Cushman SHUTTLE 2+2 G, Owner'S Manual

Page 1: ...OWNER S GUIDE 642586 GAS SHUTTLE 2 2 REVISED NOV 2015 ISSUED JAN 2015...

Page 2: ...ive hand tools If necessary contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule Repair or replacement parts are available fro...

Page 3: ...S LIABILITY FOR INCIDENTAL AND CONSE QUENTIAL DAMAGES resulting from the use of the information and materials in this Manual These are the original instructions as defined by 2006 42 EC CONTACT US E Z...

Page 4: ...in the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE The batteries discharge over time The rate of discharge changes...

Page 5: ...ES 13 General Information 13 Key and Light Switch 13 Fuel Gauge with Low Oil Pressure Indicator 13 12 Volt Power Outlet 13 Direction Selector 13 Choke 14 Accelerator Pedal 14 Brake and Parking Brake P...

Page 6: ...1 12 Volt Power Outlet 21 STARTING AND DRIVING 22 Run In 22 Starting Vehicle On A Hill 23 Coasting 24 FUEL 24 FUEL TANK 24 Early Production Fuel Tank 24 Late Production Fuel Tank 25 BATTERY 25 LABELS...

Page 7: ...ng the Oil 35 Starter Generator Belt Tension 37 Adjusting the Belt 38 Battery Cleaning 38 TIRE INSPECTION 39 BRAKES 39 Periodic Brake Test 40 LUBRICATION 40 CAPACITIES AND REPLACEMENT PARTS 41 HARDWAR...

Page 8: ...B vi TABLE OF CONTENTS Owner s Guide...

Page 9: ...of vehicle control is abusive and will not be covered under the warranty Use caution when you tow the vehicle Towing the vehicle at above the recommended speed can cause personal injury or damage to...

Page 10: ...o the stric tures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the Distributor or Dealer MUST equip the product with headlights rear lig...

Page 11: ...ehicle in any manner that changes the weight distribution decreases stability increases speed or extends the necessary distance to stop more than the factory specification E Z GO is not responsible fo...

Page 12: ...icle Do not allow loose clothing or hair to contact the moving parts Do not touch hot objects When you service the vehicle always wear eye protection Be careful when you do work around batteries or yo...

Page 13: ...that is without vehicle and person traffic Make sure you record and keep all of the maintenance history of the vehicle Vehicles are used for different purposes so it is not possible to know and inform...

Page 14: ...3G01 NEGATIVE GROUND BATTERY CLEAN GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE DO NOT SPILL FUEL ON HOT ENGINE NO TAMPERING KEEP HANDS OUT DO NOT EXPOSE TO FLAME GROUND FUEL PUMP SHORTING BATTER...

Page 15: ...RECTION SELECTOR TO F OR R PRESS ACCELERATOR TO PARK VEHICLE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD ENGAGE PARKING BRAKE FOR INFORMATION REFER TO OWNERS MANUAL OR WEBSITE WARNING READ OWNE...

Page 16: ...8 Owner s Guide SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 17: ...250 lb 110 kg Wheel Base 65 5 in 166 cm Load Capacity Vehicle 800 lb 360 kg Front Wheel Track 38 0 in 96 cm Outside Clearance Circle 19 ft 5 8 m Rear Wheel Track 38 5 in 97 cm Intersecting Aisle Clear...

Page 18: ...rocedure Pay particular attention to Notices Cautions Warnings and Dangers VEHICLE DIMENSIONS Rear 38 in 97 cm Front 38 5 in 98 cm 77 in 196 cm 46 5 in 118 cm 108 5 in 276 cm 65 5 in 166 cm 4 5 in 11...

Page 19: ...d all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 11 Owner s Guide TURNING DIAMETER AND INCLINE INFORMATION TURNING CLE...

Page 20: ...12 Owner s Guide GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 21: ...indicates the amount of gasoline in the fuel tank F indicates a full tank and E indicates an empty fuel tank The fuel gauge has a low oil pressure indicator A low engine oil pressure condition is show...

Page 22: ...s the lower part of the brake pedal to release the parking brake A parking brake that is engaged releases when you press the accelerator pedal This is a feature to make sure the vehicle is not driven...

Page 23: ...a cargo platform When in the upright position it is a rear seat for two passengers Fold the seat flat for a cargo platform 17 Rear Hand Rail There is a hand rail on each side of the rear seat to help...

Page 24: ...16 Owner s Guide INTRODUCTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 25: ...PART C label is found on the body panel below the driver seat PART D is found on the frame tube below the floorboard The other PARTS A and B is found on the frame crossmember below the front seat Lift...

Page 26: ...ear flammable materials open flame or sparks Never charge a vehicle near gas water heaters and furnaces Before a new vehicle is put into operation do the items shown in the INITIAL SERVICE CHART HOW T...

Page 27: ...ection selector is in correct position before you press the accelerator pedal Make sure you completely stop the vehicle before you move the direction selector to a different position Do not take vehic...

Page 28: ...the accelerator pedal is pressed and cause the vehi cle to move suddenly When the vehicle is parked make sure the key is in the OFF position so that the electrical system is disabled When the key swit...

