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Ezgo Shuttle 4 Owner's Manual And Service Manual

Gasoline powered cargo, personnel carrier and golf car
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See also: Service Manual , Technician's Repair and Service Manual
28642-G01-GB
OWNER'S MANUAL
AND SERVICE GUIDE
*$62/,1( 32:(5('
3(56211(/ &$55,(56
$1' *2/) &$5
STARTING MODEL YEAR: 2001

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  • Page 1 28642-G01-GB OWNER’S MANUAL AND SERVICE GUIDE *$62/,1( 32:(5(' 3(56211(/ &$55,(56 $1' *2/) &$5 STARTING MODEL YEAR: 2001...
  • Page 2 6$)(7< 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 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 CARGO, PERSONNEL CARRIER AND GOLF CAR VEHICLES Shuttle 4 Shuttle 6 E-Z-GO Division of Textron reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.
  • Page 4 127(6 To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, E-Z-GO Branch or E-Z-GO Warranty Department with vehicle serial number and manufacturer code. The use of non E-Z-GO parts may void the warranty. Overfilling battery may void the warranty.

  • Page 5: Table Of Contents

    7$%/( 2) &217(176 SAFETY ........................Inside covers NOTES ............................ii SAFETY INFORMATION......................vii BEFORE INITIAL USE ....................... 1 Fig. 1 Initial Service Chart ........................1 Preparation of Seats for Service .......................... 1 SERIAL NUMBER PLATE LOCATION ..................1 Fig. 2 Serial Number Plate Location ......................2 CONTROLS ..........................
  • Page 6 7$%/( 2) &217(176 Checking the Oil Level ............................10 Fig. 15 Shift Cable Adjustment ......................10 Fig. 16 Clean Entire Dipstick ....................... 10 Fig. 17 Check Oil Level on Dipstick ....................10 Changing the Oil ............................... 10 Fig. 18 Oil Viscosity Chart ........................10 Fig.
  • Page 7 7$%/( 2) &217(176 GENERAL SPECIFICATIONS ....................21 Shuttle 4 Gasoline Powered Personnel / Cargo Carrier ..................22 Shuttle 6 Gasoline Powered Personnel Carrier ....................23 TG5 Gasoline Powered 5 Passenger Golf Car....................24 Fig. 37 Vehicle Dimensions ........................25 Fig. 38 Vehicle Dimensions and Incline Specifications................26 Fig.
  • Page 8 7$%/( 2) &217(176 Owner’s Manual and Service Guide Page vi...

  • Page 9: General Safety Practices

    6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL manual without the manufacturer’s prior written authori- zation. Where authorized modifications have been made, The following text is provided as recommended by part II the user shall ensure that capacity, operation, warning, of ASME/ANSI B56.8-1988.
  • Page 10 6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Control of Noxious Gases and Fumes turer; 4.8.1 When equipment powered by internal com- (b) emphasis on safety of passengers, material loads, bustion engines is used in enclosed areas, the atmo- carrier operator, and other employees;...
  • Page 11 6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 5.4.9 Carriers shall not be parked or left unattended smooth, sweeping motion. such that they block or obstruct fire aisles, access to Loading stairways, or fire equipment.
  • Page 12 6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Maintenance Procedures prevent the use of the carrier until the leak has been eliminated. 6.2.1 Maintenance and inspection of all carriers (o) The carrier manufacturer’s capacity, operation, and shall be performed in conformance with the manufac- maintenance instruction plates, tags, or decals shall be...

  • Page 13: General Operation

    6$)(7< ,1)250$7,21 This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures developed by E-Z-GO. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle;...
  • Page 14 6$)(7< ,1)250$7,21 Always maintain adequate distance between vehicles. Always reduce speed in wet areas. Always use extreme caution when approaching sharp or blind turns. Always use extreme caution when driving over loose terrain. Always use extreme caution in areas where pedestrians are present. MAINTENANCE Always maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
  • Page 15 6$)(7< ,1)250$7,21 VENTILATION Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes 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.

  • Page 16: Notes

    6$)(7< ,1)250$7,21 Notes: Owner’s Manual and Service Guide Page x...
  • Page 17 6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL 5.2.1. Steep Grade The following text is provided as recommended by part II In areas where steep grades exist, golf car operations of ANSI / GCMA Z130.1 - 1993.

  • Page 18: Preventive Maintenance

    6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE liters per car per charge. Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air 6.1.
  • Page 19 6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings governors and all other safety devices shall be inspected 7. FUELS HANDLING AND STORAGE/ and maintained in a safe and proper operating condition BATTERY CHARGING and shall not be modified as supplied by the manufac- turer.
  • Page 20 6$)(7< ,1)250$7,21 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Notes: Owner’s Manual and Service Guide Page xviii...

  • Page 21: Before Initial Use

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for your purchase. The vehicle is equipped Never charge a vehicle in an area that is subject to flame with a twin cylinder overhead cam 4 cycle engine.

