- DL manuals
- Ezgo
- Utility Vehicle
- RXV ELECTRIC
- Service & Repair Manual
Ezgo RXV ELECTRIC Service & Repair Manual
Summary of RXV ELECTRIC
Page 1
Rxv electric service & repair issued january 2008 revised april 2009 605975.
Page 2: S A F E Ty
(notes, cautions and warnings continued on inside of back cover) 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 p...
Page 3: Service and Repair Manual
Page i repair and service manual service and repair manual electric powered golf cars & personal vehicles rxv fleet golf car rxv freedom golf car rxv shuttle 2+2 starting model year 2008 e-z-go division of textron, inc. Reserves the right to make design changes without obligation to make these chang...
Page 4: General Information
Page ii repair and service manual 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 ...
Page 5: Table of Contents
Page iii repair and service manual table of contents title page safety ....................................................................................................................... Inside covers models ...........................................................................................
Page 6: Table Of Contents
Page iv repair and service manual table of contents notes:.
Page 7: Safety Information
Safety information page v repair and service manual 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 d...
Page 8: Safety Information
Page vi safety information repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed o...
Page 9: Safety Information
Safety information page vii repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b ventilation hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations ...
Page 10: Safety Information
Page viii repair and service manual notes: safety information read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 11
Table of contents for section ‘a’ section title page no. General information & routine maintenance page a-i repair and service manual serial number location .................................................................................. A - 1 towing ..................................................
Page 12
Page a-ii repair and service manual notes: 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..
Page 13: Serial Number Location
General information & routine maintenance page a-1 repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings. B b thank you for purchasing this vehicle. This repair manu- al contains information tha...
Page 14: Towing
Page a-2 general information & routine maintenance repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings. B towing to reduce the possibility of severe injury or death: use extra caution when tow...
Page 15: Routine Maintenance
General information & routine maintenance page a-3 repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings. B b routine maintenance this vehicle will give years of satisfactory service pro- viding...
Page 16: Hardware
Page a-4 general information & routine maintenance repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings. B porting. Maximum speed with sun top installed is 50 mph (80 kph). If the vehicle is to...
Page 17
General information & routine maintenance page a-5 repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings. B b periodic service schedule ✓ - check c&a - check & adjust cl - clean r - replace *use...
Page 18
Page a-6 repair and service manual notes: 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..
Page 19: Safety
Table of contents for section ‘b’ section title page no. Safety page b-i repair and service manual notes, cautions and warnings ..................................................................... B - 1 important safety warning ..........................................................................
Page 20: Safety
Page b-ii repair and service manual notes: safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 21: Safety
Safety page b-1 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b notes, cautions and warnings throughout this manual, the following notes, cau- tions and warnings are used. For the prot...
Page 22: Safety
Page b-2 safety repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B if repairs are to be made that will require welding or cutting, the batteries must be removed. Additional warnings before ...
Page 23: Safety
Safety page b-3 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b accessories connected to this vehicle that do not use the accessory harness must be connected across the entire 48 volt ...
Page 24: Safety
Page b-4 safety repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that...
Page 25: Safety
Safety page b-5 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 5 battery hold down fig. 6 battery connections 14. Tighten all battery terminal hardware to 95 - 105 in. Lbs. (11 -...
Page 26: Safety
Page b-6 safety repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B to raise only the front or rear of the vehicle, place the wheel chocks in front and behind the rear wheels. The jack may b...
Page 27: Safety
Page b-7 repair and service manual notes: read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Safety.
Page 28: Safety
Page b-8 repair and service manual notes: safety read all of section a and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 29: Body
Table of contents for section ‘c’ section title page no. Body page c-i repair and service manual body ........................................................................................................................ C - 1 general ..................................................................
Page 30: Body
Page c-ii repair and service manual notes: body read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 31: Body
Body page c-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 body general vehicle accessories, such as the sun top and windshield, need to be removed before removing many body ...