Page 29: ...ot allow passengers to ride on the cargo platform When you put cargo on the platform make sure you follow information below to decrease the risk of injury damage to the vehicle or cause the vehicle to...

Page 30: ...vehicle is ready to run in the reverse direction Run In Check for possible leaks that may have developed during shipment Avoid full throttle starts and fast acceleration until the engine has reached o...

Page 31: ...er to operate continuously for more than 10 seconds Allow 30 seconds between starting tries If the vehicle does not start on the third try turn the key to the OFF position set the parking brake and fi...

Page 32: ...ys handle gasoline in a well ventilated area Always wear eye protection to protect against splashed fuel and fuel vapors Inspect the fuel cap tank and other components for leaks or damage that can cau...

Page 33: ...reserve to start the vehicle The vehicle uses a starter generator to start the engine and charge the battery The engine will not idle so the battery does not charge while the vehicle is stopped Do not...

Page 34: ...gs and Dangers Owner s Guide SUN TOP AND WINDSHIELD IF EQUIPPED The sun top does not supply protection from roll over or falling objects The windshield does not supply protection from tree branches or...

Page 35: ...water and mild detergent to protect the painted surfaces Apply wax that is for clear coat automotive finishes to improve the appearance and protection of the painted surfaces Do not apply wax to matte...

Page 36: ...e 1 Install the wheel chocks in front and behind each front wheel 2 Put the jack below the center of the rear frame crossmember 3 Lift the vehicle enough to put jack stands below the outer ends of the...

Page 37: ...over inflation can occur in seconds Never exceed the tire inflation pressure rating on the tire sidewall when seating a bead Protect the face and eyes when you remove a valve core When you remove the...

Page 38: ...flate the tires The vehicle has low pressure tubeless tires installed on one piece rims Use a tire plug to repair small holes in the tread part of the tire For large holes and cuts replace the tire Ti...

Page 39: ...to the right to secure Replacement bulbs are available from a local Distribu tor an authorized Branch or the Service Parts Depart ment Taillight Remove two Phillips head screws that secure the lens Pu...

Page 40: ...rer of the charger TRANSPORTING VEHICLE Towing Do not ride or allow other people on the vehicle being towed Do not try to tow the vehicle with ropes chains or any device different from a tow bar appro...

Page 41: ...before you do any service to the powertrain when the engine is in operation To decrease the risk of engine damage do not operate the vehicle at full throttle for more than 5 seconds with the drive whe...

Page 42: ...ssary to lift the vehicle Refer to LIFTING THE VEHICLE for correct lift procedure and safety information Four Cycle Engine The engine is an air cooled 4 stroke OHV single cylinder gasoline engine It i...

Page 43: ...ance and longevity the engine oil should be replaced after the first 8 hours of operation After the initial oil change it should be changed every 125 hours of operation or semi annually whichever come...

Page 44: ...to the engine Before installing the drain plug clean the area around the drain hole with a lint free cloth and inspect the drain plug 1 for damage replace if necessary If the O ring 2 on the drain pl...

Page 45: ...ged into the engine com partment As a final check check the oil level again with the vehicle on level ground Like all liquids oil increases in volume when warm The full H mark on the dipstick is calib...

Page 46: ...down the adjustment bolt until proper belt tension is achieved Hold the lower nut in place and tighten the upper jam nut against it Tighten the starter generator pivot bolt Battery Cleaning To decrea...

Page 47: ...ect the tire condition according to the Periodic Service Schedule Tire inflation pressures must be checked when the tires are cool Always install the valve dust cap after you check or inflate the tire...

Page 48: ...d with a new vehi cle Drive the vehicle at maximum speed on a flat dry clean paved surface Quickly press the brake pedal to lock the parking brake at the line or marker in the test area and remove foo...

Page 49: ...s Rear Axle Oil 12 oz 1 2 liters 30 WT Engine Oil Fuse 15 amp P N 18392 G1 Headlight Bulb P N 619100 Turn Signal Bulb P N 619102 Tail Light Bulb P N 21759 G1 ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT S...

Page 50: ...ne cooling system maintenance REAR AXLE The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing Unless leakage of rear axle lubricant is evide...

Page 51: ...into areas that could damage com ponents Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure SPARK PLUGS Tool List Quantity Tool L...

Page 52: ...in the engine Turn the Key Switch to OFF position and leave the Forward Reverse switch in the NEUTRAL position during stor age Perform all required routine maintenance per the Periodic Service Schedu...

Page 53: ...issing insulation Direction Selector Inspect attachment and mechanism C A C A C A C A Steering Assembly Check for excess play loose or missing hardware Tie Rods Check for excess play bent rods loose o...

Page 54: ...l Joint Check for noise and loose or missing hardware Battery Clean battery and terminals Front Wheel Bearings Check and adjust as required See Repair and Ser vice Manual for procedure C A Rear Axle C...

Page 55: ...47 Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers PERIODIC SERVICE SCHEDULE Owner s Guide...

Page 56: ...48 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Guide...

Page 57: ...n cause some components on the vehicle to fail The manufacturer can not know all possi ble component failures or the methods that failures can occur A vehicle in need of repair does not operate correc...

Page 58: ...1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine...