28641-G01 English OWNER’S MANUAL AND SERVICE GUIDE ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR STARTING MODEL YEAR: 2001
SAFETY 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 prevent 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.
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.
NOTES 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.
TABLE OF CONTENTS SAFETY ................................................................................................................... Inside covers NOTES .........................................................................................................................................ii SAFETY INFORMATION............................................................................................................. v BEFORE INITIAL USE ..............................................................
TABLE OF CONTENTS PDS MODEL VEHICLES ..........................................................................................................10 TIRES ....................................................................................................................................... 10 Tire Repair ........................................................................................................................................................ 11 Wheel Installation ..................................
SAFETY INFORMATION 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.
SAFETY INFORMATION 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.
SAFETY INFORMATION 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.
SAFETY INFORMATION Notes: Page viii Owner’s Manual and Service Guide
SAFETY INFORMATION 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. manual without the manufacturer’s prior written authorization.
SAFETY INFORMATION 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 turer; 4.8.
SAFETY INFORMATION 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 authorized speed limits. Under normal traffic conditions keep to the right.
SAFETY INFORMATION 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 manufacturer’s recommendations and the following practices. (a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed.
SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL 5.2.1. Steep Grade 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 specification.
SAFETY INFORMATION 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 maintenance facilities, trained personnel and procedures in accordance with the manufacturer’s recommendations should be provided by the controlling party. 6.2.
SAFETY INFORMATION 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 manufacturer. 6.2.5.8. After each maintenance or repair the golf car shall be driven by qualified, trained and authorized personnel to ensure proper operation and adjustment. 6.2.5.9.
SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 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 Manual and Service Guide.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings SERIAL NUMBER PLATE LOCATION Provide Protection From Elements 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.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Parking Brake Direction Selector (PDS) State of Charge Meter The foot operated parking brake is located at the left side of the instrument panel just above the floor. The brake is engaged when the pedal is depressed and is disengaged when the accelerator pedal is depressed. OFF ON Fig.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Horn The horn activating button is located either on the steering column or on the floor to the left of the brake pedal (Ref Fig. 8 on page 4). The horn is located under the seat on the driver side.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The PDS is a low power consumption unit but it will drain the vehicle batteries over a period of time if not recharged.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Additional Warnings and Cautions (applicable to PDS vehicles) alarm will beep indicating that vehicle is in ‘walk away’ condition. To prevent loss of control, do not move PDS vehicle direction selector while the vehicle is in motion.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To start the electric vehicle on a hill: Place left foot on the service brake. Place the key in the key switch, and turn the key to the ‘ON’ position. Move the direction selector to the direction desired. Place right foot on accelerator. Release park brake by applying the accelerator pedal to start the motor.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings DIRECTION SELECTOR ADJUSTMENT To ensure forward and reverse will fully engage when selected with the handle, adjust handle linkage at trunnion. Ensure handle travel is permitting the direction selector mechanism to fully engage both forward and reverse (Ref. Fig. 10 on page 8).
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Use maximum of three pumps of grease for each grease fitting - Over greasing may damage grease seals. Center of Front Axle Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PDS MODEL VEHICLES Test the PDS system at regular intervals by allowing the vehicle to roll down an incline with the accelerator pedal released. Braking force should be felt at approximately 2 mph (3 kph) indicating that the PDS system is functioning.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings lower pressure prevents tires from cutting into the turf. For vehicles being used on paved or hard surfaces, tire inflation pressure should be in the higher allowable range, but under no condition should inflation pressure be higher than recommended on tire sidewall.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CARE AND CLEANING OF THE VEHICLE To prevent cosmetic damage, do not use any abrasive or reactive solvents to • clean plastic parts. It is important that proper techniques and cleaning materials be used.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings TRAILERING HARDWARE To prevent personal injury to occupants of other highway vehicles, be sure that the vehicle and contents are adequately secured to trailer. Do not ride on vehicle being trailered. Remove windshield before trailering. Maximum speed with top is 50 mph (80 kph).
