Cushman COMMANDER 280 Owner's Manual And Service Manual

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Owner's manual and service manual (64 pages)

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606895

A Textron Company

OWNER'S MANUAL

AND SERVICE GUIDE

GASOLINE POWERED UTILITY VEHICLES

ISSUED OCTOBER 2007 REVISED MARCH 2010

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Summary of Contents for Cushman COMMANDER 280

Page 1 606895 A Textron Company OWNER’S MANUAL AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLES ISSUED OCTOBER 2007 REVISED MARCH 2010...
Page 2: Safety
SA FE TY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
Page 3 OWNER’S MANUAL AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLES ™ COMMANDER (280, 280CARB) ™ COMMANDER (2200, 2200CARB) Starting Model Year 2008 The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously.
Page 4: General Information
GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. 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
TABLE OF CONTENTS SAFETY ........................ inside covers GENERAL INFORMATION ....................... ii SAFETY INFORMATION ......................v BEFORE INITIAL USE ......................1 Fig. 1 Initial Service Chart ....................... 1 CONTROLS AND INDICATORS ....................1 KEY/LIGHT SWITCH ............................2 Fig. 2 Key/Light Switch ......................2 LOW OIL PRESSURE INDICATOR LIGHT ......................
Page 6 TABLE OF CONTENTS TOWING ................................11 NEUTRAL LOCK ...............................11 Fig. 17 Neutral Lock ........................12 HAULING ................................12 SERVICE AND MAINTENANCE ....................13 SERIAL NUMBER PLATE AND LOCATION .....................13 Fig. 18 Serial Number Plate & Location ...................14 PERIODIC SERVICE SCHEDULE ........................15 Fig. 19 Periodic Service Schedule ..................15 TIRE INSPECTION ............................16 FOUR CYCLE ENGINE ......................17 ENGINE SPECIFICATIONS ..........................17...
Page 7: Safety Information
SA FE TY IN F O RM AT ION SAFETY INFORMATION This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
Page 8 SA FE TY IN F O RM AT ION This vehicle conforms to the current applicable standard(s) for safety and performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on public streets.
Page 9 SA FE TY IN F O RM AT ION • Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. •...
Page 10 SA FE TY IN F O RM AT ION NOTES: Owner’s Manual and Service Guide Page viii...
Page 11: General Safety Practices
S A F E T Y I N F O R M AT I O N The following text is pr ovided as recommended by part II of ANSI/ITSDF B5 6.8 - 2005. The manufacturer strongly endorses the contents of this specification. 6 GENERAL SAFETY PRACTICES 6.1 Introduction 6.1.1 Like other machines, carriers can cause injury if improperly used or maintained.
Page 12 S A F E T Y I N F O R M AT I O N (2) Maintain a permanent record of the design, test(s), and implementation of the modification or alteration; (3) Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals; (4) Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been mod- ified or altered together with the date of the modification or alteration, and the name of the organization that accomplished the tasks.
Page 13 S A F E T Y I N F O R M AT I O N the carrier requires lights and, if so, shall equip the carrier with appropriate lights. 6.8 Control of Noxious Gases and Fumes When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be main- tained within limits specified in the American Conference of Governmental Industrial Hygienists publication,:Threshold Limit Values for Chemical Substances and Physical Agents in the Workroom Environment.”...
Page 14 S A F E T Y I N F O R M AT I O N 7.3.1.3 Safeguard the pedestrians at all times. Do not drive carrier in a man ner that would endanger other persons. 7.3.1.4 Riding on the carrier by persons other than the operator is authorized only on personnel seat(s) provided by the manufacturer.
Page 15: Maintenance Procedures
S A F E T Y I N F O R M AT I O N 7.3.3 Loading 7.3.3.1 Refer to operators’ manual for loading instruction. 7.3.3.2 Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered, operate with extra caution.
Page 16 S A F E T Y I N F O R M AT I O N j) Handle fuel cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken the tank and make it unsafe for use. k) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s rec- ommendations.
Page 17: Before Initial Use
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for purchasing this vehicle. Before driving the Vehicle battery must be fully charged before initial use. vehicle, we ask you to spend some time reading this Check for correct tire inflation.
Page 18: Key/Light Switch
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings KEY/LIGHT SWITCH Located on the seat support panel, this lever permits the selection of either ‘F’ (forward) or ‘R’ (reverse) (Ref Fig. 3 Located on the dash panel, this switch enables the basic on page 2).
Page 19: Accelerator Pedal
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ACCELERATOR PEDAL OPTIONAL FRONT DISC BRAKES The front disc brakes activate as the brake pedal reaches the ’park’ or ’latch’ p osition. Depressing the brake pedal further will increase the effectiveness of the front brakes Unintentional movement of the accelerator ped-...
