Cushman SHUTTLE 2+2 G Owner's Manual
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Cushman SHUTTLE 2+2 G Owner's Manual

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OWNER'S GUIDE
GAS SHUTTLE 2+2
642586
ISSUED JAN 2015
REVISED NOV 2015

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  • Page 1 OWNER’S GUIDE GAS SHUTTLE 2+2 642586 ISSUED JAN 2015 REVISED NOV 2015...
  • Page 2 WELCOME Thank you for purchasing this vehicle. Before you drive the vehicle, read this Owner’s Guide. This guide contains mainte- nance and operation information. The illustrations can show items that are optional for your vehicle. You can do most of the service procedures in this guide with common, automotive hand tools. If necessary, contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule.
  • Page 3 OWNER’S GUIDE GAS POWERED VEHICLE SHUTTLE 2+2 STARTING MODEL YEAR 2015 CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids con- tained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 4 FORWARD This vehicle was designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless other- wise indicated. Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective. Overfilling battery may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY GENERAL ......................... 1 NOTICES, CAUTIONS, WARNINGS AND DANGERS ............ 1 GENERAL OPERATION....................3 MAINTENANCE ........................ 4 VENTILATION........................5 LABELS AND PICTOGRAMS................... 6 LABELS AND PICTOGRAMS................... 7 GENERAL SPECIFICATIONS VEHICLE DIMENSIONS ....................10 TURNING DIAMETER AND INCLINE INFORMATION ..........11 INTRODUCTION FEATURES ........................
  • Page 6 TABLE OF CONTENTS OPERATING PROCEDURES SERIAL NUMBER LOCATION ..................17 BEFORE INITIAL USE..................... 18 HOW TO OPERATE THE VEHICLE ................18 Key and Headlight Switch Operation ..............19 Direction Selector Operation ................20 Accelerator Pedal Operation ................20 Brake and Parking Brake Operation ..............20 Horn Operation ....................20 Rear Seat and Cargo Platform Operation ............21 12-Volt Power Outlet ...................21...
  • Page 7 TABLE OF CONTENTS TRANSPORTING VEHICLE ................... 32 Towing ........................ 32 Neutral Lock ....................... 32 Hauling ....................... 33 SERVICE AND MAINTENANCE..................33 ROUTINE MAINTENANCE..................... 34 Four Cycle Engine ....................34 Checking the Oil Level ..................34 Changing the Oil ....................35 Starter Generator Belt Tension ................
  • Page 8 TABLE OF CONTENTS Owner’s Guide...

  • Page 9: Safety

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY GENERAL For any questions about material in this manual, contact an authorized representative. Read and understand all labels on the vehicle. Always replace any damaged or missing labels. Steep hills allow the vehicle to move at faster speeds than speeds on a flat surface.
  • Page 10 All users must read and obey this manual. Make sure you give special attention to the CAUTIONS, WARNINGS and DANGERS. For questions about this vehicle, contact your E-Z-GO/CUSHMAN dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.

  • Page 11: General Operation

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. E-Z-GO has the right to change the design of the vehicle. There is no responsibility to make the changes on units pur- chased before changes were made.

  • Page 12: Maintenance

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Read the following text and warnings before you service the vehicle. Normal use, age, wear or abuse can cause some components on the vehicle to fail. The manufacturer can not know all possible component failures or the methods that failures can occur.

  • Page 13: Ventilation

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Follow the manufacturers maintenance procedures. • Use insulated tools within the battery area to prevent sparks or battery explosion. •...

  • Page 14: Labels And Pictograms

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LABELS AND PICTOGRAMS WARNING READ THE MANUAL HIGH CENTER SECURE LOAD OF GRAVITY MAY MAX BED WEIGHT CAUSE TIP OVER 250 LBS or 110 KG MAX CENTER OF MAX SIDE...