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ✓ Check ♦ Clean, Adjust, etc.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BATTERIES AND CHARGING Safety Always observe the following warnings when working on or near batteries: To prevent battery explosion that could result in severe personal injury or death, keep all smoking materials, open flame or sparks away from the batteries. Hydrogen gas is formed when charging batteries.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Charge the batteries after each days use. Monthly • Inspect all wiring for fraying, loose terminations, corrosion or deterioration of insulation. • Check that the electrolyte level is correct and add suitable water as required. • Clean the batteries and wire terminations.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Watering gun similar to the type included in the E-Z-GO Battery Maintenance Kit 1 1/2 gallons (6 liters) Clear Water 1/4 Cup (60 ml) Sodium Bicarbonate (Baking Soda) Valve consistently fills to a predetermined level Electrolyte Level Pure Water Non Metalic Wand 2 gallon (7.5 liter) Garden Sprayer Single Battery Cell Fig.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings E L E C T R O L Y T E T E M P E R A T U R E O F +15 O C -9 BL+ to Solenoid Front of Vehicle BL- to Bon ESC To Charger +5 -15 -5 -21 -15 -26 + + + - + -25 -32 -35 -37 - - -45 -43 - - + - -55 -48 -65 -54 + -75 -60 -85 -65 -95 -71 1.100 1.140 1.180 1.220 1.260 1.300 1.120 1.160 1.200 1.240 1.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings In some portable chargers there will be a rattle present in the body of the DC plug. This rattle is caused by an internal magnet contained within the charger plug. The magnet is part of the interlock system that prevents the vehicle from being driven when the charger plug is inserted in the vehicle charging receptacle.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Using A Hydrometer 1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading. Examine the color of the electrolyte. A brown or gray coloration indicates a problem with the battery and is a sign that the battery is nearing the end of its life. 2.
ELECTRIC POWERED PERSONNEL CARRIERS & GOLF CAR Read all of manual to become thoroughly familiar with this vehicle.
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 23
GENERAL SPECIFICATIONS SHUTTLE 4 ELECTRIC POWERED PERSONNEL / CARGO CARRIER WEIGHT (without batteries) ..................................................... 710 lbs. (322 kg) TIRES (6 ply rated) .................................................................. 18 x 8.50 x 8 TIRE PRESSURE .................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ..............................1200 lbs.
GENERAL SPECIFICATIONS SHUTTLE 6 ELECTRIC POWERED PERSONNEL CARRIER WEIGHT (without batteries) ..................................................... 710 lbs. (322 kg) TIRES (6 ply rated) .................................................................. 18 x 8.50 x 8 TIRE PRESSURE .................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) .............................. 1200 lbs. (544 kg) CHASSIS .....
GENERAL SPECIFICATIONS TE5 ELECTRIC POWERED 5 PASSENGER GOLF CAR WEIGHT (without batteries) ..................................................... 710 lbs. (322 kg) TIRES (6 ply rated) .................................................................. 18 x 8.50 x 8 TIRE PRESSURE .................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) ..............................1200 lbs. (544 kg) CHASSIS .........
GENERAL SPECIFICATIONS TE5 PDS ELECTRIC POWERED 5 PASSENGER GOLF CAR WEIGHT (without batteries) ..................................................... 710 lbs. (322 kg) TIRES (6 ply rated) .................................................................. 18 x 8.50 x 8 TIRE PRESSURE .................................................................... 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passengers, cargo and accessories) .............................. 1200 lbs. (544 kg) CHASSIS ....
GENERAL SPECIFICATIONS Lowest Clearance At Differential 4.25 in. (10.8 cm) (All Models) SHUTTLE 4 SHUTTLE 6 93.5 in. (237 cm) 122 in. (310 cm) 132.5 in. (337 cm) 134.5 in. (342 cm) 46.5 in. (118 cm) TE5 93.5 in. (237 cm) 122 in. (310 cm) 46.5 in. (118 cm) Fig.
GENERAL SPECIFICATIONS 67 in. (170 cm) 49 in. (123 cm) Front 33.5 in. (85 cm) RECOMMENDED MAX SIDE TILT 25% or 14˚ MAX Rear 38 in. (97 cm) RECOMMENDED MAX RAMP GRADE 25% or 14˚ MAX Fig.
GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER 29 ft. (8.8 m) TE5 SHOWN 94 in. (240 cm) INTERSECTING AISLE CLEARANCE 94 in. (240 cm) Fig.
Read and understand the following warnings before attempting to operate the vehicle: ! ! To prevent personal injury or death, observe the following: When vehicle is to be left unattended, engage parking (PARK) brake, move direction selector to neutral, turn key to ‘OFF’ position and remove key. Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain and traffic conditions. Consider environmental factors which effect the terrain and the ability to control the vehicle.
E-Z-GO Division of Textron Inc. P.O. Box 388 Augusta, Georgia 30903-0388 USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc.
