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

Page iv Owner’s Manual and Service Guide
TABLE OF CONTENTS
PDS MODEL VEHICLES ..........................................................................................................10
TIRES .......................................................................................................................................10
Tire Repair ........................................................................................................................................................ 11
Wheel Installation .............................................................................................................................................. 11
Fig. 14 Wheel Installation .................................................................................................................... 11
LIGHT BULB REPLACEMENT .................................................................................................11
CARE AND CLEANING OF THE VEHICLE .............................................................................12
VEHICLE CARE PRODUCTS ..................................................................................................12
TOP AND WINDSHIELD ..........................................................................................................12
TRAILERING ............................................................................................................................13
HARDWARE .............................................................................................................................13
Fig. 15 Bolt Grades ............................................................................................................................. 13
TORQUE SPECIFICATIONS ...................................................................................................13
Fig. 16 Torque Specifications .............................................................................................................. 13
PERIODIC SERVICE SCHEDULE .......................................................................................14
Fig. 17 Periodic Service Schedule ...................................................................................................... 14
BATTERIES AND CHARGING .................................................................................................16
Safety ................................................................................................................................................................ 16
BATTERY .................................................................................................................................16
BATTERY MAINTENANCE ......................................................................................................16
At Each Charging Cycle .................................................................................................................................... 16
Monthly ............................................................................................................................................................. 17
Electrolyte Level and Water .............................................................................................................................. 17
Fig. 18 Correct Electrolyte Level ......................................................................................................... 17
Fig. 19 Water Purity Table .................................................................................................................. 17
Cleaning Batteries ............................................................................................................................................. 17
Fig. 20 Automatic Watering Gun ......................................................................................................... 18
Prolonged Storage ............................................................................................................................................ 18
Fig. 21 Preparing Acid Neutralizing Solution ....................................................................................... 18
Fig. 22 Freezing Point of Electrolyte ................................................................................................... 19
Battery Installation ............................................................................................................................................ 19
Fig. 23 Battery Connections ................................................................................................................ 19
Battery Charging ............................................................................................................................................... 19
AC Voltage ........................................................................................................................................................ 20
TROUBLESHOOTING ..............................................................................................................20
Hydrometer ....................................................................................................................................................... 20
Fig. 24 Hydrometer ............................................................................................................................. 20
Using A Hydrometer .......................................................................................................................................... 21
Fig. 25 Hydrometer Temperature Correction ...................................................................................... 21
BATTERY CHARGER MAINTENANCE ...................................................................................21
Fig. 26 Cleaning Auxiliary Contact in Charger Plug ............................................................................21
GENERAL SPECIFICATIONS...................................................................................................23
Shuttle 4 Electric Powered Personnel / Cargo Carrier....................................................................................... 24
Shuttle 6 Electric Powered Personnel / Carrier.................................................................................................. 25
TE5 Electric Powered 5 Passenger Golf Car..................................................................................................... 26
TE5 PDS Electric Powered 5 Passenger Golf Car ............................................................................................ 27
Fig. 27 Vehicle Dimensions................................................................................................................... 28
Fig. 28 Vehicle Dimensions and Incline Specifications......................................................................... 29
Fig. 29 Vehicle Turning Clearance........................................................................................................ 30

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page v
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; therefore it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. E-Z-GO strongly suggests that the owner-operator read this entire manual paying particular
attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees and other
operators be encouraged to do the same.
If you have any questions, contact your closest E-Z-GO representative or write to the address on the back cover of this
publication, Attention: Product Service Department.
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 manual or for incidental or consequential 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 manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety
Standards and are not equipped for operation on public streets. Some communities may permit these vehicles to be
operated on their streets on a limited basis and in accordance with local ordinances.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
Never use the chassis or body as a ground connection.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. E-Z-GO prohibits and disclaims
responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of similar vehicles when
used in the same environment. Additionally, speed should be further moderated by the environmental conditions,
locale and common sense.
GENERAL OPERATION
Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
Always read and observe all warnings and operation instruction labels affixed to the vehicle.
Always follow all safety rules established in the area where the vehicle is being operated.
Always reduce speed to compensate for poor terrain or conditions.