Page 20: Manual Lift Bed Operation
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Never fill a gas can in the bed of a vehicle. Stat- ic discharge could ignite gasoline vapor and cause an explosion.
Page 21: Operating The Vehicle
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OPERATING THE VEHICLE vehicle is to be left unattended, engage the park brake, move direction selector to for- ward position, turn key to ‘OFF’...
Page 22: Fig. 10 Clean Entire Dipstick
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Slowly depress the accelerator pedal to start the becoming contaminated and/or being discharged into the engine.
Page 23: Fuel
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings FUEL BATTERY Excessive use of accessories may drain the battery and To reduce the possibility of severe injury or leave insufficient reserve to start the vehicle.
Page 24: 12 Volt Power Outlet
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings sun top does not protect against falling objects nor does vehicle damage, read and understand all the windshield protect against flying objects and tree instructions supplied by manufacturer of pres- limbs.
Page 25: Repair
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings REPAIR LIFTING THE VEHICLE Tool List Qty. Required Floor jack ..............1 Jack stands ..............4 Chocks ................
Page 26: Wheel Installation
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for To reduce possibility of severe injury, be sure impact wrench use.
Page 27: Fig. 15 Headlight And Turn Signal Bulb Replacement
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings VEHICLE WITH A DISCHARGED BATTERY (Ref Fig. 15 on page 11). Remove screws, pull headlight out and disconnect wires. Connect wires to new he ad- light, install in cowl and se cure with screws pr eviously removed.
Page 28: Hauling
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings weight) and load. Lock the park brake and secure the vehicle using ratchet tie downs. Hole in Direction Selector Cam Unlocked Fig.
Page 29: Service And Maintenance
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings SERVICE AND MAINTENANCE water. Aerosol containers of battery terminal pro- tectant must be used with extreme care. Insulate metal container to reduce the pos- To reduce the possibility of severe injury or sibility of can contacting battery terminals...
Page 30 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Lift Flap on Access Panel Part A and B Serial Number Labels Part C/D Ref Spl 3 Label No.
Page 31: Periodic Service Schedule
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE Check Clean, Adjust, etc. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle.
Page 32: Tire Inspection
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Check for bent/binding linkage rod Check for damage or wear to latch arm or catch bracket PARK BRAKE Lubricate as req uired, use light oil.
Page 33: Four Cycle Engine
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings FOUR CYCLE ENGINE Insert the dipstick fully into the dipstick hole and remove. Examine the level of the oil on the dipstick. Engine Specifications Maximum Oil Level Fill Cold Engine...
Page 34: Fig. 22 Oil Viscosity Chart
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Clean the area around filter. Using a filter wrench, strap HEAVY DUTY WORK wrench or other suitable wrench, remove the filter (B) 10W-30 10W-30 10W-40...
Page 35: Fig. 26 Oil Drain Plug
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Both the oil dipstick and fill cap must be in place before operat- ing the engine. Failure to install the dipstick and fill cap will result in oil being discharged into the engine compartment.
Page 36: Adjusting The Belt
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BATTERY CLEANING 3/8" (1 cm) Maximum Deflection (New Belt) 1/2" (1.3 cm) Maximum To reduce the possibility of damage to vehicle or floor, Deflection (Existing Belt) neutralize acid before rinsing battery.
Page 37: Brakes
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BRAKES Non-Metalic Wandr 1/4 Cup (60 ML) Sodium Bicarbonate Dry, Level, Clean, Paved Surface (Baking Soda) Accelerate To Maximum Speed Latch...
Page 38: Periodic Brake Test For Mechanical Brakes
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Periodic Brake Test For Mechanical Brakes road use, allow to cool and then check for a build up of dirt and debris in the air intake and The purpose of this test is to compare the braking perfor- cooling fins.
Page 39: Air Cleaner Inspection And Replacement
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings positioning arrow on cover is pointing upward and all clips are fastened securely. Fill / Check Plug Air Filter Air Cleaner Element...
Page 40: Fig. 36 Lubrication Points
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings tion or poor quality fuel could also contribute to the prob- lem. King Pin King Pin Idler Arm PROLONGED STORAGE To reduce the possibility of severe injury or...
Page 41: Capacities And Replacement Parts
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Reattach fuel line to tank and drive the vehicle for identified by 6 marks on the head. Unmarked hardware is several minutes to circulate the additive through Grade 2 (Ref Fig.
Page 42: Fig. 39 Torque Specifications And Bolt Grades
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.
Page 43 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings NOTES: NOTES: Page 27 Owner’s Manual and Service Guide...
Page 44 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings NOTES: Page 28 Owner’s Manual and Service Guide...
Page 45: General Specifications
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 29...
Page 46 GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS ™ COMMANDER STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 779 lbs (353 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated)* TIRE PRESSURE 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY 800 lbs (362 kg) (including operator, passenger, cargo bed and accessories) GROUND CLEARANCE 4.5"...
Page 47 GENERAL SPECIFICATIONS ™ COMMANDER 2200 STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 828 lbs (376 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (124 - 152 kPa)* LOAD CAPACITY 1200 lbs (544 kg) (including operator, passenger, cargo bed and accessories) GROUND CLEARANCE 4.5"...
Page 48: Fig. 40 Vehicle Dimensions
GENERAL SPECIFICATIONS 10 in 47 in (25 cm) (119 cm) 66 in (168 cm) (Front) 37.5 in (95 cm) 103 in (262 cm) (Rear) 35 in (89 cm) 38 in (97 cm) 47 in COMMANDER ™ 280 (119 cm) 18 in (46 cm) 47 in ( 119 cm)
Page 49 GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER COMMANDER ™ 280 - 19 ft (5.8 m) COMMANDER ™ 2200 - 22 ft (6.7 m) Fig. 41 Vehicle Incline Specifications and Turning Clearance Diameter Owner’s Manual and Service Guide Page 33...
Page 50 GENERAL SPECIFICATIONS NOTES: Owner’s Manual and Service Guide Page 34...
Page 51: Labels And Pictograms
LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
Page 52 LABELS AND PICTOGRAMS MIN 150 See Following Pages For 614121 Explanation 614121 Of These Pictograms 601781 71131-G01 71131G01 74443G01 74443G01 71489G01 On Battery Under Seat 35493-G01 71771G01 35493G01 28203G01 250 lbs. 114 kg 4 in. 10 cm / 25% WARNING 35980G01 35980G01 35980G02...
Page 53 LABELS AND PICTOGRAMS WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD XXX lbs. AS POSSIBLE. XXX kg MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE...
Page 54 LABELS AND PICTOGRAMS CLEAN UP GASOLINE SPILLS WITH DO NOT WATER BEFORE DISPOSE OF STARTING ENGINE BATTERIES IN LANDFILL UNLEADED GASOLINE DO NOT DO NOT DRIVE ON SPILL FUEL HIGHWAY ON A HOT ENGINE WINDSHIELDS GROUND DO NOT FUEL PUMP PROVIDE PROTECTION FROM...
Page 55 LABELS AND PICTOGRAMS HEADLIGHTS KEEP ARMS AND LEGS WITHIN VEHICLE UNLOCKED TO OPERATE VEHICLE IN FORWARD: Q TURN KEY TO ON Q MOVE DIRECTION SELECTOR TO FORWARD Q DEPRESS ACCELERATOR PEDAL LOCKED AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE: Q TURN KEY TO ON Q MOVE DIRECTION SELECTOR TO REVERSE...
Page 56 LABELS AND PICTOGRAMS Notes: Owner’s Manual and Service Guide Appendix A - 6...
Page 57: Vehicle Warranties
VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Appendix B - 1...
Page 58: Domestic Warranty
VEHICLE WARRANTIES DOMESTIC WARRANTY (U.S. AND CANADA) To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer date code. Owner’s Manual and Service Guide Appendix B - 2...
Page 59: California Emission Control Warranty Statement
VEHICLE WARRANTIES - CALIFORNIA CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and E-Z-G O are pleased to explain the evaporative emission control system warranty on your 2010 vehi cle. In California, new vehi cles must be designed, built and equipped to meet the State’s stringent anti-smog standards.
Page 60 VEHICLE WARRANTIES - CALIFORNIA (3) Any warranted pa rt that is sched uled for replacement as required maintenance in the written instructions supplied is warranted for the peri od of time before the first scheduled replacement date for that part. If t he part fails before the first scheduled replacement, the part will be repaired or replaced by ABC, Inc.
Page 61: Federal Emission Component Defect Warranty
VEHICLE WARRANTIES - FEDERAL FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Kawasaki Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
Page 62 VEHICLE WARRANTIES As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. E-Z-GO recommends that you retain all receipts covering maintenance on your engine, but E-Z-GO cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
Page 63: Declaration Of Conformity
DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Appendix C - 1...
Page 64 DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Appendix C - 2...
Page 65 DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Appendix C - 3...
Page 66 DECLARATION OF CONFORMITY NOTES: Owner’s Manual and Service Guide Appendix C - 4...
Page 67 Some components are heavy, spring loaded, highly cor- rosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, Read and understand the following warnings before attempting battery acid and hydrogen gas could result in serious to operate the vehicle: bodily injury to the technician/mechanic and bystanders if not treated with the utmost caution.
Page 68 A Textron Company CUSHMAN Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609...

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