Ezgo SHUTTLE 4 Manuals

Manuals and User Guides for Ezgo SHUTTLE 4. We have 6 Ezgo SHUTTLE 4 manuals available for free PDF download: Technician's Repair And Service Manual, Owner's Manual And Service Manual, Service Manual

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

ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR

Brand: Ezgo | Category: Utility Vehicle | Size: 6.67 MB

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

Ezgo SHUTTLE 4 Owner's Manual And Service Manual (126 pages)

Electric Powered Personnel Carriers And Golf Car

Brand: Ezgo | Category: Utility Vehicle | Size: 5.29 MB

Safety
2
General Information
4
Table of Contents
5
General Operation
8
Safety Information
11
Maintenance Procedures
15
Before Initial Use
17
Fig. 1 Initial Service Chart
17
Portable Charger Installation
17
Fig. 2 Proper Charger Installation
18
Fig. 3 Charger Receptacle Location
18
On-Board Charger
18
Fig. 4 On-Board Charger
19
Controls and Indicators
19
Key/Light Switch
19
Fig. 5 Key/Light Switch & State of Charge Meter
19
Direction Selector
19
Fig. 6 Direction Selector
19
State of Charge Meter
19
Hour Meter
19
Accelerator Pedal
20
Fig. 7 Accelerator and Brake Controls
20
Combination Brake and Park Brake Pedal
20
Front Disc Brakes
20
Run - Tow/Maintenance Switch
20
Fig. 8 Run-Tow/Maintenance Switch
20
Horn
21
Operating the Vehicle
21
Fig. 10 Performance Characteristics
22
Starting and Driving
23
Starting Vehicle on a Hill
23
Coasting
23
Labels and Pictograms
23
Sun Top and Windshield
24
Vehicle Cleaning and Care
24
Vehicle Cleaning
24
Repair
24
Lifting the Vehicle
24
Wheels and Tires
25
Fig. 11 Lifting the Vehicle
25
Light Bulb Replacement
26
Fuse Replacement
26
Fig. 12 Wheel Installation
26
Fig. 13 Headlight, Turn Signal & Marker Light Bulb Replacement
27
Fig. 14 Tail and Brake Light Bulb Replacement
27
Transporting Vehicle
27
Towing
27
Hauling
27
Service and Maintenance
27
Serial Number Plate and Location
28
Fig. 15 Serial Number Plate and Location
29
Periodic Service Schedule
30
Fig. 16 Periodic Service Schedule
30
Tire Inspection
31
Brakes
31
Fig. 17 Typical Brake Performance Test
32
Rear Axle
32
Fig. 18 Add, Check and Drain Axle Lubricant
32
Lubrication
33
System Test
33
Hardware
33
Fig. 20 Torque Specifications and Bolt Grades
33
Capacities and Replacement Parts
34
Batteries and Charging
34
Safety
34
Battery
34
Fig. 21 Capacities and Replacement Parts
34
Battery Maintenance
35
Fig. 22 Correct Electrolyte Level
35
Fig. 23 Water Purity Table
36
Battery Cleaning
36
Fig. 24 Automatic Watering Gun
36
Fig. 25 Preparing Acid Neutralizing Solution
37
Battery Replacement
37
Fig. 26 48V Battery Connections
37
Fig. 27 Freezing Point of Electrolyte
38
AC Voltage
38
Battery Charging
38
Troubleshooting
39
Fig. 28 Hydrometer
39
Fig. 29 Hydrometer Temperature Correction
40
General Specifications
41
Shuttle 2 Electric Powered Personnel / Cargo Carrier
42
Shuttle 4 Electric Powered Personnel / Cargo Carrier
43
Shuttle 6 Electric Powered Personnel Carrier
44
Te5 Pds Electric Powered 5 Passenger Golf Car
45
Labels and Pictograms
51
Limited Warranties
57
Declaration of Conformity
59
T a B L E D E S M a T I E R E S
68
Consignes De Securite
69
Avant Le Premier Usage
79
Installation Du Chargeur Portable
79
Consignes D’exploitation Et Revisions
79
Chargeur a Bord
80
Commandes Et Voyants Indicateurs
81
Commutateur a Cle / Interrupteur Des Feux
81
Selecteur De Direction
81
Indicateur D'etat De Charge
81
Horametre
81
Pedale D'accelerateur
82
Pedale Mixte Frein / Frein De Stationnement
82
Freins a Disque Sur Les Roues Avant
82
Interrupteur Marche - Remorquage/Entretien
82
Klaxon
83
Utilisation Du Vehicule
83
Demarrage Et Utilisation
85
Demarrage Sur Pentes
85
Marche En Roue Libre
85
Etiquettes Et Pictogrammes
85
Toit Et Pare-Brise
86
Entretien Du Vehicule
86
Reparation
86
Levage Du Vehicule
86
Roues Et Pneus
87
Remplacement Des Ampoules
88
Remplacement Des Fusibles
88
Transport Du Vehicule
89
Remorquage
89
Transport
89
Entretien Et Maintenance
89
Emplacement De La Plaque Du Numero De Serie
90
Programme D'entretien Periodique
92
Inspection Des Pneus
93
Freins
94
Essieu Arriere
94
Graissage
95
Essai Du Systeme
95
Boulonnerie
95
Capacites Et Pieces De Rechange
96
Batteries Et Charge
96
Securite
96
Batterie
96
Entretien Des Batteries
97
Charge Des Batteries
100
Depistage Des Defauts
101
Specifications Generales
103
Vehicule Electrique Prive Et Industriel Shuttle 2
104
Vehicule Electrique Prive Et Industriel Shuttle 4
105
Vehicule Electrique Prive Shuttle 6
106
Voiturette De Golf Electrique, 5 Personnes Te5 Pds
107
Etiquettes Et Pictogrammes
113
Declaration De Conformite
121