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page vi
Always apply service brake to control speed on steep grades.
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.
Always ensure that mechanics performing repairs are trained and qualified to do so.
Always follow the manufacturer’s directions if you do any maintenance on your vehicle. Be sure to disable the vehicle
before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery
wire.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by short-
ing the battery terminals or associated wiring. Remove the batteries or cover exposed terminals with an insulating
material.
Always check the polarity of each battery terminal and be sure to rewire the batteries correctly.
Always use specified replacement parts. Never use replacement parts of lesser quality.
Always use recommended tools.
Always determine that tools 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 chocks and safety stands. Never get under a vehicle that is supported by a
jack. Lift the vehicle in accordance with the manufacturer’s instructions.
Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that could result in severe
personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury,
refer the repair or maintenance to a qualified mechanic.
Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of
both vehicular and pedestrian traffic.
Always replace damaged or missing warning, caution or information labels.
Always keep complete records of the maintenance history of the vehicle.

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page vii
VENTILATION
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because
hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air
exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the recepta-
cle when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturer’s recommendations or applicable
electrical code (whichever is more restrictive).

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page viii
Notes:

SAFETY INFORMATION
Page ix
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
GENERAL
The following text is provided as recommended by part II
of ASME/ANSI B56.8-1988. E-Z-GO strongly endorses
the contents of this specification.
PART II
FOR THE USER
4 GENERAL SAFETY PRACTICES
4.1 Introduction
4.1.1 Like other machines, carriers can cause injury
if improperly used or maintained. Part II contains broad
safety practices applicable to carrier operations. Before
operation, the user shall establish such additional spe-
cific safety practices as may reasonably be required for
safe operation.
4.2 Stability
4.2.1 Experience has shown that this vehicle, which
complies with this standard, is stable when properly
operated and when operated in accordance with specific
safety rules and practices established to meet actual
operating terrain and conditions. However, improper
operation, faulty maintenance, or poor housekeeping
may contribute to a condition of instability and defeat the
purpose of the standard. Some of the conditions which
may affect stability are failure of the user to follow safety
practices; also, ground and floor conditions, grade,
speed, loading, the operation of the carrier with improper
loads, battery weight, dynamic and static forces, and the
judgement exercised by the carrier operator.
(a) The user shall train carrier operators to adhere
strictly to the operating instructions stated in this Stan-
dard.
(b) The user shall survey specific operating conditions
and environment, and establish and train carrier opera-
tors to comply with additional, specific safety practices.
4.3 Nameplates, Markings, Capacity, and Modifica-
tions
4.3.1 The user shall maintain in a legible condition
all nameplates, warnings, and instructions which are
supplied by the manufacturer.
4.3.2 The user shall not perform any modification or
addition which 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,
the user shall ensure that capacity, operation, warning,
and maintenance instruction plates, tags, or decals are
changed accordingly.
4.3.3 As required under paras. 4.3.1 or 4.3.2, the
manufacturer shall be contacted to secure new name-
plates, warnings, or instructions which shall then be
affixed in their proper place on the carrier.
4.4 Fuel Handling and Storage
4.4.1 The user shall supervise the storage and han-
dling of liquid fuels (when used) to be certain that it is in
accordance with appropriate paragraphs of ANSI/NFPA
505 and ANSI/NFPA 30.
4.4.2 Storage and handling of liquefied petroleum
gas fuels shall be in accordance with appropriate para-
graphs of ANSI/NFPA 505 and ANSI/NFPA 58. If such
storage or handling is not in compliance with these stan-
dards, the user shall prevent the carrier from being used
until such storage and handling is in compliance with
these standards.
4.5 Changing and Charging Storage Batteries for
Electric Personnel and Burden Carriers
4.5.1 The user shall require battery changing and
charging facilities and procedures to be in accordance
with appropriate paragraphs of ANSI/NFPA 505.
4.5.2 The user shall periodically inspect facilities
and review procedures to be certain that appropriate
paragraphs of ANSI/NFPA 505, are strictly complied with,
and shall familiarize carrier operators with it.
