch turned on: Throttle switch is closed at key start, the throttle switch must be...

  • Page 154: Troubleshooting

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. DIGITAL VOLT OHM METER that is not functioning. if power is present at the connec- tor and the ground wiring is satisfactory, the only possi- A typical DVOM (digital volt ohm meter) is shown.

  • Page 155: Power Supply

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. POWER SUPPLY Tool List Qty. DVOM................1 Check For Loose or Bare Wires Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame.
  • Page 156 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page O-14 Repair and Service Manual...
  • Page 157 LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. GROUNDING REQUIREMENTS................P - 1 GROUND SYSTEMS ....................P - 1 LIGHTINIG PROTECTION REQUIREMENTS ............P - 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM ........P - 1 GROUND NETWORK REQUIREMENTS ..............
  • Page 158 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page P-ii Repair and Service Manual...

  • Page 159: Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 1.

  • Page 160: External Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REVISION: GS-726-006 TITLE: EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 6.

  • Page 161: 10. Equipment Fault And Personal Safety System

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 trating or structurally damaging the building.
  • Page 162 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page P-4 Repair and Service Manual...

  • Page 163: Specifications

    RXV ELECTRIC FLEET VEHICLE SPECIFICATIONS ..........Q - 1 RXV ELECTRIC FREEDOM VEHICLE SPECIFICATIONS ........Q - 2 RXV ELECTRIC SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS........ Q - 3 LIST OF ILLUSTRATIONS Fig. 1 Fleet & Freedom Vehicle Dimensions ............Q - 4 Fig.
  • Page 164 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page Q-ii Repair and Service Manual...
  • Page 165 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. RXV ELECTRIC - FLEET VEHICLE SPECIFICATIONS Four 12 Volt deep cycle (70 minute minimum, 140 Amp-Hour discharge rate)
  • Page 166 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. RXV ELECTRIC - FREEDOM VEHICLE SPECIFICATIONS Four 12 Volt deep cycle (70 minute minimum, 140 Amp-Hour discharge rate)
  • Page 167 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. RXV ELECTRIC - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS Four 12 Volt deep cycle (70 minute minimum, 140 Amp-Hour discharge rate)
  • Page 168 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 68.50” (174 cm) 68.50” (174 cm) 45.7” (116 cm) 45.7” (116 cm) 65.7” (167 cm) 65.7” 35.5” (90 cm) (167 cm) 94.5”...
  • Page 169 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 74” (188 cm) 45.7” (116 cm) 65.7” (167 cm) 35.5” (90 cm) 105.5” (268 cm) 38” (97 cm) 47”...
  • Page 170 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. RECOMMENDED MAX RAMP 25% GRADE OR 14° MAX RECOMMENDED MAX SIDE TILT 25% GRADE OR 14° MAX Fig. 3 Vehicle Incline Specifications and Turning Diameter Page Q-6...
  • Page 171 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. .5" 6.0" Ø .50" (1.27cm) (15.4cm) (1.27cm) 4.0" (10.15cm) 1.5" (3.9cm) Ø .24" (.61cm) 5.0" (12.7cm) 1.378" 7.75" (19.7cm) (3.5cm) 10.5"...
  • Page 172 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page Q-8...
  • Page 173 Read and understand the following warnings before attempt- Read and understand the following text and warnings before ing to operate the vehicle attempting to service vehicle: In any product, components will eventually fail to perform properly 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 To prevent personal injury or death, ob-...
  • Page 174 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA 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. Technical Communications Department...

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