Related Manuals for Cushman BELLHOP 2
Summary of Contents for Cushman BELLHOP 2
- Page 1 606893 A Textron Company OWNER’S MANUAL AND SERVICE GUIDE GASOLINE POWERED PERSONNEL CARRIERS AND GOLF CAR ISSUED OCTOBER 2007 REVISED JUNE 2012...
- Page 2 SA FE TY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. 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.
- Page 3 GASOLINE POWERED CARGO, PERSONNEL CARRIER AND GOLF CAR VEHICLES BELLHOP 2 BELLHOP 4 BELLHOP 6 Starting Model Year 2008 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.
- Page 4 N O T E S 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.
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Page 5: Table Of Contents
TA B L E O F C O N T E N T S SAFETY ......................INSIDE COVERS NOTES............................II SAFETY INFORMATION......................V BEFORE INITIAL USE ........................1 Fig. 1 Initial Service Chart ........................1 CONTROLS AND INDICATORS ....................1 KEY/LIGHT SWITCH ............................1 Fig. - Page 6 CAPACITIES AND REPLACEMENT PARTS .....................24 Fig. 35 Capacities and Replacement Parts...................24 GENERAL SPECIFICATIONS ....................27 BELLHOP 2 GASOLINE POWERED CARGO CARRIER .................28 BELLHOP 4 GASOLINE POWERED PERSONNEL / CARGO CARRIER ............29 BELLHOP 6 GASOLINE POWERED PERSONNEL CARRIER ................30 Fig. 36 Vehicle Dimensions .........................31 Fig.
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Page 7: Safety
S A F E T Y I N F O R M AT I O N SAFETY This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. - Page 8 S A F E T Y I N F O R M AT I O N This vehicle conforms to the current applicable standard(s) 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 of the United States of America (USA) and are not equipped for operation on public streets.
- Page 9 S A F E T Y I N F O R M AT I O N battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. • Use specified replacement parts. Never use replacement parts of lesser quality. •...
- Page 10 S A F E T Y I N F O R M AT I O N NOTES: Page viii Owner’s Manual and Service Guide...
- Page 11 S A F E T Y I N F O R M AT I O N The following text is provided as recommended by part II of ANSI/ITSDF B56.8 - 2005. The manufacturer strongly endorses the contents of this specification. 6 GENERAL SAFETY PRACTICES 6.1 Introduction 6.1.1 Like other machines, carriers can cause injury if improperly used or maintained.
- Page 12 S A F E T Y I N F O R M AT I O N (2) Maintain a permanent record of the design, test(s), and implementation of the modification or alteration; (3) Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals; (4) Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been mod- ified or altered together with the date of the modification or alteration, and the name of the organization that accomplished the tasks.
- Page 13 S A F E T Y I N F O R M AT I O N the carrier requires lights and, if so, shall equip the carrier with appropriate lights. 6.8 Control of Noxious Gases and Fumes When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be main- tained within limits specified in the American Conference of Governmental Industrial Hygienists publication,:Threshold Limit Values for Chemical Substances and Physical Agents in the Workroom Environment.”...
- Page 14 S A F E T Y I N F O R M AT I O N 7.3.1.3 Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger other persons. 7.3.1.4 Riding on the carrier by persons other than the operator is authorized only on personnel seat(s) provided by the manufacturer.
- Page 15 S A F E T Y I N F O R M AT I O N 7.3.3 Loading 7.3.3.1 Refer to operators’ manual for loading instruction. 7.3.3.2 Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered, operate with extra caution.
- Page 16 S A F E T Y I N F O R M AT I O N j) Handle fuel cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken the tank and make it unsafe for use. k) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s rec- ommendations.
- Page 17 S A F E T Y I N F O R M AT I O N ANSI/NGCMA Z130.1-2004 PART II: MAINTENANCE AND OPERATIONS General safety practices Introduction Like other vehicles, golf cars can cause injury if improperly used or maintained. Part II contains broad safety practices recommended for safe golf car operations.
- Page 18 S A F E T Y I N F O R M AT I O N ANSI/NGCMA Z130.1-2004 5.2.2 Wet areas or icy terrain Extreme caution should be used when driving on wet or icy terrain. Wet grassy areas or ice may cause a golf car to lose traction and may affect operator control.
