Table Of Contents - Cushman Shuttle 2 Service Manual

Table of Contents

Safety2
General Information4
Table Of Contents5
Safety Information7
General7
General Operation8
Maintenance8
Ventilation9
General Information & Routine Maintanence11
Serial Number Location13
Transporting Vehicle13
Servicing The Electric Vehicle13
Towing13
Hauling13
Routine Maintenance14
Rear Axle14
Brakes14
Tires14
Light Bulb Replacement14
Vehicle Cleaning And Care14
Vehicle Care Products15
Sun Top And Windshield15
Hardware16
Torque Specifications16
Periodic Service Schedule17
Notices, Cautions Warnings And Dangers21
Important Safety Warning21
Modifications To Vehicle21
General Maintenance21
Before Servicing The Vehicle21
Additional Warnings22
Battery Removal & Installation23
Fig. 1 Battery Connections23
Lifting The Vehicle24
View From Underside Of Vehicle24
Body27
Section Title27
Body Component Replacement29
Drill Out Metal Rivet29
Instrument Panel Replacement33
Rocker Panel Replacement33
Cowl Replacement33
Front Fascia Replacement33
Front Seat Pod Replacement34
Rear Body Replacement34
Front Seat Replacement35
Rear Bumper Replacement35
Cargo Bed Replacement36
Seat/Cargo Bed Latch36
Rear Facing Rear Seat36
Seat Support Removal37
Shuttle 2 Rear Body37
Rear Fender Removal38
Rear Valence Panel Removal39
Side Panel Removal39
Load Deck Removal39
Seat Back Removal40
Bulkhead Removal40
Bed Frame Removal41
Seat Frame Removal41
Mid Support Removal42
Rear Bed Bracket Removal42
Painting43
Minor Scratches43
Complete Panel Repair43
Larger Scratches43
Wheels And Tires45
Wheel And Tire Service47
Tire Repair47
Wheel Installation48
Wheel And Tire Installation48
Front Suspension And Steering51
Fig. 2 Lubrication Points51
Axle Mounted Steering And Front Suspension53
Lubrication54
Wheel Bearing And King Pin Bushing Inspection54
Wheel Bearing Packing54
Wheel Bearing Adjustment55
Wheel Alignment55
Front Suspension57
Front Shock Absorber Replacement57
Front Axle Replacement58
Axle Linkage Rod Replacement58
Front Spring Replacement59
To Detach Passenger Side Spring59
Front Axle Alignment60
Hub Replacement60
Wheel Bearing And Race Replacement60
Wheel Bearing Replacement61
Steering62
Rack Ball Joint Replacement62
Steering Components62
Tie Rod Inspection/Replacement63
Rack Ball Joint Installation63
Tie Rod Replacement63
Bellows Replacement64
Tool List64
Pinion Seal Replacement64
Removing Brake Caliper65
Spindle Replacement65
Rack And Pinion Unit Disassembly And Inspection66
Front Of Vehicle66
Rack And Pinion Unit Replacement67
Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance67
Steering Wheel Replacement68
Spindle Contact With Front Axle68
Checking Gap68
Clipboard Or Steering Wheel Cover Removal68
Steering Shaft And Column Replacement69
Small Retaining Ring Orientation70
Electronic Speed Control73
Performance75
Pedal-Up Feature75
Speed Control75
Walk Away Feature75
Anti Roll Back Feature75
Anti Stall Feature75
High Pedal Disable Feature76
Diagnostic Mode Feature76
Operation76
Controller77
Pedal Box77
Controller And Solenoid77
Speed Sensor77
General Troubleshooting78
Testing Battery Voltage78
Symptoms78
Testing A Switch For Continuity79
Continuity Check Of Switch79
Battery Reference Voltage79
Testing A Solenoid For Continuity79
Troubleshooting Diagrams80
Continuity Check Of Solenoid80
48 Volt Fault Codes82
Controller Connectors And Connections82
48 Volt Wiring Diagram83
J-1 Pin Connector Diagnostics84
J-2 Pin Connector Diagnostics86
Secondary Wiring Diagnostics87
Inductive Throttle Sensor (Its)88
Its And Plunger88
Its Adjustment89
Controller Replacement91
Solenoid Replacement91
Controller Wiring92
Brakes - Front Disc95
System Description97
Master Cylinder Replacement97
To Remove The Master Cylinder97
Brake Master Cylinder Fluid98