4.6 Hazardous Locations
4.6.1 The user shall determine the hazard classifi-
cation of the particular atmosphere or location in which
the carrier is to be used in accordance with ANSI/NFPA
505.
4.6.2 The user shall permit in hazardous areas only
those carriers approved and of the type required by
ANSI/NFPA 505.
4.7 Lighting for Operating Areas
4.7.1 The user, in accordance with his responsibility
to survey the environment and operating conditions, shall
determine if the carrier requires lights and, if so, shall
equip the carrier with appropriate lights in accordance
with the manufacturer’s recommendations.

SAFETY INFORMATION
Page x 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
4.8 Control of Noxious Gases and Fumes
4.8.1 When equipment powered by internal com-
bustion engines is used in enclosed areas, the atmo-
sphere shall be maintained within limits specified in the
American Conference of Governmental Industrial
Hygienists publication, “Threshold Limit Values for
Chemical Substances and Physical Agents in the Work-
room Environment”. This shall be accomplished by venti-
lation provided by the user, and/or the installation, use,
and proper maintenance of emission control equipment
recommended or provided by the manufacturer of the
equipment.
4.9 Warning Device(s)
4.9.1 The user shall make periodic inspections of
the carrier to be certain that the sound-producing and/or
visual device(s) are maintained in good operating condi-
tion.
4.9.2 The user shall determine if operating condi-
tions require the carrier to be equipped with additional
sound-producing and/or visual devices and be responsi-
ble for providing and maintaining such devices, in accor-
dance with the manufacturer’s recommendations.
5 OPERATING SAFETY RULES AND
PRACTICES
5.1 Personnel and Burden Carrier Operator
Qualifications
5.1.1 Only persons who are trained in the proper
operation of the carrier shall be authorized to operate the
carrier. Operators shall be qualified as to visual, auditory,
physical, and mental ability to safely operate the equip-
ment according to Section 5 and all other applicable
parts of this Standard.
5.2 Personnel and Burden Carrier Operators’
Training
5.2.1 The user shall conduct an operators’ training
program.
5.2.2 Successful completion of the operators’ train-
ing program shall be required by the user before opera-
tion of the carrier. The program shall be presented in its
entirety to all new operators and not condensed for those
claiming previous 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,
carrier operator, and other employees;
(c) general safety rules contained within this Standard
and the additional specific rules determined by the user
in accordance with this Standard, and why they were for-
mulated;
(d) introduction of equipment, control locations and
functions, and explanation of how they work when used
properly and when used improperly, and surface condi-
tions, grade, and other conditions of the environment in
which the carrier is to be operated;
(e) operational performance tests and evaluations dur-
ing, and at completion of, the program.
5.3 Personnel and Burden Carrier Operator
Responsibility
5.3.1 Operators shall abide by the following safety
rules and practices in paras. 5.4, 5.5, 5.6, and 5.7.
5.4 General
5.4.1 Safeguard the pedestrians at all times. Do not
drive carrier in a manner that would endanger anyone.
5.4.2 Riding on the carrier by persons other than the
operator is authorized only on personnel seat(s) provided
by the manufacturer. All parts of the body shall remain
within the plan view outline of the carrier.
5.4.3 When a carrier is to be left unattended, stop
carrier, apply the parking brake, stop the engine or turn
off power, turn off the control or ignition circuit, and
remove the key if provided. Block the wheels if machine
is on an incline.
5.4.4 A carrier is considered unattended when the
operator is 25 ft. (7.6 m) or more from the carrier which
remains in his view, or whenever the operator leaves the
carrier and it is not within his view. When the operator is
dismounted and within 25 ft. (7.6 m) of the carrier still in
his view, he still must have controls neutralized, and the
parking brake(s) set to prevent movement.
5.4.5 Maintain a safe distance from the edge of
ramps and platforms.
5.4.6 Use only approved carriers in hazardous loca-
tions, as defined in the appropriate safety standards.
5.4.7 Report all accidents involving personnel,
building structures, and equipment.
5.4.8 Operators shall not add to, or modify, the car-
rier.

SAFETY INFORMATION
Page xi
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
5.4.9 Carriers shall not be parked or left unattended
such that they block or obstruct fire aisles, access to
stairways, or fire equipment.
