- DL manuals
- Ezgo
- Utility Vehicle
- SHUTTLE 4
- Service Manual
Ezgo SHUTTLE 4 Service Manual
Summary of SHUTTLE 4
Page 1
19 17 18 13 6 5 9 15 16 7 8 10 4 3 11 1 - includes items 3 - 16 ref fcv 7 electric & precision drive system™ personnel carriers and 5 passenger golf car starting model year: 2002 service parts manual 28736-g01 revised: 12/2002.
Page 2: Service Parts Manual
Page i service parts manual service parts manual electric and precision drive system™ personnel carriers and 5 passenger golf car vehicles shuttle™ 4 shuttle™ 6 te5 te5 pds textron golf, turf & specialty products reserves the right to make design changes without obligation to make these changes on u...
Page 3
Page ii notes service parts manual to obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized branch or the warranty department with vehicle serial number and manufacturer code. The use of non original equipment manufacturer (oem) parts may void...
Page 4
Page iii table of contents service parts manual section page no. How to use the service parts manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V illustrated parts breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5
Page iv table of contents service parts manual notes:.
Page 6
Page vii service parts manual this manual is divided into several sections: general information • table of contents • how to use the service parts manual illustrated parts breakdown • contains illustrations and parts lists for all systems of the vehicle appendix • contains a listing of specialty pro...
Page 7
Page viii how to use the service parts manual service parts manual 1. When the part number is not known • determine the function and application of the part required. Turn to the index of major components and select the most appropriate component description. • turn to the page number indicated and ...
Page 8: Illustrated Parts Breakdown
Page ix service parts manual illustrated parts breakdown illustrated parts breakdown.
Page 9
Page x how to use the service parts manual service parts manual.
Page 10
Page xi service parts manual.
Page 11: Accelerator
Page a-1 service parts manual 1 - includes items 3 - 43 31 - includes items 32 - 35 33 - includes items 34, 35 16 15 14 11 12 13 17 to direction selector harness 3 29 28 9 7 8 4 5 45 3 26 20 19 24 23 22 22 ref acl 7-1 accelerator.
Page 12: Accelerator
Page a-2 service parts manual 35 34 37 32 42 37 41 43 39 38 46 ref acl 7-2 accelerator.
Page 13: Accelerator
Page a-3 service parts manual when ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3 4 5 description qty. 1 ...
Page 14: Accelerator
When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3 4 5 description qty. Page a-4 service parts manual 30...
Page 15: Battery Charger (Portable)
Page b-1 service parts manual 1 3 2 ref bcp 7 battery charger (portable).
Page 16: Battery Charger (Portable)
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 17: Battery Charger (On Board)
Page b-3 service parts manual 10 11 12 6 7 8 14 4 3 ref bco 7 1 battery charger (on board).
Page 18: Battery Charger (On Board)
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 19: Body
Page c-1 service parts manual 27 29 18 37 41 5 1 1 - includes items 2 - 5 22 21 24 25 23 43 45 44 46 38 42 4 2 3 8 9 41 19 39 49 48 7 11 12 14 15 ref bod 7-1 body.
Page 20: Body
Page c-2 service parts manual 33 34 28 113 105 106 112 111 30 29 32 107 108 109 110 114 114 52 53 57 58 54 55 56 ref bod 7-2 body.
Page 21: Body
Page c-3 service parts manual 79 77 76 71 72 80 86 81 85 73 87 74 78 64 65 68 62 61 60 62 67 66 68 98 100 101 99 102 89 90 91 92 93 94 95 96 te5 te5 71 - includes items 73, 74 72 - includes items 73, 74 90 - includes items 91 144 142 143 ref bod 7-3 body.
Page 22: Body
Page c-4 service parts manual 139 140 136 137 135 138 124 127 128 117 118 129 129 130 119 120 121 133 132 126 121 122 ref bod 7-4 body.
Page 23: Body
Page c-5 service parts manual 172 146 147 171 148 148 169 168 167 163 164 150 151 152 153 154 155 157 158 159 161 162 164 166 ref bod 7-5 body.
