Ezgo SHUTTLE 4 Owner'S Manual And Service Manual Download

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STARTING MODEL YEAR: 2001

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OWNER’S MANUAL

AND SERVICE GUIDE

28642-G01-GB

Summary of Contents for SHUTTLE 4

Page 1: ...STARTING MODEL YEAR 2001 62 1 32 5 3 56211 55 56 1 2 5 OWNER S MANUAL AND SERVICE GUIDE 28642 G01 GB...

Page 2: ...leur du Canada Read and understand all labels located on the vehicle For any questions on any of the information contact an E Z GO representative for clarification Always replace any damaged or missin...

Page 3: ...its previously sold and the information contained in this manual is subject to change without notice E Z GO Division of Textron is not liable for errors in this manual or for incidental or consequenti...

Page 4: ...governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle spec...

Page 5: ...draulic Brakes 3 Fig 7 Parking Brake for Hydraulic Brakes 3 Horn 3 Fig 8 Horn Button for Hydraulic Brakes 4 BEFORE ENTERING VEHICLE 4 OPERATING THE VEHICLE 4 Cold Starting 5 STARTING VEHICLE ON A HILL...

Page 6: ...ng Belt Tension with Gauge 13 Fig 27 Checking Belt Tension with Finger 13 Adjusting the Belt 13 Fig 28 Adjusting Belt Tension 13 AIR INTAKE AND COOLING FINS 14 Fig 29 Cleaning Air Intake 14 Fig 30 Cle...

Page 7: ...owered Personnel Carrier 23 TG5 Gasoline Powered 5 Passenger Golf Car 24 Fig 37 Vehicle Dimensions 25 Fig 38 Vehicle Dimensions and Incline Specifications 26 Fig 39 Vehicle Turning Clearance 27 LIMITE...

Page 8: ...Page vi Owner s Manual and Service Guide 7 2 217 176...

Page 9: ...affects capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made t...

Page 10: ...s experience 5 2 3 The user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads car...

Page 11: ...rakes It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns redu...

Page 12: ...ds for cleaning parts j Properly ventilate the work area k Handle LP gas cylinders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for us...

Page 13: ...damages that result from the use of the material in this manual This vehicle conforms to the current applicable standard for safety and performance requirements These vehicles are designed and manufac...

Page 14: ...and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Always support the vehicle using wheel cho...

Page 15: ...from accumulating Never fuel a vehicle in an area that is subject to flame or spark Pay particular attention to natural or propane water heaters and furnaces Never work around or operate a vehicle in...

Page 16: ...Owner s Manual and Service Guide 6 7 1 250 7 21 Page x Notes...

Page 17: ...m a safety survey peri odically and as conditions warrant to their premises to identify areas where golf cars should not be operated and to identify possible hazards 5 2 1 Steep Grade In areas where s...

Page 18: ...teries the output rate of the battery charger and the amount of time the batteries are on charge Hydrogen emissions are generally considered to be in the area of 10 to 20 cubic liters per car per char...

Page 19: ...ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 6 2 8 As required under paragraphs 6 2 6 and 6 2 7 the manufacturer shall be contacted...

Page 20: ...6 7 1 250 7 21 Page xviii Owner s Manual and Service Guide Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Notes...

Page 21: ...f 5 air exchanges per hour To reduce the chance of battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open flame or electrical equ...

Page 22: ...ved If the vehicle is equipped with E Z GO installed custom accessories some accessories remain operational with the key switch in the OFF position Direction Selectors Located either on the seat suppo...

Page 23: ...is a feature to assure the vehi cle is not driven with the parking PARK brake engaged This is not the preferred method of releasing the parking brake For mechanical brakes depressing the bottom of th...

Page 24: ...rvice brake to control speed when traveling down an incline To prevent loss of control do not move the direc tion selector of a PDS vehicle while the vehicle is in motion Moving the selector will resu...

Page 25: ...possible in order for the engine to start When the direction selector is in the reverse position a warning signal will sound This is a device to indicate the vehicle is ready to run in reverse The eng...

Page 26: ...to coast at faster than normal speeds that may be encountered on a flat surface To prevent loss of vehicle control speeds should be limited to no more than the maximum speed on level ground see GENER...

Page 27: ...starts and rapid acceleration until the engine has achieved operating temperature All engines consume more oil than normal during the first hours of operation As internal moving parts are run in oil...

Page 28: ...ed portion of the pin handle fits into the detent position in the transmission shift lever LIFTING THE VEHICLE Tool List Qty Required Floor jack 1 Jack stands 4 Chocks 4 Some servicing operations may...

Page 29: ...ps of grease in a grease fit ting could damage grease seals and cause premature bearing failure POWERTRAIN MAINTENANCE Powertrain may be accessed by raising or removing the rear forward facing seat Ad...

Page 30: ...st be in place before operat ing the engine Failure to install the dipstick and fill cap will result in oil becoming contaminated and or oil being discharged into the engine compartment Changing the O...

Page 31: ...p degreaser and brushing the metal screen clean with a soft brush Ref Fig 21 on page 11 Blow out the filter with low pressure air 30 psi 200 kPa or less from no closer than 3 8 cm and allow to air dry...