- Page 19 S A F E T Y I N F O R M AT I O N ANSI/NGCMA Z130.1-2004 Preventive maintenance A regularly scheduled inspection and preventive maintenance program in accordance with the manufacturer’s recommendations should be established. Such a program will be a valuable tool in providing the golfing patron with a safe, properly operating golf car.
- Page 20 S A F E T Y I N F O R M AT I O N ANSI/NGCMA Z130.1-2004 i) Record all maintenance performed in a maintenance record log by date, name of person performing maintenance and type of maintenance. Controlling Party should periodically inspect maintenance log to ensure currency and completeness of entries.
- Page 21 S A F E T Y I N F O R M AT I O N ANSI/NGCMA Z130.1-2004 The controlling party shall require battery changing and charging facilities and procedures to be in accordance with applicable ordinances or regulations. The controlling party shall supervise the storage and handling of liquid fuels in accordance with ANSI/NFPA 30.
- Page 22 S A F E T Y I N F O R M AT I O N NOTES: Page xx Owner’s Manual and Service Guide...
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Page 23: Before Initial Use
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for purchasing this vehicle. Before driving the Vehicle battery must be fully charged before initial use. vehicle, we ask you to spend some time reading this Check for correct tire inflation. -
Page 24: Direction Selector
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Neutral Key/Light Switch Fuel Reverse Forward Gauge REVERSE FORWARD Low Oil Pressure Indicator Light Fig. 2 Key/Light Switch, Low Oil Pressure Light and Fig. -
Page 25: Accelerator Pedal
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings problem exists within the engine and the vehicle must cle is not driven with the park brake engaged. Depress- not be driven. -
Page 26: Run-In
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Read and understand the following warnings before Do not take vehicle out of ‘gear’ while in attempting to operate the vehicle. -
Page 27: Cold Starting
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings COLD STARTING Starting a cold engine may require use of the choke. Depress the accelerator approximately 1" (2.5 cm) or until the starter just begins to operate. -
Page 28: Fuel
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings FUEL 1" minimum (2.5 cm) FUEL To reduce the possibility of severe injury or death from improper fuel handling: Do not smoke near the fuel tank. -
Page 29: Sun Top And Windshield
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings SUN TOP AND WINDSHIELD tem. Do not use pressure in excess of 700 psi to wash exterior of vehicle. -
Page 30: Wheels And Tires
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Center of Front Axle To reduce the possibility of severe injury or death from a vehicle falling from a jack: Be sure the vehicle is on a firm and level surface. -
Page 31: Wheel Installation
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings tion can occur in seconds. Never exceed chalk. Insert tire plug in accordance with manufacturer’s the tire manufacturer’s recommendation instructions. -
Page 32: Light Bulb Replacement
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIGHT BULB REPLACEMENT VEHICLE WITH A DISCHARGED BATTERY To reduce the possibility of premature bulb failure, do not touch new bulbs with bare fingers. -
Page 33: Neutral Lock
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings It is recommended that the vehicle be moved by placing Never ride on vehicle being transported. the entire vehicle on a trailer, flatbed truck or other suit- Always remove windshield before transport- able transport. -
Page 34: Serial Number Plate Location
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Some service procedures may require the vehicle to be lifted. Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information. -
Page 35: Periodic Service Schedule
OPERATION AND SERVICE INFORMATION 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. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representa- tive or see the Repair and Service Manual for this vehicle. - Page 36 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings FRONT SPRINGS Check for loose hardware, cracks at attachments FRONT WHEEL ALIGNMENT Check for unusual tire wear, align if required Check for bent/binding linkage rod Check for damage or wear to latch arm or catch bracket PARK BRAKE...