Page 24: Body
Page c-6 service parts manual 180 178 181 182 179 177 184 185 186 188 189 189 190 192 193 176 - includes items 177 - 179 ref bod 7-6 body.
Page 25: Body
Page c-7 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 26: Body
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 27: Body
Page c-9 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 28: Body
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 29: Body
Page c-11 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional i...
Page 30: Body
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 31: Body
Page c-13 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional i...
Page 32: Body
Page c-14 service parts manual body.
Page 33: Brakes - Hydraulic
Page d-1 service parts manual 6 6 7 9 10 11 13 14 19 18 23 24 25 26 27 28 33 37 40 38 39 42 43 43 44 47 34 50 51 53 54 56 57 57 58 59 62 63 64 66 65 26 48 61 17 20 21 24 46 (with lights) (without lights) 35 1 - includes items 2 - 4 16 - includes items 17 - 19 32 - includes items 33 - 35 37 - include...
Page 34: Brakes - Hydraulic
Page d-2 service parts manual 103 axle t ube 96 84 97 95 79 85 69 - includes items 71 - 92 70 - includes items 71 - 92 73 - includes items 74 - 76 87 - includes items 88 - 92 82 91 89 90 88 71 81 80 94 92 f ront of v ehicle 83 106 99 100 74 75 76 78 71 73 102 104 ref brh 7-2 brakes - hydraulic.
Page 35: Brakes - Hydraulic
Page d-3 service parts manual 118 119 121 122 124 125 123 130 131 132 133 134 135 109 129 128 109 - includes items 110 - 116 127 120 ref brh 7-3 brakes - hydraulic.
Page 36: Brakes - Hydraulic
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 37: Brakes - Hydraulic
Page d-5 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 38: Brakes - Hydraulic
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 39: Brakes - Hydraulic
Page d-7 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 40: Brakes - Hydraulic
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 41: Direction Selector
Page e-1 service parts manual 11 7 19 3 12 1 - includes items 2 - 26 2 - includes items 3 - 5 16 14 2 18 25 26 20 30 31 8 9 4 22 21 5 23 24 9 29 28 13 40 33 34 35 37 38 39 41 42 43 44 46 47 48 49 for dash mounted direction selector, see electrical system 15 ref dsl 7 direction selector.
Page 42: Direction Selector
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 43: Direction Selector
Page e-3 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 44: Direction Selector
Page e-4 service parts manual direction selector.
Page 45: Electrical System
Page f-1 service parts manual a1 s1 a2 s2 30 24 26 33 31 32 23 19 14 18 21 20 15 31 28 27 16 17 2 12 11 8 9 6 7 5 4 10 25 18 19 14 15 a d b c 1 - includes items 2 - 11 3 - includes items 4 - 11 ref ele 7-1 electrical system.
Page 46: Electrical System
Page f-2 service parts manual pds models only 117 118 red grn/blk state of charge meter and key switch 39 36 37 38 43 52 on off pds models only: dash mounted direction selector, state of charge meter and key switch 115 108 109 110 111 112 on off 49 54 53 41 44 45 46 47 48 42 113 40 - includes items ...
Page 47: Electrical System
Page f-3 service parts manual front of vehicle blk yel 64 63 61 62 electrical tape column mounted horn button floor mounted horn button ho rn floorboard 103 101 102 105 104 102 grn red orn/wht blu/wht 57 56 58 59 ref ele 7-3 electrical system.
Page 48: Electrical System
Page f-4 service parts manual 69 driver side passenger side 75 76 67 66 71 68 70 72 72 y r r g 76 75 74 headlight ref ele 7-4 electrical system.
Page 49: Electrical System
Page f-5 service parts manual turn signal 91 88 89 90 87 81 82 83 79 80 78 rear fender 85 ref ele 7-5 electrical system.
Page 50: Electrical System
Page f-6 service parts manual hour meter 94 95 96 97 98 hour meter solenoid blk yel (+) (-) 93 - includes items 94 - 98 ref ele 7-6 electrical system.
