Cushman Shuttle 4 Manuals

Manuals and User Guides for Cushman Shuttle 4. We have 3 Cushman Shuttle 4 manuals available for free PDF download: Service Manual, Owner's Manual

Cushman Shuttle 4 Service Manual (197 pages)

ELECTRIC POWERED UTILITY VEHICLE

Brand: Cushman | Category: Utility Vehicle | Size: 17 MB

Safety
2
General Information
4
- Table of Contents
  5
- General
  7
Safety Information
7
- General Operation
  8
- Maintenance
  8
- Ventilation
  9
- General Information & Routine Maintanence
  11
- Hauling
  13
- Serial Number Location
  13
- Servicing the Electric Vehicle
  13
- Towing
  13
- Transporting Vehicle
  13
- Brakes
  14
- Light Bulb Replacement
  14
- Rear Axle
  14
- Routine Maintenance
  14
- Tires
  14
- Vehicle Cleaning and Care
  14
- Sun Top and Windshield
  15
- Vehicle Care Products
  15
- Hardware
  16
- Torque Specifications
  16
- Periodic Service Schedule
  17
- Before Servicing the Vehicle
  21
- General Maintenance
  21
- Important Safety Warning
  21
- Modifications to Vehicle
  21
- Notices, Cautions Warnings and Dangers
  21
- Additional Warnings
  22
- Battery Removal & Installation
  23
- Fig. 1 Battery Connections
  23
- Lifting the Vehicle
  24
  - View from Underside of Vehicle
    24
  - Body
    27
- Section Title
  27
- Body
  28
- Body Component Replacement
  29
- Drill out Metal Rivet
  29
- General
  29
Body
31
- Instrument Panel Replacement
  33
- Rocker Panel Replacement
  33
- Cowl Replacement
  33
- Front Fascia Replacement
  33
- Front Seat Pod Replacement
  34
- Rear Body Replacement
  34
- Front Seat Replacement
  35
- Rear Bumper Replacement
  35
- Cargo Bed Replacement
  36
- Seat/Cargo Bed Latch
  36
- Rear Facing Rear Seat
  36
- Seat Support Removal
  37
- Shuttle 2 Rear Body
  37
- Rear Fender Removal
  38
- Rear Valence Panel Removal
  39
- Side Panel Removal
  39
- Load Deck Removal
  39
- Seat Back Removal
  40
- Bulkhead Removal
  40
- Bed Frame Removal
  41
- Seat Frame Removal
  41
- MID Support Removal
  42
- Rear Bed Bracket Removal
  42
- Painting
  43
- Minor Scratches
  43
- Complete Panel Repair
  43
- Larger Scratches
  43
- Wheels and Tires
  45
- Wheel and Tire Service
  47
- Tire Repair
  47
Wheels and Tires
47
- Wheel Installation
  48
- Wheel and Tire Installation
  48
Front Suspension and Steering
51
- Fig. 2 Lubrication Points
  51
- Axle Mounted Steering and Front Suspension
  53
- Lubrication
  54
- Maintenance
  54
- Wheel Bearing and King Pin Bushing Inspection
  54
- Wheel Bearing Packing
  54
- Wheel Alignment
  55
- Wheel Bearing Adjustment
  55
- Front Shock Absorber Replacement
  57
- Front Suspension
  57
- Axle Linkage Rod Replacement
  58
- Front Axle Replacement
  58
- Front Spring Replacement
  59
  - To Detach Passenger Side Spring
    59
  - Front Axle Alignment
    60
- Hub Replacement
  60
- Wheel Bearing and Race Replacement
  60
- Wheel Bearing Replacement
  61
- Rack Ball Joint Replacement
  62
- Steering
  62
  - Steering Components
    62
  - Rack Ball Joint Installation
    63
- Tie Rod Inspection/Replacement
  63
- Tie Rod Replacement
  63