Page 32: ...talled Attach the lower portion of the enclosure and swing it up into place Squeeze housing together and secure with top clips Be sure all tabs are fully inserted and all clips are fastened securely R...

Page 33: ...sed with a finger A maximum deflection of 3 8 10 mm is acceptable Ref Fig 27 on page 13 Re tighten an existing belt to 75 80 lbs 34 36 kg ten sion using the same technique A maximum deflection of 1 2...

Page 34: ...tighten the plug Over tightening can cause damage to the aluminum cylinder head threads BRAKES After the vehicle has been put into service it is recom mended that the brakes be checked by performing t...

Page 35: ...ire sidewall To prevent tire explosion pressurize tire with small amount of air applied intermittently to seat beads Never exceed the tire manufacturer s rec ommendation when seating a bead Protect fa...

Page 36: ...tions must be fol lowed in order to minimize the possibility of personal injury To prevent injury be sure mounting demount ing machine is anchored to floor Wear OSHA approved safety equipment when mou...

Page 37: ...s several prod ucts available through a local Distributor an E Z GO Branch or the E Z GO Service Parts Department among them are Touch up paint specially formulated to match vehi cle colors for use on...

Page 38: ...dd fuel stabilizer to the tank in accordance with the manufac turer s recommendations Disconnect the fuel line from the engine at the fuel tank With proper area of ventila tion start the engine and al...

Page 39: ...ions and broken missing insulation ACCELERATOR Check for smooth movement DO NOT LUBRICATE CABLE SERVICE BRAKE Check brake performance smooth operation and adjust if required PARKING BRAKE Check brake...

Page 40: ...GES Lubricate use wheel bearing grease REAR AXLE Check for unusual noise and loose or missing mounting hardware AIR CLEANER Replace OIL FILTER Clean in solvent at oil change replace O rings if require...

Page 41: ...Page 21 1 5 63 7 216 Owner s Manual and Service Guide GENERAL SPECIFICATIONS...

Page 42: ...release accelerator kick off or hand operated parking brake FRONT SUSPENSION Leaf springs with hydraulic shock absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Self comp...

Page 43: ...operated parking brake FRONT SUSPENSION Leaf springs with hydraulic shock absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Self compensating single reduction rack and pi...

Page 44: ...ng brake FRONT SUSPENSION Leaf springs with hydraulic shock absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Self compensating single reduction rack and pinion DASH PANEL...

Page 45: ...rvice Guide Fig 37 Vehicle Dimensions 46 5 in 118 cm 122 in 310 cm 132 5 in 337 cm 134 5 in 342 cm 93 5 in 237 cm SHUTTLE 4 SHUTTLE 6 46 5 in 118 cm 122 in 310 cm 93 5 in 238 cm TG5 Lowest Clearance A...

Page 46: ...nd Service Guide 1 5 63 7 216 Fig 38 Vehicle Dimensions and Incline Specifications RECOMMENDED MAX RAMP GRADE 25 or 14 MAX RECOMMENDED MAX SIDE TILT 25 or 14 MAX Front 33 5 in 85 cm Rear 38 in 97 cm 4...

Page 47: ...Page 27 1 5 63 7 216 Owner s Manual and Service Guide Fig 39 Vehicle Turning Clearance TURNING CLEARANCE DIAMETER TG5 SHOWN 29 ft 8 8 m 94 in 240 cm 94 in 240 cm INTERSECTING AISLE CLEARANCE...

Page 48: ...Page 28 Owner s Manual and Service Guide 1 5 63 7 216 Notes...

Page 49: ...Page 29 0 7 55 17 Owner s Manual and Service Guide LIMITED WARRANTY...

Page 50: ...E To obtain warranty service take your engine to the nearest authorized E Z GO distributor or dealer Bring your sales receipts indicating date of purchase for this engine The dealer or service center...

Page 51: ...MED BY A DEALER OR SERVICE CENTER AUTHORIZED BY E Z GO THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AU THORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL...

Page 52: ...Page 32 Owner s Manual and Service Guide 0 7 55 17 5...

Page 53: ...nce retard system if applicable 4 Exhaust Manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter loc...

Page 54: ...AINTENANCE REPLACEMENT OR REPAIR OF EMISSSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALER...

Page 55: ...OF TEXTRON INC Augusta Georgia herein E Z GO to which FUJI supplies the en gine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 day...

Page 56: ...or warranty stations authorized by E Z GO In the event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855...

Page 57: ...ction and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim...

Page 58: ...Page 38 Owner s Manual and Service Guide 0 7 55 17 251...

Page 59: ...OF TEXTRON INC Augusta Georgia herein E Z GO to which FUJI supplies the en gine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 day...

Page 60: ...t any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warranty service fa...

Page 61: ...mended in the 2001 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause...

Page 62: ...Page 42 Owner s Manual and Service Guide 0 7 55 17 251...

Page 63: ...ere fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating correctly take time to con...

Page 64: ...ut the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc P O Box 388 Augusta Georgia 30903 0388 USA Inside USA Phone 1 800 241 585...

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