Cushman SHUTTLE 4X Manuals

Manuals and User Guides for Cushman SHUTTLE 4X. We have 3 Cushman SHUTTLE 4X manuals available for free PDF download: Technician's Repair And Service Manual, Owner's Manual

Cushman SHUTTLE 4X Technician's Repair And Service Manual (189 pages)

ELECTRIC POWERED UTILITY VEHICLES

Brand: Cushman | Category: Utility Vehicle | Size: 15 MB

Safety
2
- Notice
  2
- Battery Prolonged Storage
  4
- Battery Disposal
  4
General Information
4
- Table of Contents
  5
- General
  7
Safety Information
7
- General Operation
  8
- Maintenance
  8
Safety
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 Component Replacement
  29
- Drill out Metal Rivet
  29
- Front Body Components
  30
- Floor Mount Gun Holder
  31
- Ashtray
  31
- Floor Mount Gun Holder and Ashtray
  31
- Larger Scratches
  33
- Complete Panel Repair
  33
- Minor Scratches
  33
- Painting
  33
Wheels and Tires
35
- Wheel and Tire Service
  37
- Tire Repair
  37
- Wheel Installation
  38
- Wheel and Tire Installation
  38
Front Suspension and Steering
41
- Fig. 2 Lubrication Points
  41
- Axle Mounted Steering and Front Suspension
  43
- Lubrication
  44
- Maintenance
  44
- Wheel Bearing and King Pin Bushing Inspection
  44
- Wheel Bearing Packing
  44
- Wheel Alignment
  45
- Wheel Bearing Adjustment
  45
- Front Shock Absorber Replacement
  47
- Front Suspension
  47
- Front Suspension Components
  47
- Axle Linkage Rod Replacement
  48
- Front Axle Replacement
  48
- Front Spring Replacement
  49
  - To Detach Driver Side Spring
    49
  - To Detach Passenger Side Spring
    49
- Hub Replacement
  50
  - Seal Installation
    50
  - Tool List
    50
- Wheel Bearing and Race Replacement
  50
- Wheel Bearing Replacement
  51
- Rack Ball Joint Replacement
  52
- Steering
  52
  - Steering Components
    52
  - Rack Ball Joint Installation
    53
- Tie Rod Inspection/Replacement
  53
  - Tie Rod Replacement
    53
  - Bellows Replacement
    54
  - Pinion Seal Replacement
    54
  - Removing Brake Caliper
    55
  - Spindle Replacement
    55
  - Rack and Pinion Unit Disassembly
    56
  - Rack and Pinion Unit Disassembly and Inspection
    56
  - Checking/Adjusting Rack Extension-To-Rack
    57
  - Rack and Pinion Unit Replacement
    57
  - Checking Gap
    58
  - Clipboard Removal
    58
  - Spindle Contact with Front Axle
    58
  - Steering Wheel Replacement
    58
  - Steering Shaft and Column
    59
  - Steering Shaft and Column Replacement
    59
  - Small Retaining Ring Orientation
    60
  - Electronic Speed Control - Tct
    63
- Changing Performance Options
  65
- General
  65
- Trucourse Technology System
  65
- Operation
  66
  - Run-Tow/Maintenance Switch
    66
  - Access to Pedal Box
    67
- Controller
  67
- Pedal Box
  67
- Speed Sensor
  67
- Battery Reference Voltage
  68
- Continuity Check
  68
- General Troubleshooting
  68
- Symptoms
  68
- Testing Battery Voltage
  68
- Testing a Solenoid for Continuity
  69
- Testing a Switch for Continuity
  69
- Continuity Check of Solenoid
  69
- Troubleshooting Diagrams
  70
- 1206HB-5201 Controller Faults and Troubleshooting
  70
- Controller Connectors and Connections
  72
- Controller Wiring Diagram
  73
- Inductive Throttle Sensor (Its)
  74
- ITS and Plunger
  74
- ITS Adjustment
  75
- Controller Replacement
  77
- Solenoid Replacement
  77
- Solenoid Wiring
  78
Motor
81
- Disconnect Battery Cable
  83
- Motor
  83
- Motor Disassembly
  83
- Motor Removal
  83
- Motor Components
  84
- Bearing Replacement
  85
- Brush Replacement
  85
- Brush Wear
  85
- Motor Assembly
  86
- Motor Installation
  86
- Motor Tests
  86
- Securing Brushes
  86
- Batteries and Charging
  89
- Battery Maintenance
  91
- Safety
  91
- At each Charging Cycle
  92
- Electrolyte Level and Water
  92
- Monthly
  92
- Automatic Watering Gun
  93
- Battery Replacement
  93
- Cleaning Batteries
