Ezgo ELECTRIC POWERED PERSONNEL CARRIERS User manual

A Textron Company
ELECTRIC POWERED
PERSONNEL CARRIERS
AND GOLF CAR
TECHNICIAN’S
REPAIR AND SERVICE MANUAL
600938
ISSUED SEPTEMBER 2004 REVISED OCTOBER 2007

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.
Engine exhaust from
this product con-
tains chemicals
known, in certain quantities, to cause can-
cer, birth defects, or other reproductive
harm. The exhaust emissions of this vehicles engine
is regulated by the Federal EPA. Significant
fines could result from modifications or tampering with the
engine, fuel, ignition or air intake systems.
Battery posts, termi-
nals and related ac-
cessories contain
lead and lead compounds. Wash hands after
handling.
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Read and understand all labels located on the vehicle. For any questions on any of the information, contact manufac-
turer’s 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 re-sold.
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
TECHNICIAN’S REPAIR AND
SERVICE MANUAL
ELECTRIC
UTILITY VEHICLES
Shuttle 2
Shuttle 4
Shuttle 6
Bellhop 2
Bellhop 4
Bellhop 6
TXT 5E
STARTING MODEL YEAR: 2005
The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include
these changes on units leased/sold previously.
The information contained in this Manual may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice.
The E-Z-GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCI-
DENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials 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., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page ii
NOTES
Owner’s Manual and Service Guide
This vehicle has been designed and manufactured in the United States of America (USA) as
a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in
the USA unless otherwise indicated.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling battery may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory
specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original
vehicle specifications in order to maintain the United States of America Federal and State
emission certification applicable at the time of manufacture.
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).

Page iii
Repair and Service Manual
TABLE OF CONTENTS
TITLE PAGE
Safety...........................................................................................................................Inside Covers
Notes.................................................................................................................................................ii
Safety Information............................................................................................................................ v
TITLE SECTION
General Information & Routine Maintenance...................................................................................A
Safety...............................................................................................................................................B
Body and Truckbed..........................................................................................................................C
Wheels and Tires .............................................................................................................................D
Front Suspension and Steering........................................................................................................E
Electronic Speed Control..................................................................................................................F
Brakes - Front Disc.......................................................................................................................... G
Brakes - Rear Mechanical................................................................................................................H
Electrical System.............................................................................................................................. J
Motor................................................................................................................................................K
Batteries and Charging..................................................................................................................... L
Rear Suspension.............................................................................................................................M
Rear Axle..........................................................................................................................................N
Weather Protection...........................................................................................................................P
Paint................................................................................................................................................ Q
Troubleshooting................................................................................................................................R
Lightning Protection and Grounding.................................................................................................S
General Specifications .....................................................................................................................T

Page iv Repair and Service Manual
TABLE OF CONTENTS
Notes:

TABLE OF CONTENTS FOR SECTION ‘A’
SECTION TITLE PAGE NO.
Page A-i
Repair and Service Manual
A
GENERAL INFORMATION & ROUTINE MAINTENANCE
SERIAL NUMBER LABEL LOCATION ............................................................................................A - 1
TRANSPORTING VEHICLE ............................................................................................................A - 1
TOWING................................................................................................................................A - 1
HAULING...............................................................................................................................A - 1
SERVICING THE ELECTRIC VEHICLE..........................................................................................A - 1
ROUTINE MAINTENANCE..............................................................................................................A - 2
REAR AXLE.....................................................................................................................................A - 2
BRAKES...........................................................................................................................................A - 2
TIRES..............................................................................................................................................A - 2
LIGHT BULB REPLACEMENT ........................................................................................................A - 2
CARE AND CLEANING OF THE VEHICLE.....................................................................................A - 2
VEHICLE CARE PRODUCTS..........................................................................................................A - 3
TOP AND WINDSHIELD..................................................................................................................A - 3
HARDWARE ....................................................................................................................................A - 4
TORQUE SPECIFICATIONS...........................................................................................................A - 4
PERIODIC SERVICE SCHEDULE...................................................................................................A - 5
LIST OF ILLUSTRATIONS
Fig. 1 Initial Service Chart ..............................................................................................................A - 1
Fig. 2 Lubrication Point...................................................................................................................A - 2
Fig. 3 Torque Specifications............................................................................................................A - 4
Fig. 4 Periodic Service Schedule ....................................................................................................A - 5

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-ii Repair and Service Manual
Notes:

A
GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-1
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes,
SERIAL NUMBER LABEL LOCATION
Two serial number and manufacture date code label are
on the vehicle. One is placed on the body below the
front, driver side of the seat. The other is located on the
chassis under the seat.
Design changes take place on an ongoing basis. In order
to obtain correct components for the vehicle, the manu-
facture date code, serial number and vehicle model must
be provided when ordering service parts.
TRANSPORTING VEHICLE
TOWING
This vehicle is not
designed to be towed.
It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flatbed truck or other suit-
able transport.
HAULING
To reduce the possi-
bility of severe inju-
ry or death while
transporting vehicle:
Secure the vehicle and contents.
Never ride on vehicle being transported.
Always remove windshield before trans-
porting.
Maximum speed with sun top installed is
50 mph (80 kph).
If the vehicle is to be transported at highway speeds, the
sun top must be removed and the seat bottom secured.
When transporting vehicle below highway speeds, check
for tightness of hardware and cracks in sun top at mount-
ing points. Always remove windshield when transporting.
Always check that the vehicle and contents are ade-
quately secured before transporting. The rated capacity
of the trailer or truck must exceed the weight of the vehi-
cle (see GENERAL SPECIFICATIONS for vehicle
weight) and load plus 1000 lbs. (454 kg). Lock the park
brake and secure the vehicle using ratchet tie downs.
SERVICING THE ELECTRIC VEHICLE
To prevent severe
injury or death,
resulting from
improper servicing techniques, observe the
following Warnings:
Do not attempt any type of servicing
operations before reading and under-
standing all notes, cautions and warn-
ings in this manual.
Any servicing requiring adjustments to
be made to the powertrain while the
motor is running must be made with
both drive wheels raised.
Wear eye protection when
working on the vehicle. In par-
ticular, use care when working
around batteries, or using sol-
vents or compressed air.
To reduce the possibility of causing an
electrical arc, which could result in a bat-
tery explosion, turn off all electrical
loads from the batteries before removing
any heavy gauge battery wires.
To prevent the possibility of motor disin-
tegration, never operate vehicle at full
throttle for more than 4 - 5 seconds while
vehicle is in a “no load” condition.
It is in the best interest of both vehicle owner and servic-
ing dealer to carefully follow the procedures recom-
mended in this manual. Adequate preventive
maintenance, applied at regular intervals, is the best
guarantee for keeping the vehicle both dependable and
economical.
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 A-1).
Vehicle batteries must be fully charged before initial use.
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Fig. 1 Initial Service Chart
ITEM SER VICE OPERATION
Batteries Charge batteries
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Establish acceptable stopping distance
Check hydraulic brake fluid level
Tires Check air pressure (see SPECIFICATIONS)
Portable Remove from vehicle and properly mount
Charger

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-2 Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
ROUTINE MAINTENANCE
Some maintenance items must be serviced
more frequently on vehicles used under severe
driving conditions.
This vehicle will give years of satisfactory service provid-
ing it receives regular maintenance. Refer to the Periodic
Service Schedule for appropriate service intervals (Ref
Fig. 4 on page A-5). Refer to Lubrication Point for appro-
priate lubrication location (Ref Fig. 2 on page A-2).
Do not use more than three (3)
pumps of grease for each grease
fitting at any one time- Excess grease may cause
grease seals to fail or grease migration into areas
that could damage components.
Putting more than three pumps of grease in a grease fit-
ting could damage grease seals and cause premature
bearing failure.
REAR AXLE
The only maintenance required for the first five years is
the periodic inspection of the lubricant level. The rear
axle is provided with a lubricant level check/fill plug
located on the bottom of the differential. Unless leakage
is evident, the lubricant need only be replaced after five
years. The procedure to follow for checking the rear axle
lubricant level is in the REAR AXLE section.
BRAKES
After the vehicle has been put into service, it is recom-
mended that the brakes be checked daily by performing
a brake test.
To prevent severe
injury or death
resulting from oper-
ating a vehicle with improperly operating
brake system, the braking system must be
properly maintained. All driving brake tests
must be done in a safe location with regard
for the safety of all personnel.
For information on conducting a brake test, refer to
BRAKES section.
TIRES
Tire condition should be inspected per the Periodic Ser-
vice Schedule. Inflation pressures should be checked
when the tires are cool. Be sure to reinstall valve dust
cap after checking or inflating. For additional information,
refer to WHEELS AND TIRES section.
LIGHT BULB REPLACEMENT
Refer to ELECTRICAL SYSTEM for information regard-
ing light bulb replacement.
CARE AND CLEANING OF THE
VEHICLE
When pressure washing vehi-
cle, do not use pressure in
excess of 700 psi (4825 kPa). To prevent cosmetic
damage, do not use any abrasive or reactive sol-
vents to clean plastic parts.
It is important that proper techniques and cleaning mate-
rials be used. Using excessive water pressure may
cause damage to seals, plastics, the electrical system,
body finish or seat material. Do not use pressure in
excess of 700 psi (4825 kPa) to wash vehicle.
Normal cleaning of vinyl seats and plastic or rubber trim
require the use of a mild soap solution applied with a
sponge or soft brush and wipe with a damp cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require
the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive
appearance and durable protection. Frequent washing
with lukewarm or cold water is the best method of pre-
serving those painted surfaces.
Do not use hot water, strong soap or harsh chemical
detergents.
Fig. 2 Lubrication Point
View From Underside Of Vehicle
Rack Ball Joint
Ref Lub 1
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