5.5 Traveling
5.5.1 Observe all traffic regulations, including autho-
rized speed limits. Under normal traffic conditions keep
to the right. Maintain a safe distance, based on speed of
travel, from a carrier or vehicle ahead; and keep the car-
rier under control at all times.
5.5.2 Yield the right of way to pedestrians, ambu-
lances, fire trucks, or other carriers or vehicles in emer-
gency situations.
5.5.3 Do not pass another carrier or vehicle travel-
ing in the same direction at intersections, blind spots, or
at other dangerous locations.
5.5.4 Keep a clear view of the path of travel,
observe other traffic and personnel, and maintain a safe
clearance.
5.5.5 Slow down or stop, as conditions dictate, and
activate the sound-producing warning device at cross
aisles and when visibility is obstructed at other locations.
5.5.6 Ascend or descend grades slowly.
5.5.7 Avoid turning, if possible, and use extreme
caution on grades, ramps, or inclines; normally travel
straight up and down.
5.5.8 Under all travel conditions the carrier shall be
operated at a speed that will permit it to be brought to a
stop in a safe manner.
5.5.9 Make starts, stops, turns, or direction rever-
sals in a smooth manner so as not to shift the load,
endanger passengers, or overturn the carrier.
5.5.10 Do not indulge in dangerous activities, such as
stunt driving or horseplay.
5.5.11 Slow down when approaching, or on, wet or
slippery surfaces.
5.5.12 Do not drive carrier onto any elevator unless
specifically authorized to do so. Approach elevators
slowly, and then enter squarely after the elevator car is
properly leveled. Once on the elevator, neutralize the
controls, shut off power, and set parking brakes. 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, reduce speed to improve
stability, then turn hand steering wheel or tiller in a
smooth, sweeping motion.
5.6 Loading
5.6.1 Handle only stable and safely arranged loads.
When handling off-center loads which cannot be cen-
tered, operate with extra caution.
5.6.2 Handle only loads within the capacity of the
carrier as specified on the nameplate.
5.6.3 Handle loads exceeding the dimensions used
to establish carrier capacity with extra caution. Stability
and maneuverability may be adversely affected.
5.7 Operator Care of Personnel and Burden
Carriers
5.7.1 At the beginning of each shift during which the
carrier will be used, the operator shall check the carrier
condition and inspect the tires, warning devices, lights,
battery(s), speed and directional controllers, brakes, and
steering mechanism. If the carrier is found to be in need
of repair, or in any way unsafe, the matter shall be
reported immediately to the designated authority and the
carrier shall not be operated until it has been restored to
safe operating condition.
5.7.2 If during operation the carrier becomes unsafe
in any way, the matter shall be reported immediately to
the designated authority, and the carrier shall not be
operated until it has been restored to safe operating con-
dition.
5.7.3 Do not make repairs or adjustments unless
specifically authorized to do so.
5.7.4 The engine shall be stopped and the operator
shall leave the carrier while refueling.
5.7.5 Spillage of oil or fuel shall be carefully and
completely absorbed or evaporated and fuel tank cap
replaced before starting engine.
5.7.6 Do not operate a carrier with a leak in the fuel
system or battery(s).
5.7.7 Do not use open flames for checking electro-
lyte level in storage battery(s) or liquid level in fuel tanks.
6 MAINTENANCE PRACTICES
6.1 Introduction
6.1.1 Carriers may become hazardous if mainte-
nance is neglected. Therefore, maintenance facilities,
trained personnel, and procedures shall be provided.
Such facilities may be on or off the premises.

SAFETY INFORMATION
Page xii 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
6.2 Maintenance Procedures
6.2.1 Maintenance and inspection of all carriers
shall be performed in conformance with the manufac-
turer’s recommendations and the following practices.
(a) A scheduled preventive maintenance, lubrication,
and inspection system shall be followed.
(b) Only qualified and authorized personnel shall be
permitted to maintain, repair, adjust, and inspect carriers.
(c) Before undertaking maintenance or repair, follow
the manufacturer’s recommendations for immobilizing
the carrier.
(d) Block chassis before working underneath it.