- Bellows Replacement
  64
- Pinion Seal Replacement
  64
  - Tool List
    64
  - Removing Brake Caliper
    65
- Spindle Replacement
  65
- Front of Vehicle
  66
- Rack and Pinion Unit Disassembly and Inspection
  66
- Checking/Adjusting Rack Extension-To-Rack and Pinion Unit Clearance
  67
- Rack and Pinion Unit Replacement
  67
- Steering Wheel Replacement
  68
- Steering Shaft and Column Replacement
  69
Small Retaining Ring Orientation
70
Electronic Speed Control
73
- Anti Roll Back Feature
  75
- Anti Stall Feature
  75
- Pedal-Up Feature
  75
- Performance
  75
- Speed Control
  75
- Walk Away Feature
  75
- Diagnostic Mode Feature
  76
- High Pedal Disable Feature
  76
- Operation
  76
- Controller
  77
- Controller and Solenoid
  77
- Pedal Box
  77
- Speed Sensor
  77
- General Troubleshooting
  78
- Symptoms
  78
- Testing Battery Voltage
  78
  - Battery Reference Voltage
    79
  - Continuity Check of Switch
    79
- Testing a Solenoid for Continuity
  79
- Testing a Switch for Continuity
  79
  - Continuity Check of Solenoid
    80
  - Troubleshooting Diagrams
    80
  - 48 Volt Fault Codes
    82
  - Controller Connectors and Connections
    82
  - 48 Volt Wiring Diagram
    83
  - J-1 Pin Connector Diagnostics
    84
  - J-2 Pin Connector Diagnostics
    86
  - Secondary Wiring Diagnostics
    87
  - Inductive Throttle Sensor (Its)
    88
  - ITS and Plunger
    88
  - ITS Adjustment
    89
  - Controller Replacement
    91
  - Solenoid Replacement
    91
  - Controller Wiring
    92
  - Brakes - Front Disc
    95
- Master Cylinder Replacement
  97
- System Description
  97
To Remove the Master Cylinder
97
Brakes - Front Disc
97
- Brake Pad Replacement
  98
- Check Brake Fluid
  98
- Rotor Replacement
  98
- Routine Maintenance
  98
- Spindle Replacement
  98
- Actuator Pivot Bushings
  99
- Bleeding Brakes
  99
- Replacement of Wear Items
  98
- Brake Master Cylinder Fluid
  98
- Mechanical Brakes
  101
- Brake System Overview
  103
- Mechanical Brake System
  103
- Wheel Brake Adjustment
  104
- How the Parking Brake Works
  104
- Compensator Assembly
  105
- Kick-Off Actuating Linkage
  105
- Parking Brake and Kick-Off Mechanism
  105
- Troubleshooting Flowchart
  106
- Troubleshooting Table
  108
- Brake Pedal Inspection
  110
- Brake Pedal Bumper Inspection
  110
- New Vehicles
  110
- Troubleshooting and Inspection
  110
- Equalizer and Compensator
  111
- Parking Brake Pedal Hinge Inspection
  112
- Periodic Brake Performance Test (PBPT)
  112
- Kick-Off Cam Inspection
  112
- Periodic Brake Performance Test
  113
- Aggressive Stop Test
  113
- Wheel Brake Inspection
  114
- Equally Load Vehicle
  114
- Adjuster Mechanism
  115
- Brake Shoe Wear
  115
- Orientation of Brake Shoe Springs
  116
- Adjusting Brake Pedal Free Travel
  116
- Free Travel Adjustment
  117
- Check Clevis Pins
  117
- Brake Drum Removal and Installation
  117
- Checking Parking Brake Latching Pressure
  117
- Wheel Brake Service
  118
- Brake Assembly
  118
- Backing Plate Removal and Installation
  119
- Wheel Brake Lubrication Points
  119
- Brake Shoe and Adjuster Replacement
  119
- Brake Shoes and Springs
  120
- Brake Cable and Equalizer Assembly
  120
- Brake Pedal Removal and Installation
  121
- Brake Cable, Equalizer and Compensator
  121
- Pedal Bumper Adjustment
  122
- Catch Bracket and Latch Arm
  122
- Installation Is in the Reverse Order of Disassembly
  123
Electrical System
125
- Digital Volt Ohm Meter
  127
- Dvom
  127
- Wiring Diagram
  128
- Power Supply
  129
- Accessory Wiring
  129
- Check Green Power Wire
  129
- Light Bulb Replacement
  129
- Headlight & Turn Signal Light Bulb Replacement
  130
- Tail & Brake Light Bulb Replacement
  130
- Fuse Replacement
  130
- Ignition Switch & Fuse Block
  131
- Horn
  132
- Turn Signal & Hour Meter
  132
Motor
135
- Motor Removal
  137
- Mark Axle and Motor
  137
- Motor Disassembly
  137
- Bearing Replacement
  138
- Motor Components
  138
- Motor Assembly
  139
- Brush Wear
  139
- Securing Brushes
  139
- Field Coil Replacement
  139
- Motor Tests
  140
- Motor Installation
  140
- Motor Wiring - Pds
  140
- Motor Wiring
  140
Batteries and Charging
143
- Battery
  145
- Battery Maintenance
  145
- Water Purity Table
  146
- Correct Electrolyte Level
  146
- Electrolyte Level and Water
  146
- At each Charging Cycle
  146
- Automatic Watering Gun
  147
- Cleaning Batteries
  147
- Preparing Acid Neutralizing Solution
  147
- Battery Replacement
  148
- Prolonged Storage
  148
- Battery Charging
  149
- AC Voltage
  149
- Troubleshooting
  149
- Freezing Point of Electrolyte
  149
- Using a Hydrometer
  150
- Hydrometer
  150
- Battery Charger
  151
- Portable Charger Installation
  151
- Charger Installation
  151
- Hydrometer Temperature Correction
  151
- Charger Maintenance
  152
- Polarized Receptacle
  152
- Charger Plug
  152
Rear Suspension
153
- Shock Absorber Removal
  155
- Rear Spring Installation
  155
- Rear Spring Removal
  155
- Shock Absorber Installation
  155
- Rear Axle Removal
  157
- Rear Axle Installation
  157
- Rear Axle Maintenance
  161
- Checking the Lubricant Level
  161
- Axle Shaft Removal and Disassembly
  161
- Rear Axle Disassembly
  161
- Removing/Installing Axle Shaft
  162
- Removing/Installing Inner Snap Ring
  162
- Axle Shaft Seal Removal and Replacement
  162
- Removing Seal
  162
- Cut Away of Outer Bearing and Brake Drum
  163
- Installing Seal
  163
- Axle Shaft Replacement
  163
Weather Protection
165
- Top and Windshield
  167
- Rear Support Installation
  167
- Front Struts
  167
- Sun Top
  167
- Shuttle 4 and Shuttle 6 Sun Top
  168
- Spilt Windshield
  169
- Full Windshield
  170
Troubleshooting
175
- Suspension and Steering
  177
- Lightning Protection and Grounding
  179
- Equipment Fault and Personal Safety System
  181
- Grounding Requirements
  181
- Lightning Protection Requirements
  181
- Ground Systems
  181
Lighting Protection and Grounding
181
- External Grounding Requirements
  182
- Materials
  182
- Earth Electrode System
  182
- Lightning Protection System
  182
General Specifications
185
- Product Specification
  187
- Configuration Highlights
  187
- Product Overview
  187

