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Shuttle 6
Cushman Shuttle 6 Manuals
Manuals and User Guides for Cushman Shuttle 6. We have
3
Cushman Shuttle 6 manuals available for free PDF download: Service Manual, Owner's Manual
Cushman Shuttle 6 Service Manual (197 pages)
ELECTRIC POWERED UTILITY VEHICLE
Brand:
Cushman
| Category:
Utility Vehicle
| Size: 17.22 MB
Table of Contents
Safety
2
General Information
4
Table of Contents
5
General
7
Safety Information
7
General Operation
8
Maintenance
8
Ventilation
9
General Information & Routine Maintanence
11
Hauling
13
Serial Number Location
13
Servicing the Electric Vehicle
13
Towing
13
Transporting Vehicle
13
Brakes
14
Light Bulb Replacement
14
Rear Axle
14
Routine Maintenance
14
Tires
14
Vehicle Cleaning and Care
14
Sun Top and Windshield
15
Vehicle Care Products
15
Hardware
16
Torque Specifications
16
Periodic Service Schedule
17
Before Servicing the Vehicle
21
General Maintenance
21
Important Safety Warning
21
Modifications to Vehicle
21
Notices, Cautions Warnings and Dangers
21
Additional Warnings
22
Battery Removal & Installation
23
Fig. 1 Battery Connections
23
Lifting the Vehicle
24
View from Underside of Vehicle
24
Body
27
Section Title
27
Body
28
Body Component Replacement
29
Drill out Metal Rivet
29
General
29
Body
31
Instrument Panel Replacement
33
Rocker Panel Replacement
33
Cowl Replacement
33
Front Fascia Replacement
33
Front Seat Pod Replacement
34
Rear Body Replacement
34
Front Seat Replacement
35
Rear Bumper Replacement
35
Cargo Bed Replacement
36
Seat/Cargo Bed Latch
36
Rear Facing Rear Seat
36
Seat Support Removal
37
Shuttle 2 Rear Body
37
Rear Fender Removal
38
Rear Valence Panel Removal
39
Side Panel Removal
39
Load Deck Removal
39
Seat Back Removal
40
Bulkhead Removal
40
Bed Frame Removal
41
Seat Frame Removal
41
MID Support Removal
42
Rear Bed Bracket Removal
42
Painting
43
Minor Scratches
43
Complete Panel Repair
43
Larger Scratches
43
Wheels and Tires
45
Wheel and Tire Service
47
Tire Repair
47
Wheels and Tires
47
Wheel Installation
48
Wheel and Tire Installation
48
Front Suspension and Steering
51
Fig. 2 Lubrication Points
51
Axle Mounted Steering and Front Suspension
53
Lubrication
54
Maintenance
54
Wheel Bearing and King Pin Bushing Inspection
54
Wheel Bearing Packing
54
Wheel Alignment
55
Wheel Bearing Adjustment
55
Front Shock Absorber Replacement
57
Front Suspension
57
Axle Linkage Rod Replacement
58
Front Axle Replacement
58
Front Spring Replacement
59
To Detach Passenger Side Spring
59
Front Axle Alignment
60
Hub Replacement
60
Wheel Bearing and Race Replacement
60
Wheel Bearing Replacement
61
Rack Ball Joint Replacement
62
Steering
62
Steering Components
62
Rack Ball Joint Installation
63
Tie Rod Inspection/Replacement
63
Tie Rod Replacement
63
Bellows Replacement
64
Pinion Seal Replacement
64
Tool List
64
Removing Brake Caliper
65
Spindle Replacement
65
Front of Vehicle
66
Rack and Pinion Unit Disassembly and Inspection
66
Checking/Adjusting Rack Extension-To-Rack and Pinion Unit Clearance
67
Rack and Pinion Unit Replacement
67
Checking Gap
68
Clipboard or Steering Wheel Cover Removal
68
Spindle Contact with Front Axle
68
Steering Wheel Replacement
68
Steering Shaft and Column Replacement
69
Small Retaining Ring Orientation
70
Electronic Speed Control
73
Anti Roll Back Feature
75
Anti Stall Feature
75
Pedal-Up Feature
75
Performance
75
Speed Control
75
Walk Away Feature
75
Diagnostic Mode Feature
76
High Pedal Disable Feature
76
Operation
76
Controller
77
Controller and Solenoid
77
Pedal Box
77
Speed Sensor
77
General Troubleshooting
78
Symptoms
78
Testing Battery Voltage
78
Battery Reference Voltage
79
Continuity Check of Switch
79
Testing a Solenoid for Continuity
79
Testing a Switch for Continuity
79
Continuity Check of Solenoid
80
Troubleshooting Diagrams
80
48 Volt Fault Codes
82
Controller Connectors and Connections
82
48 Volt Wiring Diagram
83
J-1 Pin Connector Diagnostics
84
J-2 Pin Connector Diagnostics
86
Secondary Wiring Diagnostics
87
Inductive Throttle Sensor (Its)
88
ITS and Plunger
88
ITS Adjustment
89
Controller Replacement
91
Solenoid Replacement
91
Controller Wiring
92
Brakes - Front Disc
95
Master Cylinder Replacement
97
System Description
97
To Remove the Master Cylinder
97
Brakes - Front Disc
97
Brake Pad Replacement
98
Check Brake Fluid
98