Page 51: Electrical System
Page f-7 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 52: Electrical System
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 53: Electrical System
Page f-9 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 54: Electrical System
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 55: Electronic Speed Control
Page g-1 service parts manual 2 3 28 29 30 5 6 7 8 10 12 13 14 16 24 17 9 26 27 wht blk orn blk red from control harness a2 b+ 21 20 23 19 18 22 to batteries to direction selector 11 1 - includes items 2 - 24 17 - includes items 18 - 21 b- m- to accelerator harness ref esc 7 electronic speed control.
Page 56: Electronic Speed Control
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 57
Page g-3 service parts manual j1 j2 j3 f1 f2 b+ b- m- #10 black from motor f2 (power harness) #4 black from motor a1 (power harness) #4 black from motor a1 (power harness) #4 black from motor a2 (power harness) #18 yellow from j1 pin 5 (control harness) #18 blue from j1 pin 17 (control harness) #18 ...
Page 58
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 59: Front Suspension/steering
Page h-1 service parts manual front suspension/steering ref fss 1-1 52 34 37 11 33 51 48, 49 36 *note: tie rod not shown for clarity 1 53 part of frame 45 43 44 34 4,15 19,30 53 51 40 41* 42* part of frame front of vehicle 8 6 6 5 10 9 21 22 7 20 25 50 23 4 lug 5 lug 35 *truck models only 3 - includ...
Page 60: Front Suspension/steering
Page h-2 service parts manual front suspension/steering front of vehicle 108 107 106 105 68 64 65 58 57 59 60 67 66 56 63 100 102 101 81,86 84,89 109 113 115 79 92 93 116 114 56 - includes items 57 - 68 64 - includes items 65 - 68 81 - includes items 82 - 84 86 - includes items 87 - 89 100 - include...
Page 61: Front Suspension/steering
Page h-3 service parts manual where applicable, the use of non ul parts will void any ul listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for...
Page 62: Front Suspension/steering
Where applicable, the use of non ul parts will void any ul listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item ...
Page 63: Front Suspension/steering
Page h-5 service parts manual where applicable, the use of non ul parts will void any ul listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for...
Page 64: Front Suspension/steering
Where applicable, the use of non ul parts will void any ul listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item ...
Page 65: Front Suspension/steering
Page h-7 service parts manual where applicable, the use of non ul parts will void any ul listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for...
Page 66: Front Suspension/steering
Page h-8 service parts manual front suspension/steering notes:.
Page 67: Electric Motor
Page j-1 service parts manual 3 16 4 18 5 17 19 8 9 1 - includes items 2 - 11 14 - includes items 15 - 28 pds only 10 22 7 21 6 20 11 23 24 25 26 27 28 2 15 x 1 x 2 a 1 a 2 ref mtr 7 electric motor.
Page 68: Electric Motor
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 69: Rear Axle - Hydraulic
Page k-1 service parts manual 6 7 5 3 4 note: apply a light coat of moly grease to male spline before assembly. Reference item 10 13 14 16 15 11 18 axle tube 1 - includes items 3 - 8 2 - includes items 3 - 8 a2 s2 20 front of vehicle brake mechanism brake drum 19 8 ref rax 7 rear axle - hydraulic.
Page 70: Rear Axle - Hydraulic
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 71: Rear Suspension
Page l-1 service parts manual 11 12 1 2 3 4 5 7 8 9 13 14 15 17 18 19 20 21 22 23 21 22 ref rsp 7 rear suspension.
Page 72: Rear Suspension
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 73: Seating
Page m-1 service parts manual 12 floormat 6 23 24 14 5 1 8 9 15 10 11 19 20 te5 shuttle 22 4 16 18 17 driver side passenger side 31 32 ref sea 7-1 seating.
Page 74: Seating
Page m-2 service parts manual 26 27 28 29 33 2 3 ref sea 7-2 seating.
Page 75: Seating
Page m-3 service parts manual 37 46 48 47 42 43 44 45 38 39 see body section shuttle 41 - includes items 42 - 48 te5 54 - includes items 55 - 58 41 53 55 56 57 58 51 38 39 50 37 ref sea 7-3 seating.
Page 76: Seating
Page m-4 service parts manual 70 78 77 76 69 67 75 62 65 63 71 66 68 73 61 - includes items 62 - 73 64 - includes items 65 - 71 shuttle 6 64 ref sea 7-4 seating.