Replacement Of Wear Items98
Brake Pad Replacement98
Check Brake Fluid98
Rotor Replacement98
Actuator Pivot Bushings99
Bleeding Brakes99
Mechanical Brakes101
Brake System Overview103
Mechanical Brake System103
Wheel Brake Adjustment104
How The Parking Brake Works104
Compensator Assembly105
Kick-Off Actuating Linkage105
Parking Brake And Kick-Off Mechanism105
Troubleshooting Flowchart106
Troubleshooting Table108
Troubleshooting And Inspection110
New Vehicles110
Brake Pedal Bumper Inspection110
Brake Pedal Inspection110
Equalizer And Compensator111
Parking Brake Pedal Hinge Inspection112
Periodic Brake Performance Test (Pbpt)112
Kick-Off Cam Inspection112
Periodic Brake Performance Test113
Aggressive Stop Test113
Wheel Brake Inspection114
Equally Load Vehicle114
Adjuster Mechanism115
Brake Shoe Wear115
Orientation Of Brake Shoe Springs116
Adjusting Brake Pedal Free Travel116
Free Travel Adjustment117
Check Clevis Pins117
Brake Drum Removal And Installation117
Checking Parking Brake Latching Pressure117
Wheel Brake Service118
Brake Assembly118
Backing Plate Removal And Installation119
Wheel Brake Lubrication Points119
Brake Shoe And Adjuster Replacement119
Brake Shoes And Springs120
Brake Cable And Equalizer Assembly120
Brake Cable, Equalizer And Compensator121
Brake Pedal Removal And Installation121
Pedal Bumper Adjustment122
Catch Bracket And Latch Arm122
Installation Is In The Reverse Order Of Disassembly123
Electrical System125
Digital Volt Ohm Meter127
Dvom127
Wiring Diagram128
Power Supply129
Accessory Wiring129
Check Green Power Wire129
Fuse Replacement130
Tail & Brake Light Bulb Replacement130
Headlight & Turn Signal Light Bulb Replacement130
Ignition Switch & Fuse Block131
Horn132
Turn Signal & Hour Meter132
Motor135
Motor Removal137
Mark Axle And Motor137
Motor Disassembly137
Bearing Replacement138
Motor Components138
Brush Wear139
Field Coil Replacement139
Securing Brushes139
Motor Assembly139
Motor Tests140
Motor Installation140
Motor Wiring - Pds140
Motor Wiring140
Batteries And Charging143
Battery145
Battery Maintenance145
At Each Charging Cycle146
Electrolyte Level And Water146
Correct Electrolyte Level146
Water Purity Table146
Automatic Watering Gun147
Cleaning Batteries147
Preparing Acid Neutralizing Solution147
Battery Replacement148
Prolonged Storage148
Battery Charging149
Ac Voltage149
Troubleshooting149
Freezing Point Of Electrolyte149
Hydrometer150
Using A Hydrometer150
Battery Charger151
Portable Charger Installation151
Charger Installation151
Hydrometer Temperature Correction151
Charger Maintenance152
Polarized Receptacle152
Charger Plug152
Rear Suspension153
Shock Absorber Installation155
Rear Spring Removal155
Rear Spring Installation155
Shock Absorber Removal155
Rear Axle Removal157
Rear Axle Installation157
Rear Axle Maintenance161
Checking The Lubricant Level161
Axle Shaft Removal And Disassembly161
Rear Axle Disassembly161
Removing/Installing Axle Shaft162
Removing/Installing Inner Snap Ring162
Axle Shaft Seal Removal And Replacement162
Removing Seal162
Axle Shaft Replacement163
Installing Seal163
Cut Away Of Outer Bearing And Brake Drum163
Weather Protection165
Top And Windshield167
Rear Support Installation167
Front Struts167
Sun Top167
Shuttle 4 And Shuttle 6 Sun Top168
Spilt Windshield169
Full Windshield170
Suspension And Steering177
Lightning Protection And Grounding179
Grounding Requirements181
Ground Systems181
Lightning Protection Requirements181
Equipment Fault And Personal Safety System181
Lighting Protection And Grounding181
External Grounding Requirements182
Materials182
Earth Electrode System182
Lightning Protection System182
General Specifications185
Product Specification187
Configuration Highlights187
Product Overview187