Rotor Replacement
98
Routine Maintenance
98
Spindle Replacement
98
Actuator Pivot Bushings
99
Bleeding Brakes
99
Replacement of Wear Items
98
Brake Master Cylinder Fluid
98
Mechanical Brakes
101
Brake System Overview
103
Mechanical Brake System
103
Wheel Brake Adjustment
104
How the Parking Brake Works
104
Compensator Assembly
105
Kick-Off Actuating Linkage
105
Parking Brake and Kick-Off Mechanism
105
Troubleshooting Flowchart
106
Troubleshooting Table
108
Brake Pedal Inspection
110
Brake Pedal Bumper Inspection
110
New Vehicles
110
Troubleshooting and Inspection
110
Equalizer and Compensator
111
Parking Brake Pedal Hinge Inspection
112
Periodic Brake Performance Test (PBPT)
112
Kick-Off Cam Inspection
112
Periodic Brake Performance Test
113
Aggressive Stop Test
113
Wheel Brake Inspection
114
Equally Load Vehicle
114
Adjuster Mechanism
115
Brake Shoe Wear
115
Orientation of Brake Shoe Springs
116
Adjusting Brake Pedal Free Travel
116
Free Travel Adjustment
117
Check Clevis Pins
117
Brake Drum Removal and Installation
117
Checking Parking Brake Latching Pressure
117
Wheel Brake Service
118
Brake Assembly
118
Backing Plate Removal and Installation
119
Wheel Brake Lubrication Points
119
Brake Shoe and Adjuster Replacement
119
Brake Shoes and Springs
120
Brake Cable and Equalizer Assembly
120
Brake Pedal Removal and Installation
121
Brake Cable, Equalizer and Compensator
121
Pedal Bumper Adjustment
122
Catch Bracket and Latch Arm
122
Installation Is in the Reverse Order of Disassembly
123
Electrical System
125
Digital Volt Ohm Meter
127
Dvom
127
Wiring Diagram
128
Power Supply
129
Accessory Wiring
129
Check Green Power Wire
129
Light Bulb Replacement
129
Headlight & Turn Signal Light Bulb Replacement
130
Tail & Brake Light Bulb Replacement
130
Fuse Replacement
130
Ignition Switch & Fuse Block
131
Horn
132
Turn Signal & Hour Meter
132
Motor
135
Motor Removal
137
Mark Axle and Motor
137
Motor Disassembly
137
Bearing Replacement
138
Motor Components
138
Motor Assembly
139
Brush Wear
139
Securing Brushes
139
Field Coil Replacement
139
Motor Tests
140
Motor Installation
140
Motor Wiring - Pds
140
Motor Wiring
140
Batteries and Charging
143
Battery
145
Battery Maintenance
145
Water Purity Table
146
Correct Electrolyte Level
146
Electrolyte Level and Water
146
At each Charging Cycle
146
Automatic Watering Gun
147
Cleaning Batteries
147
Preparing Acid Neutralizing Solution
147
Battery Replacement
148
Prolonged Storage
148
Battery Charging
149
AC Voltage
149
Troubleshooting
149
Freezing Point of Electrolyte
149
Using a Hydrometer
150
Hydrometer
150
Battery Charger
151
Portable Charger Installation
151
Charger Installation
151
Hydrometer Temperature Correction
151
Charger Maintenance
152
Polarized Receptacle
152
Charger Plug
152
Rear Suspension
153
Shock Absorber Removal
155
Rear Spring Installation
155
Rear Spring Removal
155
Shock Absorber Installation
155
Rear Axle Removal
157
Rear Axle Installation
157
Rear Axle Maintenance
161
Checking the Lubricant Level
161
Axle Shaft Removal and Disassembly
161
Rear Axle Disassembly
161
Removing/Installing Axle Shaft
162
Removing/Installing Inner Snap Ring
162
Axle Shaft Seal Removal and Replacement
162
Removing Seal
162
Cut Away of Outer Bearing and Brake Drum
163
Installing Seal
163
Axle Shaft Replacement
163
Weather Protection
165
Top and Windshield
167
Rear Support Installation
167
Front Struts
167
Sun Top
167
Shuttle 4 and Shuttle 6 Sun Top
168
Spilt Windshield
169
Full Windshield
170
Troubleshooting
175
Suspension and Steering
177
Lightning Protection and Grounding
179
Equipment Fault and Personal Safety System
181
Grounding Requirements
181
Lightning Protection Requirements
181
Ground Systems
181
Lighting Protection and Grounding
181
External Grounding Requirements
182
Materials
182
Earth Electrode System
182
Lightning Protection System
182
General Specifications
185
Product Specification
187
Configuration Highlights
187
Product Overview
187
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Cushman Shuttle 6 Owner's Manual (86 pages)
Cushman 48 V Electric Powered vehicle owner's guide
Brand:
Cushman
| Category:
Electric Vehicles
| Size: 12.79 MB
Table of Contents
Table of Contents
5
Read All of this Manual to Become Thoroughly Familiar with this Vehicle. Pay Particular Attention to All Notices, Cautions, Warnings, and Dangers.
7
Safety
7
Safety
8
Notices, Cautions, Warnings, and Dangers
9
General
10
General Operation
11
Maintenance
11
Ventilation
12
Labels and Pictograms
13
General Specifications
19
Introduction
29
Read All of this Manual to Become Thoroughly Familiar with this Vehicle. Pay Particular Attention to All Notices, Cautions, Warnings, and Dangers.
31
Features
31
Horn
33
Run/Tow Switch
35
Utility Bed
36
Operating Procedures
39
Serial Number Location
40
Before Initial Use
41
Portable Charger Installation
42
Using the Charger
43
Understanding the Charger
44
LED Operation Codes
44
LED Fault Codes
44
On-Board Charger
45
Maintenance Instructions
45
Operating the Vehicle
46
Performance
47
Speed Control
47
Pedal-Up Braking
47
Terrain
47
Walk-Away Feature
48
Anti-Roll Back Feature
48
Anti-Stall Feature
48
High Pedal Disable Feature
48
Diagnostic Mode Feature
48
Starting and Driving
49
Starting Vehicle on a Hill
49
Coasting
49
Labels and Pictograms
50
Sun Top and Windshield
50
Maintenance
53
Vehicle Cleaning and Care
55
Vehicle Cleaning
55
Common Sense Operation
56
Environmental Concerns
56
Repair
57
Lifting the Vehicle
57
Wheels and Tires
58
Tire Repair
58
Wheel Installation
59
Light Bulb Replacement
60
Fuse Replacement
60
Transporting Vehicle
61
Towing
61
Hauling
61
General
61
Service and Maintenance
61
Periodic Brake Test for Mechanical Brakes
63
Routine Maintenance
63
Tire Inspection
63
Brakes
63
Rear Axle
64
Checking the Lubrican Level
64
Lubrication
64
System Test
64
Hardware
65
General Operation
66
Periodic Service Schedule
66
Capacities and Replacement Parts
67
Battery Replacement
72
Battery Charging
73
Prolonged Storage
73
AC Voltage
74
Troubleshooting
74
Battery Charging and Maintenance
67
Safety
67
Battery
68
Battery Maintenance
68
At each Charging Cycle
68
Monthly
69
Electrolyte Level and Water
69
Battery Cleaning
71
Hydrometer
75
Using Hydrometer
76
Declaration of Conformity
81
Cushman Shuttle 6 Owner's Manual (78 pages)
Brand:
Cushman
| Category:
Utility Vehicle
| Size: 18.29 MB
Table of Contents
Table of Contents
5
Safety
7
Safety
8
Notices, Cautions, Warnings, and Dangers
9
General
11
General Operation
11
Maintenance
12
Ventilation
12
Labels and Pictograms
13
General Specifications
19
Introduction
29
Features
31
General Information
31
Accelerator Pedal
32
Brake and Park Brake
32
Direction Selector
32
Fuel Gauge with Low Oil Pressure Indicator Light
32
Key Switch / Headlight Switch
32
Brake Light/Turn Signal
33
Choke
33
Cup Holder
33
Front Seats
33
Glove Box
33
Hip Restraint - Front
33
Horn
33
Rear Seat (SHUTTLE 4 and 6 Only)
33
Rear View Mirror
33
Steering Wheel
33
Hip Restraint - Rear (SHUTTLE 4 and 6 Only)
34
Operating Procedures
37
Serial Number Location
39
Before Initial Use
40
Operating the Vehicle
40
Run in
41
Cold Starting
42
Starting and Driving
42
Starting the Vehicle on a Hill
42
Coasting
43
Fuel
43
Battery
44
Fuel Tank
44
Early Production Fuel Tank
44
Late Production Fuel Tank
44
Sun Top and Windshield
45
Maintenance
47
Vehicle Cleaning and Care
49
Vehicle Cleaning
49
Environmental Concerns
50
Common Sense Operation
50
Repair
51
Lifting the Vehicle
51
Wheels and Tires
52
Tire Repair
52
Wheel Installation
53
Light Bulb Replacement
53
Unidirectional Tires
53
Fuse Replacement
54
Vehicle with a Discharged Battery
54
Transporting Vehicle
54
Towing
54
Neutral Lock
55
Hauling
55
Service and Maintenance
56
Routine Maintenance
57
Tire Inspection
57
Rear Axle
57
Four Cycle Engine
57
Engine Specifications
57
Engine Description
57
Checking the Oil Level
57
Changing the Oil
58
Starter/Generator Belt Tension
61
Adjusting the Belt
62
Battery Cleaning
62
Brakes
63
Periodic Brake Test for Mechanical Brakes
63
Air Intake and Cooling Fins
64
Rear Axle
64
Checking the Lubricant Level
64
Air Cleaner Inspection and Replacement
65
Cleaning the Air Filter Element
65
Spark Plugs
66
Prolonged Storage
67
Hardware
68
Capacities and Replacement Parts
68
Periodic Service Schedule
69
General Operation
69
Declaration of Conformity
73
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