Page 32: Body
Page c-2 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B body component replace- ment the body components can be replaced by removing the securing hardware, replacing the component ...
Page 33: Body
Body page c-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b i fig. 5 floor mat fastener removal installation of the floor mat will require new christmas tree rivets — install the sho...
Page 34: Body
Page c-4 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 5. Remove three self threading nuts (20) securing the cup holder assembly (15) to the instrument panel. Remove the cup holde...
Page 35: Body
Body page c-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 10 golf car rear body, sweater basket, rear bumper & fender liner sweater basket (ref. Fig. 10) tool list qty. Torx b...
Page 36: Body
Page c-6 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fender liner (ref. Fig. 2)(ref. Fig. 10) tool list qty. Notched pry bar .......................................................
Page 37: Body
Body page c-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b installation is in the reverse order of removal. Replace any worn or damaged hardware with new as required. Fig. 11 2 + 2 ...
Page 38: Body
Page c-8 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 3. Loosen the torx head bolts (23) and nuts (22) (ref. Fig. 15) that secure the seat back mounting brackets and hip restrain...
Page 39: Body
Body page c-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b rear of the vehicle completely. Once the bolts are removed the foot rest assembly (29) may be removed from the vehicle by ...
Page 40: Body
Page c-10 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B floorboard tool list qty. Torx bit, t-50 ............................................................... 1 ratchet ...........
Page 41: Body
Body page c-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b body care maintenance cleaning tools & supplies list soft clean cotton cloth mild soap the body panels are painted and ha...
Page 42: Body
Page c-12 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B sandpaper, 1500 grit wet or dry.................................. 1 wet sanding block ........................................
Page 43: Body
Page c-13 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Body.
Page 44: Body
Page c-14 repair and service manual notes: body read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 45: Wheels And Tires
Table of contents for section ‘d’ section title page no. Wheels and tires page d-i repair and service manual wheel and tire service ................................................................................... D - 1 tire repair .....................................................................
Page 46: Wheels And Tires
Page d-ii repair and service manual notes: wheels and tires read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 47: Wheels And Tires
Wheels and tires page d-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b wheel and tire service tools list qty. Required lug wrench, 3/4" ................................................
Page 48: Wheels And Tires
Page d-2 wheels and tires repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B wheel installation do not tighten lug nuts to more than 85 ft. Lbs. (115 nm) torque. It is important to follow t...
Page 49: Wheels And Tires
Page d-3 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Wheels and tires.
Page 50: Wheels And Tires
Page d-4 repair and service manual notes: wheels and tires read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 51
Table of contents for section ‘e’ section title page no. Electronic speed contorl (ac motor) page e-i repair and service manual general................................................................................................................. E - 1 accelerator pedal assembly .....................
Page 52
Page e-ii repair and service manual notes: 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..
Page 53
Electronic speed control (ac motor) page e-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 electronic speed control general in the following text, there are references to remo...
Page 54
Page e-2 electronic speed control (ac motor) repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 3 pedal cover accelerator pedal assembly tool list qty. Ratchet ...........................
Page 55
Electronic speed control (ac motor) page e-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 4 accelerator pedal 9. Reconnect electrical harness to rotary position sensor (5) and ...
Page 56
Page e-4 electronic speed control (ac motor) repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B ness to the upper terminal of the solenoid, secure in place with a hex nut (6). 10. Reinstall...
Page 57
Electronic speed control (ac motor) page e-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b drain the stored energy from the controller. Make sure that the run/tow switch is in the ru...
Page 58
Page e-6 repair and service manual notes: 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..
Page 59
Table of contents for section ‘f’ section title page no. Front suspension and steering page f-i repair and service manual maintenance ........................................................................................................ F - 1 tire wear diagnosis.......................................
Page 60
Page f-ii repair and service manual notes: 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..
Page 61
Front suspension and steering page f-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 front suspension and steering in the following text, there are references to removing and ...