  93
- Preparing Acid Neutralizing Solution
  93
- Battery Charging
  95
- Freezing Point of Electrolyte
  95
- Prolonged Storage
  95
- Specific Gravity Electrolyte Freezing Point
  95
- AC Voltage
  96
- Hydrometer
  96
- Troubleshooting
  96
- Using a Hydrometer
  97
- Hydrometer Temperature Correction
  97
Electrical System
99
- Digital Volt Ohm Meter
  101
- Accessory Wiring Diagram
  102
- Main Harness Wiring Diagram
  103
- Check Fuse
  104
- Main & Accessory Wiring
  104
- Check Battery Condition
  104
- Power Supply
  104
- Electrical Accessories
  105
- Mechanical Brakes
  109
- Brake System Overview
  111
- How the Service Brake Works
  111
- Mechanical Brake System
  111
- Equalizer Link
  112
- Automatic Adjuster Mechanism
  112
- How the Parking Brake Works
  112
- Wheel Brake Adjustment
  112
- Parking Brake and Kick-Off Mechanism
  113
- Kick-Off Actuating Linkage
  113
- Compensator Assembly
  113
- Troubleshooting Flowchart
  114
- New Vehicles
  118
- Troubleshooting and Inspection Procedures
  118
- Brake Pedal Bumper Inspection
  118
- Brake Pedal Inspection
  118
- Checking for Excessive Free Travel
  119
- Equalizer and Compensator
  119
- Parking Brake Pedal Hinge Inspection
  120
- Kick-Off Cam Inspection
  120
- Periodic Brake Performance Test (PBPT)
  120
- Aggressive Stop Test
  121
- Periodic Brake Performance Test
  121
- Wheel Brake Inspection
  122
- Equally Load Vehicle
  122
- Adjuster Mechanism
  123
- Brake Shoe Wear
  123
- Parts Replacement Vs. Repair
  124
- Maintenance and Repairs
  124
- Orientation of Brake Shoe Springs
  124
- Adjusting Brake Pedal Free Travel
  124
Brakes
124
- Checking Parking Brake Latching Pressure
  125
- Check Clevis Pins
  125
- Free Travel Adjustment
  125
- Brake Drum Removal and Installation
  125
- Wheel Brake Service
  126
- Brake Assembly
  126
- Backing Plate/Entire Wheel Brake Assembly
  127
- Backing Plate Removal and Installation
  127
- Wheel Brake Lubrication Points
  127
- Brake Shoe and Adjuster Replacement
  127
- Setting Adjuster Screw
  128
- Brake Shoes and Springs
  128
- Brake Cable and Equalizer Assembly
  128
- Brake Cable, Equalizer and Compensator
  129
- Brake Pedal Removal and Installation
  129
- Catch Bracket and Latch Arm
  130
- Parking Brake Kick-Off Cam Removal
  130
- Pedal Bumper Adjustment
  130
Battery Charger
133
- Charger Description
  135
- Portable Charger Installation
  135
- Charger Installation
  135
- Maintenance Instructions
  136
- Led Display Information
  136
- LED Fault Code
  136
- Understanding the Charger
  136
Rear Suspension
139
- Shock Absorber Installation
  141
- Rear Spring Removal
  141
- Rear Spring Installation
  141
- Shock Absorber Removal
  141
Rear Axle
145
- Rear Axle Maintenance
  147
- Checking the Lubricant Level
  147
- Axle Shaft Removal and Disassembly
  147
- Rear Axle Disassembly
  147
- Removing Seal
  148
- Removing/Installing Inner Snap Ring
  148
- Axle Shaft Seal Removal and Replacement
  148
- Removing/Installing Axle Shaft
  148
- Axle Shaft Replacement
  149
- Installing Seal
  149
- Cut Away of Outer Bearing and Brake Drum
  149
Weather Protection
151
- Top and Windshield
  153
- Front Strut
  153
- Sun Top
  153
- Trailering
  153
- Split Windshield
  155
- Full Windshield
  156
Handheld Diagnostics
159
- Primary Connection: 4 Pin Tyco
  161
- Alternate Connection: 4 Pin Molex
  161
- Navigation
  161
- Curtis Handheld Programmer
  161
- Changing Data Value
  162
- Bookmark
  162
- Main Menu Definitions
  162
Troubleshooting
167
- Lightning Protection and Grounding
  173
- Equipment Fault and Personal Safety System
  175
- Ground Network Requirements
  175
- Ground Systems
  175
- External Grounding Requirements
  176
- Lightning Protection System
  176
- Materials
  176
- 10. Equipment Fault and Personal Safety System
  177
General Specifications
179

