User Manuals: Ezgo Bellhop 4 Utility Vehicle

Manuals and User Guides for Ezgo Bellhop 4 Utility Vehicle. We have 1 Ezgo Bellhop 4 Utility Vehicle manual available for free PDF download: Technician's Repair And Service Manual

Ezgo Bellhop 4 Technician's Repair And Service Manual

Ezgo Bellhop 4 Technician's Repair And Service Manual (192 pages)

ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR

Brand: Ezgo | Category: Utility Vehicle | Size: 6 MB

Table of Contents

Table of Contents

5
- Notes
  6
  - Serial Number Label Location
    9
  - Transporting Vehicle
    9
    
    Towing
    9
  - Servicing the Electric Vehicle
    9
    
    Hauling
    9
  - Fig. 1 Initial Service Chart
    9
  - Light Bulb Replacement
    10
  - Care and Cleaning of the Vehicle
    10
  - Fig. 2 Lubrication Point
    10
  - Vehicle Care Products
    11
  - Hardware
    12
  - Torque Specifications
    12
  - Fig. 3 Torque Specifications
    12
  - Periodic Service Schedule
    13
  - Fig. 4 Periodic Service Schedule
    14
Section 1

15
- Safety
  15
  - General (Asme / Ansi B56.8 - 1988)
    17
  - Notes, Cautions and Warnings
    24
  - Important Safety Warning
    24
  - Modifications to Vehicle
    24
  - General Maintenance
    24
  - Before Servicing the Vehicle
    25
  - Additional Warnings
    25
  - Battery Removal & Installation
    26
  - Lifting the Vehicle
    27
  - Fig. 2 Lifting the Vehicle
    27
Section 2

29
- Body
  30
  - General
    31
- Body Component Replacement
  31
  - Instrument Panel Replacement
    35
  - Cowl Replacement
    35
  - Front Shield Replacement
    35
  - Rocker Panel End Replacement
    36
  - Front Seat Pod Replacement
    36
  - Rear Body Replacement
    36
  - Foot Rest Replacement
    37
  - Rear Bumper Replacement
    37
  - Front Seat Replacement
    38
  - Front Facing Rear Seat
    38
  - Rear Facing Rear Seat
    38
  - Cargo Bed Replacement
    38
  - Seat/Cargo Bed Latch
    38
- Shuttle / Bellhop 2 Rear Body
  39
  - Seat Support Removal
    39
  - Rocker Panel Removal
    41
  - Rear Fender Removal
    41
  - Rear Valence Panel Removal
    42
  - Side Panel Removal
    42
  - Load Deck Removal
    42
  - Bulkhead Removal
    43
  - Seat Back Removal
    43
  - Bed Frame Removal
    44
  - Seat Frame Removal
    44
  - MID Support Removal
    45
  - Battery Rack Removal (Electric Vehicle Only)
    46
  - Rear Bed Bracket Removal
    46
- Wheels and Tires
  47
  - List of Illustrations
    47
Front Suspension and Steering

51
- Maintenance
  54
  - Lubrication
    54
  - Wheel Bearing and King Pin Bushing Inspection
    54
  - Wheel Bearing Packing
    54
  - Wheel Bearing Adjustment
    55
  - Wheel Alignment
    55
- Front Suspension
  57
  - Front Shock Absorber Replacement
    57
  - Front Axle Replacement
    58
  - Axle Linkage Rod Replacement
    58
  - Front Spring Replacement
    58
  - Hub Replacement
    59
  - Wheel Bearing and Race Replacement
    60
- Steering
  62
  - Rack Ball Joint Replacement
    62
Electronic Speed Control

71
- Speed Control
  73
- Operation
  74
- Pedal Box
  75
  - Speed Sensor
    75
  - Controller
    75
- General Troubleshooting
  76
  - Symptoms
    76
  - Testing
    76
  - Testing Battery Voltage
    76
  - Continuity Check
    77
  - Testing a Switch for Continuity
    77
  - Testing a Solenoid for Continuity
    77
Brakes - Front Disc

91
- Brake Master Cylinder Fluid
  93
  - Check Brake Fluid
    93
- Master Cylinder Replacement
  93
- System Description
  93
- Routine Maintenance
  94
  - Brake Pad Replacement
    94
  - Rotor Replacement
    94
  - Spindle Replacement
    94
- Bleeding Brakes
  95
- General Description
  99
- Electrical System
  121
- Motor
  134
Batteries and Charging

135
- Battery
  137
- Battery Maintenance
  137
  - At each Charging Cycle
    137
  - Cleaning Batteries
    139
  - Battery Replacement
    139
  - Battery Charging
    141
  - AC Voltage
    141
- Safety
  137
- Troubleshooting
  141
  - Hydrometer
    141
  - Using a Hydrometer
    142
- Battery Charger
  142
  - Description
    142
  - Portable Charger Installation
    142
  - Charger Maintenance
    143
- Rear Suspension
  145
- Rear Axle
  149
  - Rear Axle
    151
Weather Protection

155
- Top and Windshield
  157
  - Transporting
    157
- Shuttle 4 and Shuttle 6 Sun Top
  158
  - Sun Top
    159
- Txt 5E Sun Top
  160
  - Rear Support Installation
    160
  - Front Support Installation
    160
  - Sun Top Installation
    160
- Fold down Windshield
  162
- Full Front Windshield
  163
- Rear Windshield
  164
- Paint
  165
Troubleshooting

169
- Electrical System
  171
- Basic Electrical Power System Troubleshooting
  172
  - Basic Electrical Troubleshooting for Accessories
    172
- Suspension and Steering
  173
- Lightning Protection and Grounding
  175
  - Grounding Requirements
    177
  - Ground Systems
    177
  - Lightning Protection Requirements
    177
  - Equipment Fault and Personal Safety System
    177
  - Ground Network Requirements
    177
  - External Grounding Requirements
    178
  - Materials
    178
  - Earth Electrode System
    178
  - Lightning Protection System
    179
  - 10. Equipment Fault and Personal Safety System
    179
- General Specifications
  181
  - Brakes
    183
  - Tires
    183

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