(e) Before disconnecting any part of the engine fuel
system of a gasoline or diesel powered carrier with grav-
ity feed fuel systems, be sure shutoff valve is closed, and
run engine until fuel system is depleted and engine stops
running.
(f) Before disconnecting any part of the engine fuel
system of LP gas powered carriers, close the LP gas cyl-
inder valve and run the engine until fuel in the system is
depleted and the engine stops running.
(g) Operation to check performance of the carrier shall
be conducted in an authorized area where safe clear-
ance exists.
(h) Before commencing operation of the carrier, follow
the manufacturer’s instructions and recommended pro-
cedures.
(i) Avoid fire hazards and have fire protection equip-
ment present in the work area. Do not use an open flame
to check level or leakage of fuel, battery electrolyte, or
coolant. Do not use open pans of fuel or flammable
cleaning fluids 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 use.
(l) Brakes, steering mechanisms, speed and direc-
tional control mechanisms, warning devices, lights, gov-
ernors, guards, and safety devices shall be inspected
regularly and maintained in a safe operating condition.
(m) Special carriers or devices designed and
approved for hazardous area operation shall be
inspected to ensure that maintenance preserves the orig-
inal approved safe operating features.
(n) Fuel systems shall be checked for leaks and condi-
tion of parts. If a leak is found, action shall be taken to
prevent the use of the carrier until the leak has been
eliminated.
(o) The carrier manufacturer’s capacity, operation, and
maintenance instruction plates, tags, or decals shall be
maintained in legible condition.
(p) Batteries, motors, speed and directional control-
lers, limit switches, protective devices, electrical conduc-
tors, and connections shall be inspected and maintained
in conformance with manufacturers recommended pro-
cedures.
(q) Carriers shall be kept in a clean condition to mini-
mize fire hazards and facilitate detection of loose or
defective parts.
(r) Modifications and additions which affect capacity
and safe machine operation shall not be performed by
the customer or user without manufacturer’s prior written
authorization; where authorized modifications have been
made, the user shall ensure that capacity, operation,
warning, and maintenance instruction plates, tags, or
decals are changed accordingly.
(s) Care shall be taken to ensure that all replacement
parts are interchangeable with the original parts and of a
quality at least equal to that provided in the original
equipment.
END OF ASME/ANSI B56.8 - 1988 TEXT

SAFETY INFORMATION
Page xiii
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
GENERAL
The following text is provided as recommended by part II
of ANSI / GCMA Z130.1 - 1993. E-Z-GO, as a member of
the National Golf Car Manufacturers Association
(NGCMA), strongly endorses the contents of this specifi-
cation.
PART II
MAINTENANCE AND OPERATIONS
5. GENERAL SAFETY PRACTICES
5.1. Introduction
Like other machines, golf cars can cause injury if improp-
erly used or maintained. This section contains broad
safety practices recommended for safe golf car opera-
tions. Before operation, the controlling party should
establish such additional specific safety practices as may
be reasonably required for safe operations.
Experience has shown that golf cars which comply with
the provisions stated in Part II of this Standard are safe
when properly operated in accordance with the safety
and operation warnings affixed to every golf car. The safe
operation is enhanced when the golf cars are operated
within a specific set of operation instructions, safety rules
and practices established to meet actual operating ter-
rain and conditions.
The safety information contained in Part II is intended to
provide the controlling party with basic safety information
and to encourage the controlling party to implement a
golf car safety program.
It is suggested and recommended that Part II be
reprinted in the golf car manufacturer’s operation and
service manuals to encourage safe operations and prac-
tices at the controlling party’s facility.
5.2. Safety Survey
The controlling party shall perform 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 steep grades exist, golf car operations
should be restricted to the designated golf car pathways
where possible, and shall be identified with a suitable
warning giving the following information: “Warning, steep
grade, descend slowly with one foot on brake.”
5.2.2. Wet Areas
Wet grassy areas may cause a golf car to lose traction
and may affect stability. Wet areas shall be chained or
roped off to prevent golf car operations or be identified by
a suitable warning not to operate golf cars in this area
due to wet terrain.