  • Page 15: Labels And Pictograms

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LABELS AND PICTOGRAMS TO OPERATE VEHICLE: - TURN KEY TO ON FOR INFORMATION DO NOT OPERATE REMAIN SEATED - MOVE DIRECTION SELECTOR TO REFER TO OWNERS NO PUBLIC UNDER DRUG/ALCOHOL...
  • Page 16 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...

  • Page 17: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS MODEL: CUSHMAN SHUTTLE 2+2 G TYPE: GASOLINE POWERED PERSONNEL CARRIER MODEL YEAR: 2015 Part No:. 641356...

  • Page 18: Vehicle Dimensions

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE DIMENSIONS 46.5 in (118 cm) 4.5 in (11 cm) 77 in. 65.5 in (166 cm) (196 cm) 108.5 in (276 cm) Front 38 in.

  • Page 19: Turning Diameter And Incline Information

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING DIAMETER AND INCLINE INFORMATION TURNING CLEARANCE DIAMETER 19 ft (5.8 m) Owner’s Guide...
  • Page 20 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...

  • Page 21: Introduction

    INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INTRODUCTION FEATURES General Information If the vehicle has accessories that were installed at the factory, some accessories continue to operate with the key switch in the OFF position.

  • Page 22: Choke

    INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 5. Choke The choke is found on the seat panel below the driver seat. The choke helps start the vehicle when the engine is cold. Refer to the COLD-START section for operation instructions.

  • Page 23: Brake Light And Turn Signal

    INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 15. Brake Light and Turn Signal The brake light and turn signal assemblies are one unit. They are found on the rear fenders. 16.
  • Page 24 INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...

  • Page 25: Operating Procedures

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. OPERATING PROCEDURES SERIAL NUMBER LOCATION The vehicle has two serial number and manufacture date code plates. PART C label is found on the body panel below the driver seat.

  • Page 26: Before Initial Use

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BEFORE INITIAL USE Read, understand and follow the safety label on the instrument panel. Make sure you understand how to safely operate the vehicle and its equipment.

  • Page 27: Key And Headlight Switch Operation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not drive fast downhill. Sudden stops or change of direction can cause a loss of control. Use the brake to control the speed of the vehicle when you drive down a slope.

  • Page 28: Direction Selector Operation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Direction Selector Operation Direction Selector To prevent loss of control, do not move the direction selector to a different position while the vehicle is in motion.

  • Page 29: Rear Seat And Cargo Platform Operation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Seat and Cargo Platform Operation To prevent damage to the rear seat, move any accessories that are installed on the hand rail, when you fold the seat.

  • Page 30: Starting And Driving

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTING AND DRIVING To decrease the risk of roll-back, do not release the service brake until the engine has started. To operate the vehicle: •...

  • Page 31: Starting Vehicle On A Hill

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Change the oil according to the Periodic Service Schedule while the engine is warm.. See the Repair and Service Manual for procedures to check the oil level and change the oil.

  • Page 32: Coasting

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Coasting Do not allow the vehicle to coast at above recommended speeds. Control vehicle speed with the service brake. Steep hills allow the vehicle to move at faster speeds than speeds on a flat surface.

  • Page 33: Late Production Fuel Tank

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Early production fuel tanks can be identified by the location of the fuel cap which is located in the middle of the top of the tank as shown.

  • Page 34: Sun Top And Windshield (If Equipped)

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUN TOP AND WINDSHIELD (IF EQUIPPED) The sun top does not supply protection from roll-over or falling objects. The windshield does not supply protection from tree branches or moving objects.

  • Page 35: Maintenance

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE VEHICLE CLEANING AND CARE Read and understand all instructions supplied by the manufacturer of the pressure washer before use.

  • Page 36: Lifting The Vehicle

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE You must lift the front, the rear or the entire vehicle for some service and maintenance operations. The vehicle is not stable during the lifting process.

  • Page 37: Wheels And Tires

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lower the vehicle: Lift the vehicle enough to remove the jack stands. Carefully lower the vehicle to the ground with the jack. Flat Portion of Frame Center of...