Cushman Shuttle 4 Owner's Manual (86 pages)

Cushman 48 V Electric Powered vehicle owner's guide

Brand: Cushman | Category: Electric Vehicles | Size: 12 MB

Table of Contents

5
- Read All of this Manual to Become Thoroughly Familiar with this Vehicle. Pay Particular Attention to All Notices, Cautions, Warnings, and Dangers.
  7
  - Safety
    7
    
    Safety
    8
    
    Notices, Cautions, Warnings, and Dangers
    9
    
    General
    10
    
    General Operation
    11
    
    Maintenance
    11
    
    Ventilation
    12
    
    Labels and Pictograms
    13
  - General Specifications
    19
Introduction

29
- Read All of this Manual to Become Thoroughly Familiar with this Vehicle. Pay Particular Attention to All Notices, Cautions, Warnings, and Dangers.
  31
  - Features
    31
    
    Horn
    33
    
    Run/Tow Switch
    35
    
    Utility Bed
    36
Operating Procedures

39
- Serial Number Location
  
  40
- Before Initial Use
  
  41
- Portable Charger Installation
  
  42
  - Using the Charger
    43
  - Understanding the Charger
    44
  - LED Operation Codes
    44
  - LED Fault Codes
    44
  - On-Board Charger
    45
  - Maintenance Instructions
    45
- Operating the Vehicle
  
  46
- Performance
  
  47
  - Speed Control
    47
  - Pedal-Up Braking
    47
  - Terrain
    47
  - Walk-Away Feature
    48
  - Anti-Roll Back Feature
    48
  - Anti-Stall Feature
    48
  - High Pedal Disable Feature
    48
  - Diagnostic Mode Feature
    48
- Starting and Driving
  
  49
  - Starting Vehicle on a Hill
    49
  - Coasting
    49
  - Labels and Pictograms
    50
  - Sun Top and Windshield
    50
Maintenance

53
- Vehicle Cleaning and Care
  
  55
  - Vehicle Cleaning
    55
- Common Sense Operation
  
  56
- Environmental Concerns
  
  56
- Repair
  
  57
  - Lifting the Vehicle
    57
- Wheels and Tires
  
  58
  - Tire Repair
    58
  - Wheel Installation
    59
- Light Bulb Replacement
  
  60
- Fuse Replacement
  
  60
- Transporting Vehicle
  
  61
  - Towing
    61
  - Hauling
    61
  - General
    61
- Service and Maintenance
  
  61
- Periodic Brake Test for Mechanical Brakes
  
  63
- Routine Maintenance
  
  63
  - Tire Inspection
    63
  - Brakes
    63
- Rear Axle
  
  64
  - Checking the Lubrican Level
    64
- Lubrication
  
  64
- System Test
  
  64
- Hardware
  
  65
  - General Operation
    66
- Periodic Service Schedule
  
  66
- Capacities and Replacement Parts
  
  67
  - Battery Replacement
    72
  - Battery Charging
    73
  - Prolonged Storage
    73
  - AC Voltage
    74
  - Troubleshooting
    74
- Battery Charging and Maintenance
  
  67
  - Safety
    67
  - Battery
    68
  - Battery Maintenance
    68
  - At each Charging Cycle
    68
  - Monthly
    69
  - Electrolyte Level and Water
    69
  - Battery Cleaning
    71
- Hydrometer
  
  75
  - Using Hydrometer
    76
    
    Declaration of Conformity
    81

Cushman Shuttle 4 Owner's Manual (78 pages)

Brand: Cushman | Category: Utility Vehicle | Size: 18 MB

Table of Contents

5
- Safety
  7
  - Safety
    8
  - Notices, Cautions, Warnings, and Dangers
    9
  - General
    11
  - General Operation
    11
  - Maintenance
    12
  - Ventilation
    12
  - Labels and Pictograms
    13
- General Specifications
  19
Introduction

29
- Features
  31
- General Information
  31
- Accelerator Pedal
  32
- Brake and Park Brake
  32
- Direction Selector
  32
- Fuel Gauge with Low Oil Pressure Indicator Light
  32
- Key Switch / Headlight Switch
  32
- Brake Light/Turn Signal
  33
- Choke
  33
- Cup Holder
  33
- Front Seats
  33
- Glove Box
  33
- Hip Restraint - Front
  33
- Horn
  33
- Rear Seat (SHUTTLE 4 and 6 Only)
  33
- Rear View Mirror
  33
- Steering Wheel
  33
- Hip Restraint - Rear (SHUTTLE 4 and 6 Only)
  34
Operating Procedures