5.2.3. Sharp Turns, Blind Corners, Bridge
Approaches
Sharp turns, blind spots, bridge approaches and other
potentially hazardous areas shall be either chained or
roped off to prevent golf car operations or identified with
a suitable warning to the operator of the nature of the
hazard and stating the proper precautions to be taken to
avoid the hazard.
5.2.4. Loose Terrain
Loose terrain may cause a golf car to lose traction and
may affect stability. Areas of loose terrain should be
repaired if possible, or chained or roped off to prevent
golf car operation or identified by a suitable warning to
operators not to operate golf cars in this area due to
loose terrain or possible hazardous conditions.
5.2.5. Golf Car/Pedestrian Interference Areas
Areas where pedestrians and golf cars interfere shall be
avoided whenever possible by rerouting the golf car traf-
fic or the pedestrian traffic to eliminate the interference. If
elimination of the interference is not possible or is highly
impractical, signs shall be erected warning pedestrians
of the golf car traffic and golf car operators of the pedes-
trian traffic and to drive slowly and use extreme caution.

SAFETY INFORMATION
Page xiv 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
6. MAINTENANCE
6.1. Introduction
6.1.1. Golf cars may become hazardous if maintenance
is neglected or improperly performed. Therefore mainte-
nance facilities, trained personnel and procedures in
accordance with the manufacturer’s recommendations
should be provided by the controlling party.
6.2. Preventive Maintenance
A regularly scheduled inspection and preventive mainte-
nance program in accordance with the manufacturer’s
recommendations should be established. Such a pro-
gram will be a valuable tool in providing the golfing patron
with a safe, properly operating golf car and thereby help
to avoid accidents.
6.2.1. Personnel
Only qualified, trained and authorized personnel shall be
permitted to inspect, adjust and maintain golf cars.
6.2.2. Parts and Materials
Only manufacturer’s recommended replacement parts
and materials shall be used.
6.2.3. Ventilation
Maintenance and storage areas shall be properly venti-
lated to avoid fire hazards in accordance with applicable
fire codes and ordinances.
6.2.3.1. Ventilation for gasoline powered golf cars shall
be provided to remove flammable vapors, fumes and
other flammable materials. Consult applicable fire codes
for specific levels of ventilation.
6.2.3.2. Ventilation for electric powered golf cars shall
be provided to remove the accumulation of flammable
hydrogen gas emitted during the charging process. The
amount of hydrogen gas emitted depends upon a num-
ber of factors such as the condition of the batteries, 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 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
changes per hour is recommended. The controlling party
shall consult applicable fire and safety codes for the spe-
cific ventilation levels required as well as the use of
explosion proof electrical apparatus.
6.2.4. Maintenance Procedures
All maintenance shall be performed in accordance with
the manufacturer’s recommended maintenance proce-
dures as outlined in the manufacturer’s operation and
service manuals.
6.2.5. Maintenance Safety Procedures
All maintenance shall be performed in accordance with
the manufacturer’s recommended safety procedures as
outlined in the manufacturer’s operation and service
manuals. The following list of recommended safety pro-
cedures are general in nature and in no way supersede
the manufacturer’s specific instructions.
6.2.5.1. Follow manufacturer’s instructions for immobi-
lizing golf car before beginning any maintenance.
6.2.5.2. Block chassis before working underneath golf
car.
6.2.5.3. Before disconnecting any part of the fuel sys-
tem, drain the system and turn all shut off valves to the
‘OFF’ position to prevent leakage or accumulation of
flammable fuels in the work area.
6.2.5.4. Avoid fire hazards and have fire protection
equipment available.
6.2.5.5. Before performing any maintenance on an elec-
tric golf car, disable the electrical system in accordance
with the manufacturer’s instructions.
6.2.5.6. Use only properly insulated tools when working
on electrically powered golf cars or around batteries.
6.2.5.7. Brakes, steering mechanisms, warning devices,

SAFETY INFORMATION
Page xv
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
governors and all other safety devices shall be inspected
and maintained in a safe and proper operating condition
and shall not be modified as supplied by the manufac-
turer.
6.2.5.8. After each maintenance or repair the golf car
shall be driven by qualified, trained and authorized per-
sonnel to ensure proper operation and adjustment.
6.2.5.9. Driving golf car to check for proper operation
and adjustment after repair shall be performed in an area
that is free of vehicular and pedestrian traffic.
6.2.5.10. Record all maintenance performed in a mainte-
nance record log by date, name of person performing
maintenance and type of maintenance. Controlling party
management should periodically inspect maintenance
log to ensure currency and completeness of entries.
6.2.5.11. Provide operator comment cards to assist in
identifying non-periodic maintenance needs for specific
golf cars.
6.2.6. The controlling party shall maintain in a legible
condition all nameplates, warnings and instructions
which are supplied by the manufacturer.
6.2.7. The controlling party shall not perform any modifi-
cation or addition which affects capacity or safe opera-
tion, or make any change not in accordance with the
owner’s manual without the manufacturer’s prior written
authorization. Where authorized modifications have been
made, the controlling party shall 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 to secure new name-
plates, warnings or instructions which shall then be
affixed in their proper place on the golf car.
7. FUELS HANDLING AND STORAGE/
BATTERY CHARGING
7.1. The controlling party shall supervise the storage
and handling of liquid fuels in accordance with applicable
fire and safety requirements.
7.2. Storage and handling of liquefied petroleum gas
fuels shall be in accordance with American Gas Associa-
tion recommendations and applicable fire safety require-
ments.
7.3. The controlling party shall require battery chang-
ing and charging facilities and procedures to be in accor-
dance with applicable ordinances or regulations (also
see paragraph 6.2.3.2).
7.4. The controlling party shall periodically inspect
facilities and review procedures to be certain that the
procedures in paragraphs 6.2.3.2 and 7.3 are being fol-
lowed.
8. OPERATING SAFETY RULES AND
PRACTICES
8.1. Operator Qualifications
8.1.1. Only authorized persons shall be allowed to oper-
ate golf cars. It is recommended that no persons be
allowed to operate golf cars except those persons who
posses a valid motor vehicle driver’s license.
8.1.2. The controlling party shall display the operation
and safety instructions as recommended by the golf car
manufacturers and the golf course safety rules in a con-
spicuous place near the golf car rental area or golf car
pick-up area. It is also recommended, as with all motor
vehicles, that the warning “Do not operate golf cars when
under the influence of alcohol or drugs.” be posted in a
conspicuous location.

SAFETY INFORMATION
Page xvi 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 1
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
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR
Thank you for your purchase. The vehicle is equipped
with an electronic speed control unit that is the most
advanced in the industry. Before driving the vehicle, we
ask you to spend some time reading this Owner’s Man-
ual and Service Guide. This guide contains information
that will assist you in maintaining your highly reliable
vehicle. This guide covers the operation of several vehi-
cles, therefore some pictorial views may not represent
your vehicle. Physical differences in controls will be illus-
trated. Some illustrations may show items that are
optional for your vehicle.
Most of the service procedures in this guide can be
accomplished by an individual using common automotive
hand tools. Refer to an authorized service representative
for information on servicing the vehicle in accordance
with the Periodic Service Schedule.
To facilitate maintenance, a Service Parts Manual and a
Technician’s Repair and Service Manual is available from
a local Distributor, an authorized Branch or the E-Z-GO
Service Parts Department. When ordering parts or
requesting information for your vehicle, provide vehicle
model, serial number and manufacture code.
BEFORE INITIAL USE
Read, understand and follow safety label on the instru-
ment panel. Be sure you understand the vehicle, its
equipment and how to use it safely. Although the vehicles
have been designed to provide safe and reliable opera-
tion, maintaining good performance depends to a large
extent on the operator. Hydrogen gas is generat-
ed as a natural part of the
lead acid battery charg-
ing process. A 4% concentration of hydrogen gas is
explosive and could cause severe injury or death.
Charging must take place in an area that is adequate-
ly ventilated (minimum of 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 equipment that could cause an electrical
arc.
Hydrogen gas is generated in the charging cycle of bat-
teries and is explosive in concentrations as low as 4%.
Because hydrogen gas is lighter than air, it will collect in
the ceiling of buildings necessitating proper ventilation.
Five air exchanges per hour is considered the minimum
requirement.