  • Page 38: Wheel Installation

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use caution when you inflate the tires. Because of the low volume of the small tires, over inflation can occur in seconds. Over inflation can cause the tire to separate from the wheel or cause a tire explosion.

  • Page 39: Light Bulb Replacement

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIGHT BULB REPLACEMENT To decrease the risk of premature bulb failure, do not allow your fingers to contact new bulbs. Use clean, dry paper or paper towels to touch the glass part of the bulb.

  • Page 40: Vehicle With A Discharged Battery

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE WITH A DISCHARGED BATTERY To decrease the risk of severe injury or death from accidental movement, do not use a jumper cable to start a vehicle.

  • Page 41: Hauling

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hauling Make sure you secure the vehicle and all items before you move a vehicle on a trailer. Do not allow any people on a vehicle being moved on a trailer. Remove the windshield before you move a vehicle on a trailer.

  • Page 42: Routine Maintenance

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The vehicle owner and service technician must carefully follow the procedures recommended in this manual. The pre- ventative maintenance, applied at recommended intervals, keeps the vehicle dependable and decreases the costs for the repairs.

  • Page 43: Changing The Oil

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The engine can be operated safely as long as oil is within the safe operating range as indicated on the dip stick. Do not operate vehi- Maximum Oil Level cle if oil level is below the safe area indicated on the dipstick.
  • Page 44 MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Place a drain pan under engine. Wipe top of the engine clean with a cloth. Oil Fill Cap Remove the oil fill cap. Be careful of hot oil when drained.

  • Page 45: Starter Generator Belt Tension

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Oil capacity is 1 1/3 quarts (1.3 liters). Add slightly less than 1 1/3 quarts (1.3 liters) to allow for possible residual oil left in engine.

  • Page 46: Adjusting The Belt

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten a new starter/generator belt to 110 - 130 lbs. (50 - 59 kg) ten- sion when a gauge is applied half way between the two pulleys. A new belt may be checked manually.

  • Page 47: Tire Inspection

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Preparing Acid Neutralizing Solution 2 teaspoons (10 ml) 1 quart (1 liter) Sodium Bicabonate Plastic Spray Clear Water (Baking Soda) Bottle The correct cleaning method is to spray the top and sides of the battery with a solution of baking soda and water.

  • Page 48: Periodic Brake Test

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Periodic Brake Test This test compares the brake performance of the vehicle to the brake performance of new or ‘known to be good’ vehicles or to an established acceptable stopping distance.

  • Page 49: Capacities And Replacement Parts

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CAPACITIES AND REPLACEMENT PARTS Fuel (Early Production) 6.0 gal. (22.7 liters) Fuel (Late Production) 5.6 gal. (21.4 liters) Rear Axle Oil 12 oz (1.2 liters) 30 WT Engine Oil Fuse (15 amp) P/N 18392-G1...

  • Page 50: Air Intake And Cooling Fins

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. AIR INTAKE AND COOLING FINS To prevent possible burns, engine parts should be kept clean to reduce risk of overheating and ignition of accumulated debris.

  • Page 51: Cleaning The Air Filter Element

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cleaning the Air Filter Element Air Filter Element Air Cleaner Canister Do not use compressed air to clean the air filter; doing so will damage the filter which may result in damage to the Dust Collector engine.
  • Page 52 MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PROLONGED STORAGE Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.

  • Page 53: Periodic Service Schedule

    PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - Check pressure and inspect condition of tires &...
  • Page 54 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REMARKS Front Wheel Alignment - Inspect for unusual tire wear. C&A C&A C&A King Pins - Check for excessive play and tightness of retaining nuts. Rear Axle - Check for unusual noise and loose/missing mounting hardware.
  • Page 55 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...
  • Page 56 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...
  • Page 57 Normal use, age, wear or abuse can cause some components on the vehicle to fail. The manufacturer can not know all possi- ble component failures or the methods that failures can occur. A vehicle in need of repair does not operate correctly and can be dangerous.
  • Page 58 E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Road, Augusta, Georgia 30906-3852 USA CONTACT US: North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GETEZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts &...

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