Ezgo EZGO 2001 User manual

STARTING MODEL YEAR: 2001
ELECTRIC POWERED
PERSONNEL CARRIERS
AND GOLF CAR
OWNER’S MANUAL
AND SERVICE GUIDE
28641-G01
English

SAFETY
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
NOTES, CAUTIONS AND WARNINGS
Throughout this guide NOTE, CAUTION and WARNING
will be used. A NOTE indicates a condition that should be
observed.
A CAUTION indicates a condition that
may result in damage to the vehicle.
A WARNING indicates a
hazardous condition that
could result in severe
injury or death.
Please observe these NOTES, CAUTIONS and WARN-
INGS; be aware that servicing a vehicle requires
mechanical skill and a regard for conditions that could be
hazardous. Improper service or repair may damage the
vehicle or render it unsafe. Battery posts, terminals
and related accessories
contain lead and lead
compounds. Wash hands after handling.
! !
! !
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. (See vehicle specification.) Limit speed by applying the service brake.
Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situations that could result in an unsafe condition.
Be sure that this manual remains as part of the permanent service record should the vehicle be resold.
WASH HANDS
AFTER HANDLING!
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
BATTERY WARNING
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
BATTERIES
CONTAIN LEAD
AND RELATED PARTS

Page i
Owner’s Manual and Service Guide
OWNER’S MANUAL AND
SERVICE GUIDE
ELECTRIC POWERED
CARGO, PERSONNEL CARRIER
AND GOLF CARS
VEHICLES
Shuttle 4
Shuttle 6
TE5
TE5 PDS
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.
E-Z-GO Division of Textron is not liable for errors in this manualor for incidentalorconsequentialdamages that result from the use of the material in this manual.
CUSTOMER SERVICE DEPARTMENT IN USA PHONE: [phone] FAX: [phone]
OUTSIDE USA PHONE: [phone] FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA USA 30903-0388

Page ii
NOTES
Owner’s Manual and Service Guide
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 batteries may void the warranty.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75° F (-60° C).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain, such as the battery charger. Disconnect the battery charger cable
from the vehicle batteries when not charging.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
Refer to the ‘Prolonged Storage’ section within the BATTERIES AND CHARGING section of
this manual.

Page iii
TABLE OF CONTENTS
Owner’s Manual and Service Guide
SAFETY ...................................................................................................................Inside covers
NOTES.........................................................................................................................................ii
SAFETY INFORMATION............................................................................................................. v
BEFORE INITIAL USE ...............................................................................................................1
Fig. 1 Initial Service Chart ......................................................................................................................1
Preparation of Seats for Service ..........................................................................................................................1
Charger Installation ..............................................................................................................................................1
Fig. 2 Charger Installation ......................................................................................................................2
Fig. 3 Charger Receptacle .....................................................................................................................2
SERIAL NUMBER PLATE LOCATION ......................................................................................2
Fig. 4 Serial Number Plate Location ......................................................................................................2
CONTROLS AND INDICATORS ................................................................................................2
Key/Light Switch ..................................................................................................................................................2
Fig. 5 Key/Light Switch ..........................................................................................................................3
Accelerator Pedal ................................................................................................................................................3
Fig. 6 Accelerator and Brake Controls ...................................................................................................3
Service Brake Pedal ............................................................................................................................................3
Parking Brake ......................................................................................................................................................3
Direction Selector ................................................................................................................................................3
Fig. 7 Direction Selector ........................................................................................................................3
Horn .....................................................................................................................................................................4
Fig. 8 Horn Button ..................................................................................................................................4
State of Charge Meter .........................................................................................................................................4
Run - Tow/Maintenance Switch (on PDS vehicles only) ......................................................................................4
Fig. 9 Run-Tow/Maintenance Switch .....................................................................................................4
Controller Diagnostics (PDS vehicles only) .........................................................................................................5
BEFORE ENTERING VEHICLE .................................................................................................5
OPERATING THE VEHICLE ......................................................................................................5
Additional Warnings and Cautions (applicable to PDS vehicles) .........................................................................6
STARTING VEHICLE ON A HILL ..............................................................................................6
General ................................................................................................................................................................6
PDS Vehicle .........................................................................................................................................................6
Non PDS Vehicle (with hand operated park brake) .............................................................................................6
Non PDS Vehicle (with foot operated park brake) ...............................................................................................6
Anti-Stall Feature (PDS Vehicle) .........................................................................................................................7
COASTING .................................................................................................................................7
Vehicle with PDS .................................................................................................................................................7
Vehicle without PDS ............................................................................................................................................7
SERVICING THE ELECTRIC VEHICLE ....................................................................................7
DIRECTION SELECTOR ADJUSTMENT ..................................................................................8
Fig. 10 Direction Selector Adjustment ...................................................................................................8
TOWING ..................................................................................................................................... 8
LIFTING THE VEHICLE .............................................................................................................8
Fig. 11 Lifting the Vehicle ......................................................................................................................9
ROUTINE MAINTENANCE ........................................................................................................9
Fig. 12 Lubrication Points ......................................................................................................................9
REAR AXLE ...............................................................................................................................9
Checking the Lubricant Level ..............................................................................................................................9
Fig. 13 Add, Check and Drain Rear Axle Lubricant .............................................................................10
BRAKES ...................................................................................................................................10
Daily Brake Test ................................................................................................................................................10