Page 62
Page f-2 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B of the tread. Wear on either side of a correctly inflated tire indicates a tire that is out of alig...
Page 63
Front suspension and steering page f-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 6. To adjust the wheel alignment, loosen the tie rod jam nut (1) and turn the tie rods and equal ...
Page 64
Page f-4 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B struts (ref fig. 5) tool list qty. Wrench, 15mm ......................................................
Page 65
Front suspension and steering page f-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 5 hub, spindle, strut and a-arm assemblies a-arm assembly (ref fig. 5) tool list qty. Wrench...
Page 66
Page f-6 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B clipboard and steering wheel (ref fig. 6) (ref fig. 7) (ref fig. 8) tool list qty. Socket, 24 mm......
Page 67
Front suspension and steering page f-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b clipboard with a new one. 11. Carefully press the top two tabs into the matching slots in the ste...
Page 68
Page f-8 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B yoke onto the shaft. Do not tighten the upper cross bolt and nut. 8. To install the steering column...
Page 69
Front suspension and steering page f-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 4. Repeat steps 3 through 5 for the remaining tie rod end. 5. Remove the lower cross bolt securin...
Page 70
Page f-10 repair and service manual notes: 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..
Page 71: Motor & Motor Brake
Table of contents for section ‘g’ section title page no. Motor & motor brake page g-i repair and service manual general .................................................................................................................G - 1 motor...........................................................
Page 72: Motor & Motor Brake
Page g-ii repair and service manual notes: motor & motor brake read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 73: Motor & Motor Brake
Motor & motor brake page g-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 motor general the only serviceable items for the electric motor are the motor brake handle and the e...
Page 74: Motor & Motor Brake
Page g-2 motor & motor brake repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B . Fig. 2 motor connections 10. Pull the motor wires out through the bagwell. 11. Remove the six hex head bolt...
Page 75: Motor & Motor Brake
Motor & motor brake page g-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b motor brake the motor brake may be removed with the motor still in the vehicle or the motor and motor brake...
Page 76: Motor & Motor Brake
Page g-4 repair and service manual notes: motor & motor brake read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 77: Batteries & Charging
Table of contents for section ‘h’ section title page no. Batteries & charging page h-i repair and service manual safety .................................................................................................................... H - 1 battery.....................................................
Page 78: Notes:
Page h-ii repair and service manual notes: batteries & charging read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 79: Batteries & Charging
Batteries & charging page h-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 batteries and charging receptacle safety always observe the following warnings when working on or n...
Page 80: Batteries & Charging
Page h-2 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B always wear a safety shield or approved safety goggles when adding water or charging batteries. Any electrol...
Page 81: Batteries & Charging
Batteries & charging page h-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b the electrolyte level is important since any portion of the plates exposed to air will be ruined beyond re...
Page 82: Batteries & Charging
Page h-4 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B metallic components adjacent to the batteries which should also be sprayed with the baking soda solution. Fi...
Page 83: Batteries & Charging
Batteries & charging page h-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 8. Check the area surrounding the battery tray for corro- sion. If any corrosion is found, it should be im...
Page 84: Batteries & Charging
Page h-6 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B . Fig. 9 battery connections to prevent battery explosion that could result in severe personal injury or dea...
Page 85: Batteries & Charging
Batteries & charging page h-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 10 freezing point of electrolyte battery charging the battery charger is designed to fully charge the...
Page 86: Batteries & Charging
Page h-8 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B lyte becomes. The higher the density, the higher the state of charge. Fig. 11 hydrometer to prevent battery ...
Page 87: Batteries & Charging
Batteries & charging page h-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 12 hydrometer temperature correction.
Page 88: Batteries & Charging
Page h-10 repair and service manual notes: batteries & charging read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 89: Battery Charger
Table of contents for section ‘i’ section title page no. Battery charger page i-i repair and service manual charger description .........................................................................................I - 1 portable charger installation ..................................................