Page 77: Seating
Page m-5 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 78: Seating
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 79: Seating
Page m-7 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 80: Seating
Page m-8 service parts manual seating.
Page 81: Weather Protection
Page n-1 service parts manual 6 5 5 strut 3 7 4 2 front of vehicle windshield retainer fold down windshield 1 - includes items 2 - 9 strut 8 9 front of vehicle 16 15 strut 13 17 14 12 front of vehicle rear windshield 15 11 - includes items 12 - 17 24 23 23 strut 21 25 22 20 front of vehicle full win...
Page 82: Weather Protection
Page n-2 service parts manual sun top 38 45 47 front strut 45 46 front of vehicle 29 41 42 39 40 (inside) 43 49 (front passenger side shown) front of vehicle 44 48 36 30, 31 34 34 33 (driver side shown) 35 sun top (shuttles) a c b e 45 45 32 46 rear strut 37 28 rear of vehicle d b c a e d 27 - inclu...
Page 83: Weather Protection
Page n-3 service parts manual 57 52 55 54 (driver side shown) front of vehicle 58 56 55 59 61 60 63 62 64 65 68 67 front of vehicle 66 66 69 67 68 (driver side rear shown) front of vehicle sun top (te5/tg5) a d c b a d b 51 - includes items 52 - 69 c ref wea 7-3 weather protection.
Page 84: Weather Protection
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 85: Weather Protection
Page n-5 service parts manual the use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional in...
Page 86: Weather Protection
The use of non u.L. Parts will void any u.L. Listing. When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3...
Page 87: Wheels and Tires
Page p-1 service parts manual 4 9 2 7 3 8 11 8" chrome hubcap 14 silver / gold spoke hubcap 15, 16 6" chrome hubcap 13 1 - includes items 2 - 4 6 - includes items 7 - 9 ref whl 7 wheels and tires.
Page 88: Wheels and Tires
When ordering parts, please specify the model and serial number of the product. * indicates a component that is not available as an individual part. G** indicates consult customer service department for additional information. Item part no. 1 2 3 4 5 description qty. Page p-2 service parts manual 1 ...
Page 89: Wheels and Tires
Page p-3 service parts manual wheels and tires.
Page 90: Specialty Products
Appendix a-1 service parts manual specialty products specialty products.
Page 91
Appendix a-2 specialty products service parts manual special tools part no. Battery maintenance kit ........................................................................................................................ 25587-g01 seal installation tool (rear axle shaft seal) ..........................
Page 92
Appendix a-3 service parts manual specialty products battery cleaner, 32 ounce (950 ml) with trigger sprayer ....................................................... 75506-g01 bio-degradeable cleaner, 32 ounce (950 ml) with trigger sprayer ..................................... 75507-g01 multi-purpose...
Page 93
Appendix a-4 specialty products service parts manual notes:.
Page 94: Options/accessories
Appendix b-1 service parts manual options/accessories options/accessories.
Page 95
Appendix b-2 options/accessories service parts manual item kit no. Comments accessories listing kit no. Section chrome hub cap 8" . . . . . . . . . . . . . . . . . . . . . . . . . . 14913-g1 . . . . . . . . . . . . . . Wheels and tires chrome hub cap 6" . . . . . . . . . . . . . . . . . . . . . . . ...
Page 96: Index of
Index-1 service parts manual index of major components index of major components.
Page 97
Index-2 index of major components service parts manual by part description b battery rack ................................................................ C-8 bearing and race ........................................................ H-3 brake assembly (driver side)................................. D...
Page 98
Index-3 service parts manual index of major components p pedal box assembly ................................................... A-3 pedal box assembly, pds model only ................. A-3 pinion seal..................................................................... H-5 push rod assembly ...........
Page 99
Index-4 index of major components service parts manual 70643-g03 master cylinder service kit ............... D-5 70664-g02 leaf spring (heavy duty)....................... H-4 70830-g01 direction selector assembly ............ E-2 70835-g** seat bottom (te5) ...................................... M-6...
Page 100
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. Technical communications department 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...