Ezgo SHUTTLE 4 Owner's Manual And Service Manual (74 pages)

GASOLINE POWERED PERSONNEL CARRIERS AND GOLF CAR

Brand: Ezgo | Category: Offroad Vehicle | Size: 1.49 MB

Safety

2
- Service Guide
  3
Notes

4
- Table of Contents
  5
Safety Information

7
- General Operation
  8
- Preventive Maintenance
  16
Before Initial Use

19
- Fig. 1 Initial Service Chart
  19
Controls and Indicators

19
- Key/Light Switch
  19
- Fig. 2 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge
  20
- Direction Selector
  20
- Fig. 3 Direction Selector
  20
- Choke
  20
- Fuel Gauge
  20
- Low Oil Pressure Indicator Light
  20
- Accelerator Pedal
  20
  - Fig. 5 Accelerator and Brake Controls
    21
- Horn
  21
Operating the Vehicle

21
- Run-In
  22
  - Fig. 7 Check Oil Level on Dipstick
    22
- Cold Starting
  22
- Starting and Driving
  22
- Starting the Vehicle on a Hill
  23
- Coasting
  23
- Fuel
  23
- Battery
  23
- Labels and Pictograms
  24
- Sun Top and Windshield
  24
Vehicle Cleaning and Care

24
- Vehicle Cleaning
  24
Repair

24
- Lifting the Vehicle
  24
- Wheels and Tires
  25
  - Tire Repair
    25
    
    Fig. 9 Lifting the Vehicle
    25
  - Wheel Installation
    26
- Light Bulb Replacement
  26
- Fig. 10 Wheel Installation
  26
- Fuse Replacement
  26
- Vehicle with a Discharged Battery
  26
Transporting Vehicle

28
- Towing
  28
- Neutral Lock
  28
- Fig. 13 Neutral Lock
  28
- Hauling
  28
Service and Maintenance

28
- Serial Number Plate Location
  29
- Periodic Service Schedule
  30
  - Fig. 14 Periodic Service Schedule
    30
- Tire Inspection
  32
- Checking the Oil Level
  32
  - Fig. 15 Clean Entire Dipstick
    32
  - Fig. 16 Check Oil Level on Dipstick
    32
- Changing the Oil
  32
  - Fig. 17 Oil Viscosity Chart
    33
  - Fig. 18 Clean Top of Engine
    33
  - Fig. 19 Remove Oil Filter
    33
  - Fig. 20 Clean Oil Filter
    33
  - Fig. 21 Blowing out Oil Filter
    34
  - Fig. 22 Add Engine Oil
    34
- Starter/Generator Belt Tension
  34
  - Fig. 23 Checking Belt Tension with Gauge
    34
  - Adjusting the Belt
    35
    
