Table Of Contents - Cushman SHUTTLE 4X Technician's Repair And Service Manual

Table of Contents

Safety2
Notice2
General Information4
Battery Prolonged Storage4
Battery Disposal4
Table Of Contents5
Safety Information7
General7
General Operation8
Maintenance8
Ventilation9
General Information & Routine Maintanence11
Serial Number Location13
Transporting Vehicle13
Towing13
Hauling13
Servicing The Electric Vehicle13
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
Front Body Components30
Floor Mount Gun Holder31
Ashtray31
Floor Mount Gun Holder And Ashtray31
Painting33
Minor Scratches33
Complete Panel Repair33
Larger Scratches33
Wheels And Tires35
Wheel And Tire Service37
Tire Repair37
Wheel Installation38
Wheel And Tire Installation38
Front Suspension And Steering41
Fig. 2 Lubrication Points41
Axle Mounted Steering And Front Suspension43
Lubrication44
Wheel Bearing And King Pin Bushing Inspection44
Wheel Bearing Packing44
Wheel Alignment45
Wheel Bearing Adjustment45
Front Suspension47
Front Shock Absorber Replacement47
Front Suspension Components47
Front Axle Replacement48
Axle Linkage Rod Replacement48
Front Spring Replacement49
To Detach Passenger Side Spring49
To Detach Driver Side Spring49
Hub Replacement50
Wheel Bearing And Race Replacement50
Seal Installation50
Tool List50
Wheel Bearing Replacement51
Steering52
Rack Ball Joint Replacement52
Steering Components52
Tie Rod Inspection/Replacement53
Tie Rod Replacement53
Rack Ball Joint Installation53
Bellows Replacement54
Pinion Seal Replacement54
Spindle Replacement55
Removing Brake Caliper55
Rack And Pinion Unit Disassembly And Inspection56
Rack And Pinion Unit Disassembly56
Rack And Pinion Unit Replacement57
Checking/Adjusting Rack Extension-To-Rack57
Steering Wheel Replacement58
Spindle Contact With Front Axle58
Checking Gap58
Clipboard Removal58
Steering Shaft And Column Replacement59
Steering Shaft And Column59
Small Retaining Ring Orientation60
Electronic Speed Control - Tct63
Trucourse Technology System65
Changing Performance Options65
Run-Tow/Maintenance Switch66
Operation66
Controller67
Pedal Box67
Speed Sensor67
Access To Pedal Box67
General Troubleshooting68
Testing Battery Voltage68
Continuity Check68
Battery Reference Voltage68
Symptoms68
Testing A Switch For Continuity69
Testing A Solenoid For Continuity69
Continuity Check Of Solenoid69
Troubleshooting Diagrams70
1206Hb-5201 Controller Faults And Troubleshooting70
Controller Connectors And Connections72
Controller Wiring Diagram73
Inductive Throttle Sensor (Its)74
Its And Plunger74
Its Adjustment75
Controller Replacement77
Solenoid Replacement77
Solenoid Wiring78
Motor81
Disconnect Battery Cable83
Motor Removal83
Motor Disassembly83
Motor Components84
Bearing Replacement85
Brush Replacement85
Brush Wear85
Motor Tests86
Motor Installation86
Securing Brushes86
Motor Assembly86
Batteries And Charging89
Battery Maintenance91
At Each Charging Cycle92
Monthly92
Electrolyte Level And Water92
Cleaning Batteries93
Battery Replacement93
Automatic Watering Gun93
Preparing Acid Neutralizing Solution93
Prolonged Storage95
Battery Charging95
Freezing Point Of Electrolyte95
Specific Gravity Electrolyte Freezing Point95
Hydrometer96
Ac Voltage96
Troubleshooting96
Using A Hydrometer97
Hydrometer Temperature Correction97
Electrical System99
Digital Volt Ohm Meter101
Accessory Wiring Diagram102
Main Harness Wiring Diagram103
Power Supply104
Main & Accessory Wiring104
Check Battery Condition104
Check Fuse104
Electrical Accessories105
Mechanical Brakes109
Brake System Overview111
How The Service Brake Works111
Mechanical Brake System111
Equalizer Link112
Automatic Adjuster Mechanism112
How The Parking Brake Works112
Wheel Brake Adjustment112
Compensator Assembly113
Kick-Off Actuating Linkage113
Parking Brake And Kick-Off Mechanism113
Troubleshooting Flowchart114
New Vehicles118
Troubleshooting And Inspection Procedures118
Brake Pedal Bumper Inspection118
Brake Pedal Inspection118
Checking For Excessive Free Travel119
Equalizer And Compensator119
Parking Brake Pedal Hinge Inspection120
Kick-Off Cam Inspection120
Periodic Brake Performance Test (Pbpt)120
Aggressive Stop Test121
Periodic Brake Performance Test121
Wheel Brake Inspection122
Equally Load Vehicle122
Adjuster Mechanism123
Brake Shoe Wear123
Parts Replacement Vs. Repair124
Maintenance And Repairs124
Orientation Of Brake Shoe Springs124
Adjusting Brake Pedal Free Travel124
Brake Drum Removal And Installation125
Check Clevis Pins125
Free Travel Adjustment125
Checking Parking Brake Latching Pressure125
Wheel Brake Service126
Brake Assembly126
Backing Plate/Entire Wheel Brake Assembly127
Backing Plate Removal And Installation127
Wheel Brake Lubrication Points127
Brake Shoe And Adjuster Replacement127
Setting Adjuster Screw128
Brake Shoes And Springs128
Brake Cable And Equalizer Assembly128
Brake Cable, Equalizer And Compensator129
Brake Pedal Removal And Installation129
Pedal Bumper Adjustment130
Catch Bracket And Latch Arm130
Parking Brake Kick-Off Cam Removal130
Battery Charger133
Charger Description135
Portable Charger Installation135
Charger Installation135
Understanding The Charger136
Led Fault Code136
Maintenance Instructions136
Led Display Information136
Rear Suspension139
Shock Absorber Installation141
Rear Spring Removal141
Rear Spring Installation141
Shock Absorber Removal141
Rear Axle Maintenance147
Checking The Lubricant Level147
Axle Shaft Removal And Disassembly147
Rear Axle Disassembly147
Removing/Installing Axle Shaft148
Removing/Installing Inner Snap Ring148
Axle Shaft Seal Removal And Replacement148
Removing Seal148
Axle Shaft Replacement149
Installing Seal149
Cut Away Of Outer Bearing And Brake Drum149
Weather Protection151
Top And Windshield153
Front Strut153
Sun Top153
Trailering153
Split Windshield155
Full Windshield156
Handheld Diagnostics159
Primary Connection: 4 Pin Tyco161
Alternate Connection: 4 Pin Molex161
Navigation161
Curtis Handheld Programmer161
Changing Data Value162
Bookmark162
Main Menu Definitions162
Lightning Protection And Grounding173
Ground Systems175
Equipment Fault And Personal Safety System175
Ground Network Requirements175
External Grounding Requirements176
Materials176
Lightning Protection System176
10. Equipment Fault And Personal Safety System177
General Specifications179