Cushman SHUTTLE 2+2 Service & Parts Manual
  1. Manuals
  2. Brands
  3. Cushman Manuals
  4. Utility Vehicle
  5. SHUTTLE 2+2
  6. Service & parts manual

Cushman SHUTTLE 2+2 Service & Parts Manual

72v electric powered utility vehicle
Hide thumbs
Table of Contents

Advertisement

Quick Links

72V SHUTTLE 2+2
Service Parts Manual
661605 - R

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SHUTTLE 2+2 and is the answer not in the manual?

Questions and answers

Michael F Collins
April 21, 2025

how to change the oil

0

Related Manuals for Cushman SHUTTLE 2+2

Summary of Contents for Cushman SHUTTLE 2+2

  • Page 1 72V SHUTTLE 2+2 Service Parts Manual 661605 - R...
  • Page 3 SERVICE PARTS MANUAL 72V ELECTRIC POWERED UTILITY VEHICLE SHUTTLE 2+2 STARTING MODEL YEAR 2017 CALIFORNIA Proposition 65 Warning WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead and lead compounds and other chemicals identified by the State of California to potentially cause can- cer, birth defects, and other reproductive harm.
  • Page 4 GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA). 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.
  • Page 5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL ..........V ACCELERATOR .
  • Page 6 NOTES Page iv 661605 Service Parts Manual...
  • Page 7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: • GENERAL INFORMATION • ILLUSTRATED PARTS BREAKDOWN The first section, GENERAL INFORMATION, contains the following information: • WARRANTY INFORMATION • GENERAL INDEX • HOW TO USE THE SERVICE PARTS MANUAL The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your vehicle.
  • Page 8 HOW TO USE THE SERVICE PARTS MANUAL Title Title *See Body Section for decal information 102,104 Front of Vehicle 83,88 81,86 84,89 82,87 128 129 Left hand illustration page Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN •...
  • Page 9 HOW TO USE THE SERVICE PARTS MANUAL 3. COLOR CODE FOR BODY COMPONENTS The last two digits of the part number for the body part will denote the color code, locate the part number for the cowl, rear body, seat pod, side panel or seat wrap then locate your color in the list below, replace the last ** or XX with the two digit color code.
  • Page 10 ACCELERATOR To harness from direction selector Part of Frame PEDAL BOX ASSEMBLY includes items 2 - 34 ACCELERATOR PEDAL ASSEMBLY includes items 28 - 30 PEDAL HARNESS includes items 33 - 34 Page A-1 661605 Service Parts Manual...
  • Page 11 ACCELERATOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 12 ACCELERATOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 13 ACCELERATOR Notes: Page A-4 661605 Service Parts Manual...
  • Page 14 BATTERY CHARGER Page B-1 661605 Service Parts Manual...
  • Page 15 BATTERY CHARGER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 16 BATTERY CHARGER Notes: Page B-3 661605 Service Parts Manual...
  • Page 17 BATTERY CHARGER Notes: Page B-4 661605 Service Parts Manual...
  • Page 18 BODY Front of Vehicle Front of Vehicle INSTRUMENT PANEL ASSEMBLY includes items 19 - 27 INSTRUMENT PANEL ASSEMBLY WITH BALL DEFLECTOR includes items 20 - 24 Front of Vehicle Page C-1 661605 Service Parts Manual...
  • Page 19 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 20 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 21 BODY Notes: Page C-4 661605 Service Parts Manual...
  • Page 22 BODY Front of Vehicle Front of Vehicle Page C-5 661605 Service Parts Manual...
  • Page 23 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 24 BODY FOR VEHICLES MANUFACTURED BEFORE JUNE 02, 2019 FOR VEHICLES MANUFACTURED AFTER JUNE 02, 2019 Page C-7 661605 Service Parts Manual...
  • Page 25 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 26 BODY Front of Vehicle Front of Vehicle Rear Bumper Installation Page C-9 661605 Service Parts Manual...
  • Page 27 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 28 BODY Notes: Page C-11 661605 Service Parts Manual...
  • Page 29 BODY Notes: Page C-12 661605 Service Parts Manual...
  • Page 30 BRAKES BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) includes items 2 - 28 WHITE BLACK Page D-1 661605 Service Parts Manual...
  • Page 31 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 32 BRAKES COMPENSATOR ASSEMBLY includes items 37 - 49 Front of Vehicle Part of Frame Accelerator Pedal Page D-3 661605 Service Parts Manual...
  • Page 33 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 34 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 35 BRAKES Notes: Page D-6 661605 Service Parts Manual...
  • Page 36 BRAKES BRAKE ASSEMBLY (DRIVER SIDE) includes items 3 - 9 BRAKE ASSEMBLY (PASSENGER SIDE) includes items 3 - 8, 10 BRAKE DRUM ASSEMBLY includes items 17, 18 TOP PULL Front of Vehicle Tension Pin Page D-7 661605 Service Parts Manual...
  • Page 37 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 38 BRAKES Notes: Page D-9 661605 Service Parts Manual...
  • Page 39 BRAKES Notes: Page D-10 661605 Service Parts Manual...
  • Page 40 ELECTRICAL Front of Vehicle *Battery design may vary by part number Page E-1 661605 Service Parts Manual...
  • Page 41 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 42 ELECTRICAL CHARGER RECEPTACLE ASSEMBLY includes items 11 - 19 DC-DC Converter and Fuse Block Installation Fender Liner Instrument Panel Part of Front of Vehicle Assembly Battery Installation Front of Vehicle Page E-3 661605 Service Parts Manual...
  • Page 43 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 44 ELECTRICAL CONTROL PANEL ASSEMBLY includes items 2 - 9 Front of Vehicle Solenoid Installation Page E-5 661605 Service Parts Manual...
  • Page 45 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 46 ELECTRICAL Front of Vehicle Front of Vehicle REVERSE BUZZER Floorboard Front of Vehicle GREEN BLACK /WHITE HORN BUTTON HORN Page E-7 661605 Service Parts Manual...
  • Page 47 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 48 ELECTRICAL Front of Vehicle HEADLIGHT ASSEMBLY Front of Vehicle TAILLIGHT ASSEMBLY TURN SIGNAL SWITCH ASSEMBLY Rear Body includes item 13 TAILLIGHT ASSEMBLY, (DRIVER SIDE) includes item 24, 26 - 28 TAILLIGHT ASSEMBLY, (PASSENGER SIDE) includes item 25 - 28 LED HEADLIGHT REPLACEMENT KIT includes items 29, 30 Light Assembly To Bezel Page E-9...
  • Page 49 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 50 ELECTRICAL Notes: Page E-11 661605 Service Parts Manual...
  • Page 51 ELECTRICAL Notes: Page E-12 661605 Service Parts Manual...
  • Page 52 ELECTRONIC SPEED CONTROL CONTROLLER ASSEMBLY includes items 2 - 11 Battery Tray To Motor Front of Vehicle Page F-1 661605 Service Parts Manual...
  • Page 53 ELECTRONIC SPEED CONTROL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 54 ELECTRONIC SPEED CONTROL Notes: Page F-3 661605 Service Parts Manual...
  • Page 55 ELECTRONIC SPEED CONTROL Notes: Page F-4 661605 Service Parts Manual...
  • Page 56 FRONT SUSPENSION AND STEERING Front of Vehicle Part of Frame Front of Vehicle Part of Frame 4 LUG SPINDLE AND HUB ASSEMBLY (PASSENGER SIDE) includes items 6 - 15 SPINDLE AND HUB ASSEMBLY (DRIVER SIDE) includes items 5, 7 - 15 Page G-1 661605 Service Parts Manual...
  • Page 57 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 58 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 59 FRONT SUSPENSION AND STEERING Notes: Page G-4 661605 Service Parts Manual...
  • Page 60 FRONT SUSPENSION AND STEERING TIE ROD ASSEMBLY includes items 8 - 12 STEERING COLUMN KIT includes items 28 - 38 Front of Vehicle Page G-5 661605 Service Parts Manual...
  • Page 61 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 62 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 63 FRONT SUSPENSION AND STEERING Notes: Page G-8 661605 Service Parts Manual...
  • Page 64 FRONT SUSPENSION AND STEERING RACK AND PINION UNIT includes items 2 - 23 TIE ROD END includes items 24 - 25 Page G-9 661605 Service Parts Manual...
  • Page 65 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 66 FRONT SUSPENSION AND STEERING Notes: Page G-11 661605 Service Parts Manual...
  • Page 67 FRONT SUSPENSION AND STEERING Notes: Page G-12 661605 Service Parts Manual...