Never charge a vehicle in an area that is subject to flame
or spark. Pay particular attention to natural gas or pro-
pane gas water heaters and furnaces.
Before a new vehicle is put into operation, it is recom-
mended that the items shown in the INITIAL SERVICE
CHART be performed (Ref Fig. 1 on page 1).
Vehicle batteries must be fully charged before initial use.
Preparation of Seats for Service
Remove the protective plastic coverings from the seats
before placing the vehicle in service. The only function of
the plastic covering is to protect the seat bottom and
back rest during shipping. If the plastic covering is left on
the seat and becomes torn, dirt may get under the plastic
covering and be ground into the cover material. Water
getting under the plastic covering can become trapped
and eventually will damage the seat assembly.
Charger Installation
To prevent overheating
that may cause serious
damage to the charger
and create the potential for fire, do not block or
obstruct the airways. Portable chargers must be
mounted on a platform above the ground or in such a
manner as to permit the maximum air flow under-
neath and around the charger.
If the charger is operated in an outdoor location, rain and
sunprotectionmustbeprovided(Ref.Fig.2onpage 2).
A dedicated circuit is required for the charger. Refer to
the charger manual for appropriate circuit protection. The
charger may remain plugged into the AC outlet. To
charge the vehicle, refer to the instruction labels on the
charger. Insert the DC plug completely into the vehicle
receptacle located on the panel underneath the driver’s
seat (Ref Fig. 3 on page 2). After inserting the polarized
DC plug, wait a few seconds and observe ammeter on
! !
Fig. 1 Initial Service Chart
ITEM SERVICE OPERATION
Charger Remove from vehicle and properly mount
Batteries Charge batteries
Seats Remove protective plastic covering
Brakes Check hydraulic brake fluid level
Check operation and adjust if necessary
Tires Check air pressure (see SPECIFICATIONS)
! !

Page 2
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR
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
charger to make sure it moves indicating that charger is
charging.
The charger will automatically start a few seconds after
plug insertion. The charger will automatically stop when
batteries are fully charged and the DC plug can be
removed to permit use of the vehicle.
To prevent a physical
hazard that could result
in an electrical shock or
electrocution, be sure that the charger plug is not
damaged and is inserted into a grounded receptacle.
The power (AC) cord is equipped with a grounded
plug, do not attempt to pull out, cut or bend the
ground post.
If vehicle is to be charged with a non - E-Z-GO
charger, refer to the manufacturer’s instructions
supplied with the charger.
SERIAL NUMBER PLATE LOCATION
The serial and manufacturing numbers are located on a
plate on the passenger side of the dash panel (Ref Fig. 4
on page 2).
Design changes take place on an ongoing basis. In order
to obtain correct components for the vehicle, the manu-
facturing date and serial number must be provided when
ordering service parts.
CONTROLS AND INDICATORS
The controls on the vehicle consist of:
•key/light switch
•accelerator pedal
•service brake pedal
•parking brake pedal or handle
•direction selector lever or switch
•horn
•state of charge meter
•run - tow/maintenance switch (PDS only)
Key/Light Switch
The vehicles are equipped with a combination key/light
switch. Located on the dash panel, this switch enables
the basic electrical system of the vehicle to be turned on
and off by turning the key. If the vehicle is equipped with
lights, this switch also has a position for operating the
lights. The lights will illuminate only when the key is
turned to the light icon position (Ref Fig. 5 on page 3).
To prevent inadvertent operation of the vehicle when left
unattended, the key should be turned to the ‘OFF’ posi-
tion and removed.
If the vehicle is equipped with E-Z-GO installed
custom accessories, some accessories remain
operational with the key switch in the ‘OFF’ position.
Fig. 2 Charger Installation
Fig. 3 Charger Receptacle
Provide Protection From Elements
Do Not Block Louvered Airways
NEMA 15 - 5R Grounded AC Receptacle
110 - 120 VAC. Dedicated 15 AMP Circuit
Locations outside the US and Canada: Reference
appropriate local electrical code and charger manu-
facturer recommendations for AC power requirements
! !
Fig. 4 Serial Number Plate Location
OFF
OFF
ON
ON