Page 90: Battery Charger
Page i-ii repair and service manual notes: battery charger read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 91: Battery Charger
Battery charger page i-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b charger description the powerwise qe 48v charger is automatic and is designed specifically for charging electri...
Page 92: Battery Charger
Page i-2 battery charger repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B looping the dc cord through the steering wheel when charg- ing serves as a good reminder to store the cord out of...
Page 93: Battery Charger
Page i-3 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Battery charger.
Page 94: Battery Charger
Page i-4 repair and service manual notes: battery charger read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 95: Brakes
Table of contents for section ‘j’ section title page no. Brakes page j-i repair and service manual general ..................................................................................................................J - 1 brake pedal assembly .......................................................
Page 96: Brakes
Page j-ii repair and service manual notes: brakes read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 97: Brakes
Brakes page j-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 brake pedal general for information on the motor brake see the motor sec- tion of this manual, section g. In the ...
Page 98: Brakes
Page j-2 brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B using an insulated wrench, disconnect the bat- tery cable at the negative (-), bl-, battery ter- minal. To access the peda...
Page 99: Brakes
Brakes page j-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b (8) and to the brake switch (10). 13. Place pedal assembly (5) in position on the floorboard and secure with four socket...
Page 100: Brakes
Page j-4 repair and service manual notes: brakes read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 101
Table of contents for section ‘k’ section title page no. Electrical components & wiring page k-i repair and service manual main wiring harness ......................................................................................... K - 1 replacing the main wiring harness ..............................
Page 102
Table of contents for section ‘k’ (cont.) section title page no. Electrical components & wiring page k-ii repair and service manual fig. 28 trim panel hardware ...............................................................................K - 15 fig. 29 fuel gauge/state of charge meter.................
Page 103
Electrical components & wiring page k-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 main electrical harness main wiring harness the main electrical harness for the vehicle i...
Page 104
Page k-2 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B instrument panel through a slot in the cowl, squeeze the legs of the tab together and push to the ...
Page 105
Electrical components & wiring page k-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 22. Remove the two torx head screws (10) securing the reverse warning indicator (11) to the spla...
Page 106
Page k-4 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B e) connect the wires to the brake pedal rotary posi- tion sensor (8) and the brake enable switch c...
Page 107
Electrical components & wiring page k-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b . Fig. 12 controller connections p) plug the 23 pin connector (3) from the wire har- ness into t...
Page 108
Page k-6 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 21. Replace the controller splash shield and secure it to the body with two torx head screws. 22. ...
Page 109
Electrical components & wiring page k-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 1. Disconnect the battery cable at the negative (-), bl-, battery terminal using an insulated wr...
Page 110
Page k-8 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 19 main wiring harness s1 12 3 4 5 6 7 8 16 17 18 19 20 21 22 23 91 0 1 1 12 13 14 15 b a 1 2...
Page 111
Electrical components & wiring page k-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 20 accessory wiring harness turn signal ps turn l t. Black ba ds turn l t. Ps headlight ds ...
Page 112
Page k-10 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 21 accessory wiring harness and accessories accessory wiring harness the accessory wiring ha...
Page 113
Electrical components & wiring page k-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 4. Remove the christmas tree rivet holding the brake switch relay in place on the front splash ...
Page 114
Page k-12 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B replacing electrical accesso- ries using an insulated wrench, disconnect the bat- tery cable at t...
Page 115
Electrical components & wiring page k-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 25 trim panel hardware 2. Pull the top of the trim panel (11) away from the instru- ment p...
Page 116
Page k-14 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 2. Unplug the flasher unit from the turn signal wire har- ness. 3. Install the new flasher unit i...
Page 117
Electrical components & wiring page k-15 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b the vehicle and secure in place with the hex head bolt. 4. Connect the accessory wire harness t...