    Fig. 24 Checking Belt Tension Manually
    35
    
    Fig. 25 Adjusting Belt Tension
    35
- Battery Cleaning
  35
- Brakes
  35
  - Periodic Brake Test for Mechanical Brakes
    36
    
    Fig. 26 Preparing Acid Neutralizing Solution
    36
    
    Fig. 27 Typical Brake Performance Test
    36
- HYDRAULIC FRONT DISC BRAKES (if Equipped)
  37
- Air Intake and Cooling Fins
  37
  - Checking the Lubricant Level
    37
    
    Fig. 28 Cleaning Air Intake
    37
    
    Fig. 29 Cleaning the Cooling Fins
    37
- Rear Axle
  38
- Air Cleaner Inspection and Replacement
  38
  - Fig. 31 Air Cleaner
    38
  - Cleaning the Air Filter Element
    38
- Lubrication
  38
- Spark Plugs
  39
- DIRECTION SELECTOR (Dual Cable System)
  39
  - Fig. 33 Shift Cable Adjustment
    39
- Prolonged Storage
  39
- Hardware
  39
  - Fig. 34 Torque Specifications
    40
- Capacities and Replacement Parts
  41
  - Fig. 35 Capacities and Replacement Parts
    41
General Specifications

43
Vehicle Warranties

53
Declaration of Conformity

63
Labels and Pictograms

67

Ezgo SHUTTLE 4 Owner's Manual And Service Manual (50 pages)

ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR

Brand: Ezgo | Category: Offroad Vehicle | Size: 0.65 MB

Safety
2
Service Guide
3
Notes
4
- Table of Contents
  5
- General Operation
  7
Safety Information
7
Preventive Maintenance
16
Before Initial Use
19
Serial Number Plate Location
20
- Fig. 4 Serial Number Plate Location
  20
Controls and Indicators
20
- Key/Light Switch
  20
  - Fig. 5 Key/Light Switch
    21
- Accelerator Pedal
  21
  - Fig. 6 Accelerator and Brake Controls
    21
- Service Brake Pedal
  21
- Parking Brake
  21
- Direction Selector
  21
- Fig. 7 Direction Selector
  21
- Horn
  22
- State of Charge Meter
  22
- Run - Tow/Maintenance Switch (on PDS Vehicles Only)
  22
- Fig. 9 Run-Tow/Maintenance Switch
  22
- Controller Diagnostics (PDS Vehicles Only)
  23
Before Entering Vehicle
23
Operating the Vehicle
23
- Additional Warnings and Cautions (Applicable to PDS Vehicles)
  24
Starting Vehicle on a Hill
24
Coasting
25
- Vehicle with PDS
  25
- Vehicle Without PDS
  25
Servicing the Electric Vehicle
25
Direction Selector Adjustment
26
- Fig. 10 Direction Selector Adjustment
  26
Towing
26
Lifting the Vehicle
26
- Fig. 11 Lifting the Vehicle
  27
Routine Maintenance
27
- Fig. 12 Lubrication Points
  27
Rear Axle
27
- Checking the Lubricant Level
  27
  - Fig. 13 Add, Check and Drain Rear Axle Lubricant
    28
Pds Model Vehicles
28
Tires
28
- Tire Repair
  29
- Wheel Installation
  29
- Fig. 14 Wheel Installation
  29
Brakes
28
- Daily Brake Test
  28
Light Bulb Replacement
29
Care and Cleaning of the Vehicle
30
Vehicle Care Products
30
Top and Windshield
30
Fig. 16 Torque Specifications
31
Trailering
31
Hardware
31
- Fig. 15 Bolt Grades
  31
Torque Specifications
31
Periodic Service Schedule
32
- Fig. 17 Periodic Service Schedule
  32
Batteries and Charging
34
- Safety
  34
Battery
34
Battery Maintenance
34
- At each Charging Cycle
  34
- Monthly
  35
- Electrolyte Level and Water
  35
  - Fig. 18 Correct Electrolyte Level
    35
  - Fig. 19 Water Purity Table
    35
- Cleaning Batteries
  35
  - Fig. 20 Automatic Watering Gun
    36
- Prolonged Storage
  36
  - Fig. 21 Preparing Acid Neutralizing Solution
    36
  - Fig. 22 Freezing Point of Electrolyte
    37
- Battery Installation
  37
  - Fig. 23 Battery Connections
    37
- Battery Charging
  37
- AC Voltage
  38
Troubleshooting
38
- Hydrometer
  38
- Using a Hydrometer
  39
  - Fig. 25 Hydrometer Temperature Correction
    39
Battery Charger Maintenance
39
- Fig. 26 Cleaning Auxiliary Contact in Charger Plug
  39
General Specifications
41