  • Page 22: Controls

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 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 support panel or between the front seats in the console, this lever permits the selection...

  • Page 23: Accelerator Pedal

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Depressing the accelerator pedal will release the parking brake if it is engaged. This is a feature to assure the vehi- cle is not driven with the parking (PARK) brake engaged.

  • Page 24: Before Entering Vehicle

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings page 3) or later hydraulic brakes or located on the pas- Use extra care and reduced speed when driving senger side of the steering column on vehicles with early on poor surfaces, such as loose dirt, wet grass, gravel, etc.

  • Page 25: Cold Starting

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Depressing the accelerator pedal releases the combina- The engine stops when the accelerator pedal is released. tion service/park brake and the pedal mounted parking To stop the vehicle more quickly, depress the service brake (which ever is applicable) and energizes the starter...

  • Page 26: Starting A Vehicle With A Discharged Battery

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings cle on hill by using accelerator and engine. Leaving drive FUEL train in a stalled condition for more than 3 - 4 seconds will The fuel tank is located under the rear, forward facing cause permanent damage to drive train components.

  • Page 27: Servicing The Vehicle

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings A low oil pressure indicator light (if equipped) is located During the initial period, check the oil level at least every between the key switch and the fuel gauge or low fuel 8 operational hours (Ref.

  • Page 28: Neutral Lock

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Use extra caution when towing vehicle. To prevent possible inju- Do not tow in excess of 12 mph (19 r y or death resulting kph).

  • Page 29: Routine Maintenance

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Place the jack at the center of the front axle. Raise the Putting more than three pumps of grease in a grease fit- vehicle and position jack stands under the frame cross- ting could damage grease seals and cause premature member as indicated.

  • Page 30: Checking The Oil Level

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Maximum oil level Fill cold engine for hot engine to this point Factory Do not overfill Installed Length 1 3/8"...

  • Page 31: Fig. 19 Clean Top Of Engine

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Be aware that engine flu- ids may be hot and con- t a c t t o t h e s k i n m a y cause severe burns.

  • Page 32: Air Cleaner Inspection/Replacement

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Do not use compressed air to clean the air filter. Doing so will damage the filter and will damage the engine.

  • Page 33: Starter/Generator Belt Tension

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Starter/Generator Belt Tension Re-tighten an existing belt to 75 - 80 lbs (34 - 36 kg) ten- sion using the same technique.

  • Page 34: Air Intake And Cooling Fins

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings AIR INTAKE AND COOLING FINS Plug .028-.030" (.71-.76 mm) Fig. 29 Cleaning Air Intake Fig.

  • Page 35: Daily Brake Test For Hydraulic Brakes

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings It is important to periodically check and maintain proper brake fluid levels in the brake master cylinder. The fill cap Accelerate for the cylinder is located under the front seat.

  • Page 36: Tire Repair

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings lower pressure prevents tires from cutting into the turf. To prevent injury caused For vehicles being used on paved or hard surfaces, tire by a broken socket, use only sockets designed inflation pressure should be in the higher allowable...

  • Page 37: Care And Cleaning Of The Vehicle

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CARE AND CLEANING OF THE VEHICLE that will not crack, peel or flake over a wide tem- perature range.

  • Page 38: Trailering

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings TRAILERING Place the direction selector in the neutral position and engage the neutral lock (Ref. Fig. 11 on page 8). Add fuel To prevent personal inju- stabilizer to the tank in accordance with the manufac- ry to occupants of other...

  • Page 39: Periodic Service Schedule

    *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ✓ Check ♦ Clean, Adjust, etc. ▲ Replace NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY ♦...
  • Page 40 *$62/,1( 32:(5(' 3(56211(/ &$55,(56 *2/) &$5 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ✓ Check level, add if required and check for leakage (DOT 3) HYDRAULIC BRAKE FLUID ✓...

  • Page 41: General Specifications

    *(1(5$/ 63(&,),&$7,216 GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 21...
  • Page 42 *(1(5$/ 63(&,),&$7,216 SHUTTLE 4 GASOLINE POWERED PERSONNEL / CARGO CARRIER WEIGHT (dry fuel tank)............1014 lbs. (460 kg) TIRES (4 ply rated) ..............18 x 8.50 x 8 TIRE PRESSURE ..............18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ......1200 lbs.

  • Page 43: Shuttle 6 Gasoline Powered Personnel Carrier

    *(1(5$/ 63(&,),&$7,216 SHUTTLE 6 GASOLINE POWERED PERSONNEL CARRIER WEIGHT (dry fuel tank)............1014 lbs. (460 kg) TIRES (6 ply rated) ..............18 x 8.50 x 8 TIRE PRESSURE ..............18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ......
  • Page 44 *(1(5$/ 63(&,),&$7,216 GASOLINE POWERED 5 PASSENGER GOLF CAR WEIGHT (dry fuel tank)............1014 lbs. (460 kg) TIRES (4 ply rated) ..............18 x 8.50 x 8 TIRE PRESSURE ..............18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ......1200 lbs.