37
- Serial Number Location
  39
- Before Initial Use
  40
- Operating the Vehicle
  40
  - Run in
    41
  - Cold Starting
    42
- Starting and Driving
  42
- Starting the Vehicle on a Hill
  42
- Coasting
  43
  - Fuel
    43
  - Battery
    44
  - Fuel Tank
    44
    
    Early Production Fuel Tank
    44
    
    Late Production Fuel Tank
    44
  - Sun Top and Windshield
    45
Maintenance

47
- Vehicle Cleaning and Care
  
  49
  - Vehicle Cleaning
    49
- Environmental Concerns
  
  50
- Common Sense Operation
  
  50
- Repair
  
  51
  - Lifting the Vehicle
    51
- Wheels and Tires
  
  52
  - Tire Repair
    52
  - Wheel Installation
    53
- Light Bulb Replacement
  
  53
  - Unidirectional Tires
    53
- Fuse Replacement
  
  54
- Vehicle with a Discharged Battery
  
  54
- Transporting Vehicle
  
  54
  - Towing
    54
  - Neutral Lock
    55
  - Hauling
    55
- Service and Maintenance
  
  56
- Routine Maintenance
  
  57
  - Tire Inspection
    57
  - Rear Axle
    57
  - Four Cycle Engine
    57
  - Engine Specifications
    57
  - Engine Description
    57
  - Checking the Oil Level
    57
  - Changing the Oil
    58
  - Starter/Generator Belt Tension
    61
  - Adjusting the Belt
    62
  - Battery Cleaning
    62
  - Brakes
    63
- Periodic Brake Test for Mechanical Brakes
  
  63
- Air Intake and Cooling Fins
  
  64
- Rear Axle
  
  64
  - Checking the Lubricant Level
    64
- Air Cleaner Inspection and Replacement
  
  65
  - Cleaning the Air Filter Element
    65
- Spark Plugs
  
  66
- Prolonged Storage
  
  67
- Hardware
  
  68
- Capacities and Replacement Parts
  
  68
- Periodic Service Schedule
  
  69
  - General Operation
    69
  - Declaration of Conformity
    73

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Cushman Shuttle 4 Service Manual (197 pages)

Table of Contents

Cushman Shuttle 4 Owner's Manual (86 pages)

Table of Contents

Table of Contents

Introduction

Operating Procedures

Serial Number Location

Before Initial Use

Portable Charger Installation

Operating the Vehicle

Performance

Starting and Driving

Maintenance

Vehicle Cleaning and Care

Common Sense Operation

Environmental Concerns

Repair

Wheels and Tires

Light Bulb Replacement

Fuse Replacement

Transporting Vehicle

Service and Maintenance

Periodic Brake Test for Mechanical Brakes

Routine Maintenance

Rear Axle

Lubrication

System Test

Hardware

Periodic Service Schedule

Capacities and Replacement Parts

Battery Charging and Maintenance

Hydrometer

Cushman Shuttle 4 Owner's Manual (78 pages)

Table of Contents

Table of Contents

Introduction

Operating Procedures

Maintenance

Vehicle Cleaning and Care

Environmental Concerns

Common Sense Operation

Repair

Wheels and Tires

Light Bulb Replacement

Fuse Replacement

Vehicle with a Discharged Battery

Transporting Vehicle

Service and Maintenance

Routine Maintenance

Periodic Brake Test for Mechanical Brakes

Air Intake and Cooling Fins

Rear Axle

Air Cleaner Inspection and Replacement

Spark Plugs

Prolonged Storage

Hardware

Capacities and Replacement Parts

Periodic Service Schedule

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