Ezgo SHUTTLE 4 Owner's Manual And Service Manual (64 pages)

GASOLINE POWERED CARGO, PERSONNEL CARRIER AND GOLF CAR

Brand: Ezgo | Category: Utility Vehicle | Size: 1.77 MB

Table of Contents
5
General Safety Practices
9
General Operation
13
Notes
16
Preventive Maintenance
18
Before Initial Use
21
- Preparation of Seats for Service
  21
Serial Number Plate Location
21
Controls
22
- Key/Light Switch
  22
- Direction Selectors
  22
- Choke
  22
  - Fig. 2 Serial Number Plate Location
    22
- Accelerator Pedal
  23
- Combination Service and Parking Brake Pedal for Mechanical Brakes
  23
- Service Brake Pedal for Hydraulic Brakes
  23
- Parking Brake for Hydraulic Brakes
  23
- Horn
  23
  - Fig. 5 Choke
    23
Before Entering Vehicle
24
Operating the Vehicle
24
- Fig. 8 Horn Button for Hydraulic Brakes
  24
- Cold Starting
  25
Starting Vehicle on a Hill
25
Coasting
26
Fuel
26
- Fuel Gauge, Low Fuel and Low Oil Pressure Indicator Lights
  26
Servicing the Vehicle
27
Break-In
27
Towing
27
- Neutral Lock
  28
Lifting the Vehicle
28
Routine Maintenance
29
Powertrain Maintenance
29
- Direction Selector
  29
- Checking the Oil Level
  30
- Changing the Oil
  30
  - Fig. 19 Clean Top of Engine
    31
Air Cleaner Inspection/Replacement
32
Rear Axle
32
- Checking the Lubricant Level
  32
  - Fig. 23 Adding Engine Oil
    32
- Starter/Generator Belt Tension
  33
- Adjusting the Belt
  33
Air Intake and Cooling Fins
34
Spark Plugs
34
Brakes
34
- Periodic Brake Test for Mechanical Brakes
  34
- Daily Brake Test for Hydraulic Brakes
  35
Tires
35
- Tire Repair
  36
- Wheel Installation
  36
Light Bulb Replacement
36
Care and Cleaning of the Vehicle
37
Vehicle Care Products
37
Top and Windshield
37
Trailering
38
Winter or Prolonged Storage
38
Hardware
38
Torque Specifications
38
Periodic Service Schedule
39
General Specifications
41
- Shuttle 6 Gasoline Powered Personnel Carrier
  43
Limited Warranty
49
California Emission Control Warranty Statement
55

Ezgo SHUTTLE 4 Service Manual (100 pages)

ELECTRIC & PRECISION DRIVE SYSTEM PERSONNEL CARRIERS AND 5 PASSENGER GOLF CAR

Brand: Ezgo | Category: Offroad Vehicle | Size: 3.1 MB

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Section 2

Front Suspension and Steering

Electronic Speed Control

Brakes - Front Disc

Batteries and Charging

Weather Protection

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Ezgo SHUTTLE 4 Owner's Manual And Service Manual (126 pages)

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Notes

Safety Information

Before Initial Use

Controls and Indicators

Operating the Vehicle

Vehicle Cleaning and Care

Repair

Transporting Vehicle

Service and Maintenance

General Specifications

Vehicle Warranties

Declaration of Conformity

Labels and Pictograms

Ezgo SHUTTLE 4 Owner's Manual And Service Manual (50 pages)

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