Page 118
Page k-16 repair and service manual notes: electrical components & wiring read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 119: Rear Suspension
Table of contents for section ‘l’ section title page no. Rear suspension page l-i repair and service manual general ..................................................................................................................L - 1 shock absorber ....................................................
Page 120: Rear Suspension
Page l-ii repair and service manual notes: rear suspension read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 121: Rear Suspension
Rear suspension page l-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 rear suspension general in the following text, there are references to removing/installing hardware (nut...
Page 122: Rear Suspension
Page l-2 rear suspension repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B manual. Place wheel chocks in front and behind the front wheels and check the stability of the vehicle on the jac...
Page 123: Rear Suspension
Rear suspension page l-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 5. Remove the hex head bolt (7) and nut (4) from the for- ward leaf spring mounting bracket. The leaf spring (1...
Page 124: Rear Suspension
Page l-4 repair and service manual notes: rear suspension read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 125: Rear Axle
Table of contents for section ‘m’ section title page no. Rear axle page m-i repair and service manual rear axle maintenance....................................................................................M - 1 checking torque to rotate ................................................................
Page 126: Rear Suspension
Page m-ii repair and service manual notes: rear suspension read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 127: Rear Axle
Rear axle page m-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 rear axle rear axle maintenance the only maintenance required for the first five years or 1000 hours of operat...
Page 128: Rear Axle
Page m-2 rear axle repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B to reduce the possibility of personal injury, fol- low the lifting procedure in section b of this manual. Place wheel c...
Page 129: Rear Axle
Rear axle page m-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b any repair procedure. Never work on a vehicle that is supported by a jack alone. . Rear hub tool list qty. Needle nos...
Page 130: Rear Axle
Page m-4 rear axle repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 6 press bearing from shaft 4. Remove the inner snap ring. Use care to prevent damage to the inner surface of the a...
Page 131: Rear Axle
Page m-5 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Rear axle.
Page 132: Rear Axle
Rear axle page m-6 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b.
Page 133: Weather Protection
Table of contents for section ‘n’ section title page no. Weather protection page n-i repair and service manual top and windshield ........................................................................................... N - 1 windshield.................................................................
Page 134: Weather Protection
Page n-ii repair and service manual notes: weather protection read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 135: Weather Protection
Weather protection page n-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 top and windshield top and windshield the top does not provide protection from roll over or falling o...
Page 136: Weather Protection
Page n-2 weather protection repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B windshield tool list qty. Torx bit, 50 ip .............................................................. 1 rat...
Page 137: Weather Protection
Weather protection page n-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b the matching holes in the sweater basket and seat back support, install the hex head bolts (5) and nuts (4) ...
Page 138: Weather Protection
Page n-4 weather protection repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 2 + 2 top tool list qty. Socket, 15 mm.............................................................1 ratchet ....
Page 139: Weather Protection
Weather protection page n-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 3. Lift the top (3) off of the struts and set it aside. 4. Remove the access cover (1) by sliding a flat scr...
Page 140: Weather Protection
Page n-6 repair and service manual notes: weather protection read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 141
Table of contents for section ‘o’ section title page no. Troubleshooting and diagnostics page o-i repair and service manual how to use the hand held diagnostic unit..............................................O - 1 menus .................................................................................
Page 142
Page o-ii repair and service manual notes: troubleshooting and diagnostics read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 143
Troubleshooting and diagnostics page o-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b how to use the hand held diag- nostic unit the e-z-go hand held diagnostic unit, p/n 606215 is ...
Page 144
Page o-2 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B . 2. Calculated battery current: displayed as ’current’, the next line displays calculated curren...
Page 145
Troubleshooting and diagnostics page o-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 16. Solenoid: displayed as ’solenoid’, the next line displays the solenoid state as ’on’ or ’of...
Page 146
Page o-4 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B error messages 1. Current error message is displayed on the error status screen 2. Past 7 error c...
Page 147
Troubleshooting and diagnostics page o-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b code description possible causes diagnostic step action (post diagnos- tics) 8976 ac over curre...