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Page 37: Tire Inspection
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings TIRE INSPECTION Tire condition should be inspected per the Periodic Ser- vice Schedule (Ref. Fig. 15 on page 13). Inflation pres- sures should be checked when the tires are cool. -
Page 38: Fig. 18 Oil Viscosity Chart
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Extension, 3/8" drive, 8" ..........1 Oil Fill Cap Oil drain pan ..............1 Wrench, 3/4"..............1 For maximum performance and longevity, the engine oil should be replaced after the first 8 hours of operation. -
Page 39: Starter/Generator Belt Tension
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Be careful of hot oil when drained. It may be hot enough to burn you severely Drain the oil by removing the drain plug found at the rear of the engine base. -
Page 40: Adjusting The Belt
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Adjusting The Belt Loosen the starter/generator pivot bolt. While holding the lower adjusting nut with a wrench, loosen the upper jam nut with another wrench. -
Page 41: Brakes
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings should be paid to metal components adjacent to the bat- tery which should also be sprayed with the sodium bicar- Dry, Level, Clean, Paved Surface bonate (baking soda) solution. -
Page 42: Air Intake And Cooling Fins
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings cles, several vehicles should be tested when new and the range of stopping locations or distances recorded. Over time, a subtle loss of performance may take place;... -
Page 43: Lubrication
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Fill / Check Plug Air Filter Air Cleaner Element Canister Dust Air Cleaner Collector Cover Ref Air 2 Fig. -
Page 44: Spark Plugs
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings SPARK PLUG at the rear axle cable mount. Lubricate the direction selector, linkage and related moving parts periodically Tool List Qty. -
Page 45: Hardware
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Reattach fuel line to tank and drive the vehicle for with the Torque Specifications table (Ref Fig. 34 on page several minutes to circulate the additive through 23). -
Page 46: Capacities And Replacement Parts
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CAPACITIES AND REPLACEMENT PARTS Fuel Tank / Fuel 5.3 gal (20.0 liters) / 87 Octane Min Engine Oil 1.4 US qt (1.3 liters) Oil Filter... - Page 47 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings NOTES: Owner’s Manual and Service Guide Page 25...
- Page 48 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings NOTES: Owner’s Manual and Service Guide Page 26...
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Page 49: General Specifications
G E N E R A L S P E C I F I C AT I O N S GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 27... -
Page 50: Bellhop 2 Gasoline Powered Cargo Carrier
VIBRATION, HAV .............. The weighted RMS acceleration is 6.68 m/s² BELLHOP 2 CARB Same as BELLHOP 2 Gasoline except for fuel system parts to meet California emissions standards. See Parts Manual for replacement parts * Do not use low inflation pressure tires on any E-Z-GO vehicle. Do not use any tire which has a recommended inflation pressure less than the inflation pressure recommended in Owner’s Manual. -
Page 51: Bellhop 4 Gasoline Powered Personnel / Cargo Carrier
G EN ER AL S PE CI F I CA TI O NS BELLHOP 4 BELLHOP 4 GASOLINE POWERED PERSONNEL / CARGO CARRIER WEIGHT (dry fuel tank)............NA** TIRES ................18 x 8.50 x 8 (LINKS 4 ply) TIRE PRESSURE .............. 18 - 22 psi (124 - 152 kPa)* LOAD CAPACITY (including operator, passengers, cargo and accessories) ...... -
Page 52: Bellhop 6 Gasoline Powered Personnel Carrier
G EN ER AL S PE C I FI C ATI O N S BELLHOP 6 BELLHOP 6 GASOLINE POWERED PERSONNEL CARRIER WEIGHT (dry fuel tank)............NA** TIRES................. 18 x 8.50 x 8 (LINKS 6 ply) TIRE PRESSURE .............. 18 - 22 psi (124 - 152 kPa)* LOAD CAPACITY (including operator, passengers, cargo and accessories) ...... -
Page 53: Fig. 36 Vehicle Dimensions
G E N E R A L S P E C I F I C AT I O N S Lowest Clearance At Differential NA** (All Models) BELLHOP 4 BELLHOP 6 93.5 in. (237 cm) 122 in. (310 cm) 132.5 in. (337 cm) 134.5 in. -
Page 54: Fig. 37 Vehicle Dimensions Continued
G E N E R A L S P E C I F I C AT I O N S BELLHOP 2 93.5 in. (237 cm) 122 in. (310 cm) 138 in. (351 cm) 44.5 in. (113 cm) Fig. 37 Vehicle Dimensions Continued Owner’s Manual and Service Guide... -
Page 55: Fig. 38 Vehicle Dimensions And Incline Specifications
G E N E R A L S P E C I F I C AT I O N S NA** NA** w/o Front Brake RECOMMENDED MAX SIDE TILT 33.5 in. (85 cm) 25% or 14° MAX With Front Brake 36 in. -
Page 56: Fig. 39 Turning Clearance Diameter & Intersecting Isle Clearance
G E N E R A L S P E C I F I C AT I O N S TURNING CLEARANCE DIAMETER 25ft 6inches (7.8 m) 94 in. (240 cm) INTERSECTING AISLE CLEARANCE 94 in. (240 cm) Fig. 39 Turning Clearance Diameter & Intersecting Isle Clearance Owner’s Manual and Service Guide Page 34... - Page 57 G E N E R A L S P E C I F I C AT I O N S NOTES: Owner’s Manual and Service Guide Page 35...