  • Page 45: Fig. 37 Vehicle Dimensions

    *(1(5$/ 63(&,),&$7,216 Lowest Clearance At Differential 4.25 in. (10.8 cm) (All Models) SHUTTLE 4 SHUTTLE 6 93.5 in. (237 cm) 122 in. (310 cm) 132.5 in. (337 cm) 134.5 in. (342 cm) 46.5 in. (118 cm) 93.5 in. (238 cm) 122 in.

  • Page 46: Fig. 38 Vehicle Dimensions And Incline Specifications

    *(1(5$/ 63(&,),&$7,216 67 in. (170 cm) 49 in. (123 cm) Front RECOMMENDED MAX SIDE TILT 33.5 in. (85 cm) 25% or 14˚ MAX Rear 38 in. (97 cm) RECOMMENDED MAX RAMP GRADE 25% or 14˚ MAX Fig. 38 Vehicle Dimensions and Incline Specifications Owner’s Manual and Service Guide Page 26...

  • Page 47: Fig. 39 Vehicle Turning Clearance

    *(1(5$/ 63(&,),&$7,216 TURNING CLEARANCE DIAMETER 29 ft. (8.8 m) TG5 SHOWN 94 in. (240 cm) INTERSECTING AISLE CLEARANCE 94 in. (240 cm) Fig. 39 Vehicle Turning Clearance Owner’s Manual and Service Guide Page 27...
  • Page 48 *(1(5$/ 63(&,),&$7,216 Notes: Owner’s Manual and Service Guide Page 28...

  • Page 49: Limited Warranty

    /,0,7(' :$55$17< LIMITED WARRANTY Owner’s Manual and Service Guide Page 29...
  • Page 50 /,0,7(' :$55$17<  )('(5$/  EMISSION COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all states, except the State of California. Fuji Heavy Industries Ltd. (herein “FUJI”) and E-Z-GO Division OF TEXTRON, INC. Augusta, Georgia, (herein “E- Z-GO”) warrant to the initial retail purchaser and each subsequent owner, that specialty vehicle engine (herein “en- gine”) was designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
  • Page 51 /,0,7(' :$55$17<  )('(5$/  THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper use and maintenance of the engine. You should keep all receipts and mainte- nance records covering the performance of maintenance records should be transferred to each subsequent owner of the engine.
  • Page 52 /,0,7(' :$55$17<  )('(5$/  Owner’s Manual and Service Guide Page 32...
  • Page 53 /,0,7(' :$55$17<  )('(5$/  EMISSION COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all states, except the State of California. Fuji Heavy Industries Ltd. and E-Z-GO Division OF TEXTRON, INC. Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Nonroad engine (herein “engine”) has been de- signed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
  • Page 54 /,0,7(' :$55$17<  )('(5$/  You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by E-Z-GO when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO War- ranty Department at 1-800-241-5855 for the information.

  • Page 55: California Emission Control Warranty Statement

    /,0,7(' :$55$17<  &$/,)251,$  CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein “FUJI”) are pleased to explain the emis- sion control system warranty on your 2000 and later small off-road engine (herein “engine”). In California, the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards.
  • Page 56 /,0,7(' :$55$17<  &$/,)251,$  part which is scheduled for replacement as required maintenance shall be warranted for the pe- riod of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or warranty station.
  • Page 57 /,0,7(' :$55$17<  &$/,)251,$  (4) Exhaust Manifold (5) Miscellaneous Items Used in Above Systems (i) Fuel hoses, clamps and sealing gaskets I. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2000 and later Owner’s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended.
  • Page 58 /,0,7(' :$55$17<  &$/,)251,$  Owner’s Manual and Service Guide Page 38...
  • Page 59 /,0,7(' :$55$17<  &$/,)251,$  CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein “FUJI”) are pleased to explain the emis- sion control system warranty on your 2001 and later small off-road engine (herein “engine”). In California, the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards.
  • Page 60 /,0,7(' :$55$17<  &$/,)251,$  part which is scheduled for replacement as required maintenance shall be warranted for the pe- riod of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or service provider.
  • Page 61 /,0,7(' :$55$17<  &$/,)251,$  (iii) Spark advance/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 lock assembly (gaseous fuel, if applicable) I.
  • Page 62 /,0,7(' :$55$17<  &$/,)251,$  Owner’s Manual and Service Guide Page 42...
  • Page 63 Read and understand the following warnings Some components are heavy, spring loaded, highly cor- before attempting to operate the vehicle: rosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, prevent personal battery acid and hydrogen gas could result in serious injury or death, observe bodily injury to the technician/mechanic and bystanders if the following:...
  • Page 64 E-Z-GO Division of Textron Inc. P.O. Box 388 Augusta, Georgia 30903-0388 USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 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.

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