Page 148
Page o-6 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 12818 dc bus high - hardware detected 1. Battery pack voltage is over 67 volts. Note: it is unlik...
Page 149
Troubleshooting and diagnostics page o-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b 20755 5v supply low or high voltage 1. Typically caused by a short in the 5 volt wire harness. ...
Page 150
Page o-8 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 25106 reverse alarm test failed 1. Reverse warning alarm failed at startup check. The controller ...
Page 151
Troubleshooting and diagnostics page o-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b warning dc bus low dc bus voltage is less than 24 volts. 1. Verify that all battery wires are s...
Page 152
Page o-10 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B warning heat sink temp high 1. Measured heat sink temper- ature is greater than 85°c (185°f) but...
Page 153
Troubleshooting and diagnostics page o-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b warning throttle switch closed (dump cir- cuit monitoring tim- eout) 1. If this occurs with th...
Page 154
Troubleshooting and diagnostics page o-12 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b digital volt ohm meter a typical dvom (digital volt ohm meter) is shown. A rec- ommended model...
Page 155
Page o-13 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B power supply tool list qty. Dvom...................................................................
Page 156
Page o-14 repair and service manual notes: troubleshooting and diagnostics read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 157
Table of contents for section ‘p’ section title page no. Lightning protection and grounding page p-i repair and service manual grounding requirements............................................................................... P - 1 ground systems .....................................................
Page 158: Notes:
Page p-ii repair and service manual notes: 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..
Page 159
A lightning protection and grounding page p-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b gs-726-006 effective: 10/19/92 revision: supercedes: rev -, ecn 027194 title : general spe...
Page 160
Page p-2 lightning protection and grounding repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B gs-726-006 effective: 10/19/92 revision: a supercedes: title: general specification: lightning...
Page 161
A lightning protection and grounding page p-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b gs-726-006 effective: 10/19/92 revision: supercedes: rev -, ecn 027194 title : general spe...
Page 162
Page p-4 repair and service manual notes: 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..
Page 163: Specifications
Table of contents for section ‘q’ section title page no. Specifications page q-i repair and service manual rxv electric fleet vehicle specifications..............................................Q - 1 rxv electric freedom vehicle specifications .......................................Q - 2 rxv electri...
Page 164: Notes:
Page q-ii repair and service manual notes: specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 165: Specifications
Specifications page q-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b rxv electric - fleet vehicle specifications ** do not use low inflation pressure tires on any e-z-go vehicle. Do...
Page 166: Specifications
Page q-2 specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B rxv electric - freedom vehicle specifications ** do not use low inflation pressure tires on any e-z-go vehicle. Do not use any tire which ha...
Page 167: Specifications
Specifications page q-3 read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b rxv electric - shuttle 2 + 2 vehicle specifications ** do not use low inflation pressure tires on any e-z-go vehicle. Do not use any tire ...
Page 168: Specifications
Page q-4 specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 1 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...
Page 169: Specifications
Specifications page q-5 read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 2 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 170: Specifications
Page q-6 specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 3 vehicle incline specifications and turning diameter recommended max ramp 25% grade or 14° max recommended max side tilt 25% grade or ...
Page 171: Specifications
Specifications page q-7 read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 4 powerwise qe 48v charger 3.5" (9cm) 4.5" (11.4cm) 10.5" (26.7cm) 7.25" (18.5cm) Ø .25'' (.65cm) 7.75" (19.7cm) 5.0" (12.7cm) 3.19" ...
Page 172: Specifications
Page q-8 notes: specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 173
Read and understand the following warnings before attempt- ing to operate the vehicle : to prevent personal injury or death, ob- serve the following: when vehicle is to be left unattended, en- gage park brake, move direction selector to neutral, turn key to ‘off’ position and remove key. Drive vehic...
Page 174
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 e-z-go division of textron inc., 1451 marvin griffin road, augusta, georgia 30906 - 3852 usa.