  • Page 68 MOTOR SPEED SENSOR KIT includes items 8- 9 Rear Axle Front of Vehicle Front of Vehicle 661605 Service Parts Manual Page H-1...
  • Page 69 MOTOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 70 MOTOR Notes: 661605 Service Parts Manual Page H-3...
  • Page 71 MOTOR Notes: 661605 Service Parts Manual Page H-4...
  • Page 72 REAR AXLE REAR AXLE, 16.99:1 includes items 4 - 42 Front of Vehicle Rear Axle Use Existing Hardware Page J-1 661605 Service Parts Manual...
  • Page 73 REAR AXLE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 74 REAR AXLE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 75 REAR AXLE Notes: Page J-4 661605 Service Parts Manual...
  • Page 76 REAR SUSPENSION Front of Vehicle 661605 Service Parts Manual Page K-1...
  • Page 77 REAR SUSPENSION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 78 REAR SUSPENSION Notes: 661605 Service Parts Manual Page K-3...
  • Page 79 REAR SUSPENSION Notes: 661605 Service Parts Manual Page K-4...
  • Page 80 SEATING SEAT BOTTOM ASSEMBLY includes items 17 - 26 Front of Vehicle SEAT BACK ASSEMBLY includes items 2 - 4 SEAT BACK ASSEMBLY includes items 5 - 9 Front of Vehicle FLIP SEAT BOTTOM ASSEMBLY includes items 31 - 38 SEAT BOTTOM ASSEMBLY includes items 33 - 35 Front of Vehicle Page L-1...
  • Page 81 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 82 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 83 SEATING Notes: Page L-4 661605 Service Parts Manual...
  • Page 84 SEATING REAR FLIP SEAT HANDRAIL KIT includes items 32 - 37 Flip Seat Bottom Assembly Front of Vehicle Page L-5 661605 Service Parts Manual...
  • Page 85 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 86 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 87 SEATING Notes: Page L-8 661605 Service Parts Manual...
  • Page 88 WEATHER PROTECTION Front of Vehicle DETAIL D (REAR) (Passenger Side Shown) SUN TOP KIT (BLACK) includes items 2 - 29 SUN TOP KIT (WHITE) includes items 3 - 29, 33 SUN TOP KIT (TAN) includes items 3 - 29, 36 Front of Vehicle DETAIL A (Driver Side Shown)
  • Page 89 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 90 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 91 WEATHER PROTECTION Notes: Page M-4 661605 Service Parts Manual...
  • Page 92 WEATHER PROTECTION Strut FULL WINDSHIELD KIT includes items 2 - 8 Front of Vehicle Windshield Retainer Front of Vehicle Rubber Latch Strut SPLIT WINDSHIELD KIT (CLEAR) includes items 12, 13 SPLIT WINDSHIELD HARDWARE KIT includes items 3 - 6, 11 SPLIT WINDSHIELD KIT includes items 33, 34 SPLIT WINDSHIELD HARDWARE KIT includes items 3 - 6, 11 21 22 23 24 25 26 27 28 29...
  • Page 93 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 94 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 95 WEATHER PROTECTION Notes: Page M-8 661605 Service Parts Manual...
  • Page 96 WHEELS AND TIRES FRONT WHEEL AND TIRE ASSEMBLY (HOLE-N-ONE) includes items 4, 5, 10 REAR WHEEL AND TIRE ASSEMBLY (USA TRAIL) includes items 7 - 10 Tire design may vary by Part Number Page N-1 661605 Service Parts Manual...
  • Page 97 WHEELS AND TIRES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 98 WHEELS AND TIRES Notes: Page N-3 661605 Service Parts Manual...
  • Page 99 WHEELS AND TIRES Notes: Page N-4 661605 Service Parts Manual...
  • Page 100 DECALS AND LABELS Cowl Rear Body Rear Body Page P-1 661605 Service Parts Manual...
  • Page 101 DECALS AND LABELS THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 102 DECALS AND LABELS Steering Column Front of Vehicle Page P-3 661605 Service Parts Manual...
  • Page 103 DECALS AND LABELS THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 104 DECALS AND LABELS Notes: Page P-5 661605 Service Parts Manual...
  • Page 105 DECALS AND LABELS Notes: Page P-6 661605 Service Parts Manual...
  • Page 106 Phone: 001-706-798-4311, FAX: 001-706-771-4609 Owner's guides and repair manuals are available from a local Distributor, or an authorized Branch, Parts & Accessories Department or at www.cushman.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...

Table of Contents

Save PDF