- Page 58 G E N E R A L S P E C I F I C AT I O N S NOTES: Owner’s Manual and Service Guide Page 36...
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Page 59: Vehicle Warranties
VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 37... -
Page 60: (U.s. And Canada)
VEHICLE WARRANTIES DOMESTIC WARRANTY (U.S. AND CANADA) 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 date code. Owner’s Manual and Service Guide Page 38... -
Page 61: Vehicle Warranties Federal 2006
VEHICLE WARRANTIES - FEDERAL (2008) FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Kawasaki Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been de- signed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. - Page 62 VEHICLE WARRANTIES - FEDERAL (2008) deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte- nance. As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
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Page 63: Vehicle Warranties California 2006
VEHICLE WARRANTIES - CALIFORNIA (2008) CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board and E-Z-GO Division of Textron Inc. (E-Z-GO) are pleased to explain the evapora- tive emission control system (EECS) on your 2006 gasoline powered vehicle. In California, new equipment that use small off-engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards. - Page 64 VEHICLE WARRANTIES - CALIFORNIA (2008) DIAGNOSIS: The owner shall not be charged for diagnostic labor that leads to the determination that the warranted part is defective if the diagnostic work is performed at an authorized E-Z-GO service center. CONSEQUENTIAL DAMAGE: E-Z-GO may be liable for damages to other engine or equipment components caused by the failure of a warranted part still under warranty.
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Page 65: Declaration Of Conformity
D EC LAR AT IO N O F C O N FO R MI TY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Page 43... - Page 66 D EC LAR AT IO N O F C O N FO R MI TY NOT AVAILABLE AT THE TIME OF PUBLICATION Owner’s Manual and Service Guide Page 44...
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Page 67: Labels And Pictograms
L A B E L S A N D P I C TO G R A M S LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1... - Page 68 L A B E L S A N D P I C TO G R A M S Appendix A - 2 Owner’s Manual and Service Guide...
- Page 69 L A B E L S A N D P I C TO G R A M S WAR NING WAR NING READ MANU A L FOR MA XIMUM LOA D BED CAP ACI T Y. MAXIMUM RA MP/HILL READ MANU A L SECURE LO AS FAR F ORW ARD XXX lbs.
- Page 70 L A B E L S A N D P I C TO G R A M S DO NO T CLEAN UP GASOLINE SPILLS WITH W ATE R EXPOSE BEFORE STAR TING TO FLAME ENGINE UNLEADED DO NO T GASOLINE DISPOSE OF BAT TERIES...
- Page 71 L A B E L S A N D P I C TO G R A M S KEEP CLEAR OPERA T E HAND OR FROM FINGERS CAN DRIVERS SIDE BE TR A PPED ONLY POSITION KEEP ARMS AND LEGS POSITION WITHIN VEHICLE HEADLIGHTS...
- Page 72 L A B E L S A N D P I C TO G R A M S MAXIMUM TAI L GA TE LOA D DEPRESS PEDAL RELEASE & DEPRESS PEDAL SIMULT A NEOUSLY NOTE: All Pictograms may not apply to your product. Ref Pic 1-4 Appendix A - 6 Owner’s Manual and Service Guide...
- Page 73 care when working on any vehicle. When diagnosing, removing or replacing any components that are not operat- ing correctly, take time to consider the safety of yourself Read and understand the following warnings before attempting to and others around you should the component move unex- operate the vehicle: pectedly.
- Page 74 E-Z-GO Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 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.