Cushman SHUTTLE 4X Technician's Repair And Service Manual (214 pages)

GASOLINE POWERED UTILITY VEHICLE

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

Table of Contents

5
- Safety
  2
- General Information
  4
  - Table of Contents
    5
- Safety Information
  7
General Information & Routine Maintenance

11
- General Information & Routine Maintenance
  13
  - Serial Number Location
    13
  - Starting the Vehicle with Adischarged Battery
    13
  - Servicing the Vehicle
    13
  - Fuel
    14
  - Towing
    14
  - Routine Maintenance
    15
  - Powertrain Maintenance
    15
  - Brakes
    16
  - Tires
    16
  - Trailering
    16
  - Top and Windshield
    16
  - Winter or Prolonged Storage
    16
  - Care and Cleaning of the Vehicle
    17
  - Vehicle Care Products
    17
  - Hardware
    17
  - Torque Specifications
    18
  - Periodic Service Schedule
    19
- Safety
  25
- Body
  32
Wheels and Tires

45
- Wheel and Tire Service
  47
  - Tire Repair
    47
  - Wheel Installation
    48
- Fig. 1 Wheel and Tire Installation
  48
- Front Suspension and Steering
  53
Speed Control

83
- Section Title
  
  85
- System Operation
  
  85
  - Pedal Box Operation
    85
  - Governor Operation
    86
- Troubleshooting
  
  86
- Speed Control
  
  86
- Pedal Box Adjustments
  
  88
  - Accelerator Pedal Arm Adjustment
    88
  - Micro Switch Adjustment
    88
  - Road Test
    89
Engine

91
- Section Title
  
  93
- Powertrain Maintenance
  
  93
  - Changing the Oil
    93
  - Checking the Oil Level
    93
- Air Filter Inspection/Replacement
  
  95
  - Cleaning the Air Filter Element
    96
- Starter/Generator Belt Tension
  
  96
  - Adjusting the Belt
    96
- Starter/Generator Replacement
  
  97
- Spark Plug
  
  98
- Cooling System Cleaning
  
  98
- Four Cycle Engine
  
  99
  - Engine Specifications
    99
  - Engine Description
    99
- Cylinder Head
  
  99
  - Compression Measurement
    99
  - Rocker Cover Removal
    100
  - Valve Clearance Inspection
    100
  - Valve Clearance Adjustment
    100
- Engine Removal
  
  101
  - Controls and Wiring
    102
  - Removing the Engine from the Vehicle
    102
  - Engine Installation
    102
- Drive Clutch Removal
  
  102
Fuel System

105
- Fuel System
  106
  - General
    107
  - Carburetor Operation
    108
    
    Float System
    108
    
    Pilot Jet System
    108
    
    Main Jet System
    108
    
    Carburetor Service
    108
    
    Choke System
    108
    
    Choke Operation
    108
  - Fuel System Component Service and Replacement
    109
    
    Choke Cable and Housing Removal
    109
    
    Choke Cable and Housing Installation
    109
    
    Carburetor Removal
    110
    
    Carburetor Disassembly
    110
    
    Float Level Alignment
    111
    
    Carburetor Installation
    111
  - Fuel Pump
    111
    
    Fuel Pump Replacement
    112
  - Fuel Lines and Filter
    112
  - Fuel Tank Removal
    113
- Continuously Variable Transmission (Cvt)
  117
- Direction Selector
  125
Electrical

131
- Section Title
  
  133
  - Circuits and Controls
    133
  - Generator
    133
  - Starter
    133
  - Testing Ignition Circuit
    133
    
    Testing the Magneto
    136
  - Wiring
    133
  - Testing Charging Circuit
    137
  - Testing Starting Circuit
    137
- Inspection
  
  138
  - Starter/Generator
    138
    
    Disassembly
    139
  - Battery Voltage Test
    139
- Troubleshooting
  
  140
  - Dvom (Digital Volt Ohm Meter)
    140
  - Power Supply
    140
  - Storage of Battery
    140
Mechanical Brakes

143
- Section Title
  143
  - Page no
    143
- Mechanical Brakes
  145
  - Brake System Overview
    145
    
    General Description
    145
    
    How the Service Brake Works
    145
    
    Equalizer Link
    145
    
    Automatic Adjuster Mechanism
    146
    
    How the Parking Brake Works
    146
    
    Compensator Assembly
    147
    
    Kick-Off Actuating Linkage
    147
  - Troubleshooting Table
    148
  - Troubleshooting and Inspection
    150
    
    New Vehicles
    150
    
    Troubleshooting and Inspection Procedures
    150
    
    Brake Pedal and Linkage Inspection
    150
    
    Periodic Brake Performance Test (PBPT)
    152
    
    Aggressive Stop Test
    153
    
    Wheel Brake Inspection
    154
  - Maintenance and Repairs
    156
- Rear Suspension
  165
- Rear Axle
  171
Weather Protection

177
- Sun Top
  179
  - Rear Support Installation
    179
  - Front Strut
    179
- Sun Top and Windshield
  179
- Split Windshield
  181
- Full Windshield
  182
- Split Windshield (Clip-On Type)
  183
- Full Windshield (Clip-On Type)
  184
Troubleshooting

187
- Engine Overheating
  191
- Poor Low Speed Performance
  191
- Poor Midrange or High Speed Performance
  191
- Backfiring
  192
- Excessive Smoking
  192
- Repeated Spark Plug Fouling
  192
- Carburetor
  193
  - Overflow Leak
    194
  - Poor Acceleration
    194
  - Hard Starting
    194
  - Abnormal Combustion (Fuel Mixture)
    195
  - Loss of Power (Insufficient Fuel)
    195
  - Loss of Power (Insufficient Air)
    195
  - Stiff Steering
    196
- Erratic, Surging, or Sudden Change in Governed Speed
  193
- Fuel Accumulation in the Crankcase
  193
  - Fuel Distribution
    193
  - Mechanical
    193
- Brake System
  197
  - Neither Wheel Locks When Park Brake Is Latched
    198
  - Grabbing Brakes (over Sensitive)
    198
- General Specifications
  202

Cushman SHUTTLE 4X Owner's Manual (80 pages)

48 V ELECTRIC POWERED VEHICLE

Brand: Cushman | Category: Golf Cars | Size: 8 MB

Table of Contents

5
- 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

25
- Accelerator Pedal
  27
- Direction Selector
  27
- Features
  27
- General Information
  27
- Key Switch / Headlight Switch
  27
- State of Charge Meter
  27
- Brake and Park Brake
  28
- Brake Light/Turn Signal
  29
- Charger with DC to DC Converter
  29
- Cup Holder
  29
- Front Seats
  29
- Glove Box
  29
- Hip Restraint, Front
  29
- Horn
  29
- Rear View Mirror
  29
- Steering Wheel
  29
- Weather Enclosure
  29
- Run/Tow Switch
  30
- Ash Tray
  31
- Cargo Platform
  31
- Convertible Seat
  31
- Handrail, Rear
  31
- Hour Meter
  31
Operating Procedures

35
- Serial Number Location
  36
- Before Initial Use
  37
- Poratable Charger Installation
  38
- Understanding the Charger
  39
- Using the Charger
  39
- LED Fault Codes
  40
- LED Operation Codes
  40
- Maintenance Instructions
  41
- Operating the Vehicle
  41
- General
  42
- SHUTTLE 4X Trucourse Technology
  42
- Trucourse Technology System Performance Options & Diagnostics
  42
- Changing Performance Options
  43
- Operation
  43
- Regenerative Braking
  44
- Anti-Roll Back Feature
  45
- Anti-Stall Feature
  45
- Pedal-Up Braking
  45
- Terrain
  45
- Walk-Away Feature
  45
- Diagnostic Mode Feature
  46
- High Pedal Disable Feature
  46
- Starting and Driving
  46
- Starting Vehicle on a Hill
  46
- Coasting
  47
- Labels and Pictograms
  47
- Sun Top and Windshield
  47
Maintenance

49
- Vehicle Cleaning
  51
- Vehicle Cleaning and Care
  51
- Common Sense Operation
  52
- Environmental Concerns
  52
- Lifting the Vehicle
  53
- Repair
  53
- Tire Repair
  54
- Wheels and Tires
  54
- Wheel Installation
  55
- Fuse Replacement
  56
- Light Bulb Replacement
  56
- Hauling
  57
- Service and Maintenance
  57
- Towing
  57
- Transporting Vehicle
  57
- Brakes
  58
- Routine Maintenance
  58
- Tire Inspection
  58
- Checking the Lubricant Level
  59
- Periodic Brake Test for Mechanical Brakes
  59
- Rear Axle
  59
- Hardware
  60
- Lubrication
  60
- Periodic Service Schedule
  61
- Battery Charging and Maintenance
  62
- Safety
  62
- At each Charging Cycle
  63
- Battery
  63
- Battery Maintenance
  63
- Electrolyte Level and Water
  63
- Monthly
  63
- Battery Cleaning
  65
- Battery Replacement
  66
- AC Voltage
  67
- Battery Charging
  67
- Troubleshooting
  67
- Hydrometer
  68
- Using Hydrometer
  69
- Prolonged Storage
  70

Cushman Categories

Utility Vehicle Offroad Vehicle Golf Cars Electric Vehicles Tractor

More Cushman Manuals

Cushman SHUTTLE 4X Manuals

Cushman SHUTTLE 4X Technician's Repair And Service Manual (189 pages)

Table of Contents

Cushman SHUTTLE 4X Technician's Repair And Service Manual (214 pages)

Table of Contents

Table of Contents

General Information & Routine Maintenance

Wheels and Tires

Speed Control

Section Title

System Operation

Troubleshooting

Speed Control

Pedal Box Adjustments

Engine

Section Title

Powertrain Maintenance

Air Filter Inspection/Replacement

Starter/Generator Belt Tension

Starter/Generator Replacement

Spark Plug

Cooling System Cleaning

Four Cycle Engine

Cylinder Head

Engine Removal

Drive Clutch Removal

Fuel System

Electrical

Section Title

Inspection

Troubleshooting

Mechanical Brakes

Weather Protection

Troubleshooting

Cushman SHUTTLE 4X Owner's Manual (80 pages)

Table of Contents

Table of Contents

Introduction

Operating Procedures

Maintenance

Related Products

Cushman Categories