Cushman SHUTTLE 2+2 Leitfaden

72V SHUTTLE 2+2

Service Parts Manual

661605 - R

Page i

661605 Service Parts Manual

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. These chemicals are found in vehicles, vehicle parts and accesso-

ries, both new and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease,

fumes, and particulates, all identified by the State of California to potentially cause cancer, birth defects, and other

reproductive harm.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed be-

yond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles prohibits

and dis-claims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

TSV reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these

changes on units sold previously.

The information contained in this manual may be revised periodically by TSV, and therefore is subject to change without notice.

TSV DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS 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.

TO CONTACT US:

Textron Specialized Vehicles, Inc.

1451 Marvin Griffin Road

Augusta, Georgia, USA 30906-3852

NORTH AMERICA:

Technical Assistance & Warranty PHONE: 1-800-774-3946, FAX: 1-800-448-8124

Service Parts PHONE: 1-888-438-3946, FAX: 1-800-752-6175

International: PHONE: 001-706-798-4311, FAX: 001-706-771-4609

email: [email protected]m

Page ii

GENERAL INFORMATION

661605 Service Parts Manual

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.

Failure to properly maintain batteries may void the warranty. Refer to the battery manual for

instructions on the proper maintenance and care of the batteries.

BATTERY PROLONGED STORAGE

Batteries self-discharge over time. The rate of self-discharge varies depending on the ambi-

ent temperature, the age and condition of the batteries.

Fully charged batteries will not freeze in winter temperatures unless the temperature falls

below -75°F (- 60°C).

For winter storage, the batteries must be clean, fully charged and disconnected from any

source of electrical drain.

The battery charger may remain connected to the vehicle to maintain a full charge on the

batteries, provided the charger is plugged into an active electrical source. If power to the

electrical source is disconnected or interrupted, the battery charger continues to check the

charge on the battery pack. This pulls power from the battery pack and eventually drains the

batteries if power is not restored in a timely manner.

As with all electric vehicles, the batteries must be checked and recharged as required or at

a minimum of 30 day intervals.

Check and maintain the proper fluid level in all battery cells during the storage period.

Proper fluid level is required for maximum battery performance.

BATTERY DISPOSAL

Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer

or lead smelter for recycling. For neutralized spills, place residue in acid-resistant contain-

ers with absorbent material such as sand. Dispose in accordance with local, state and fed-

eral regulations for acid and lead compounds. Contact local and/or state environmental

officials regarding disposal information.

SECTION Page No.

Service Parts Manual

TABLE OF CONTENTS

Page iii

661605 Service Parts Manual

HOW TO USE THE SERVICE PARTS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

BATTERY CHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B

BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E

ELECTRONIC SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F

FRONT SUSPENSION AND STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K

SEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L

WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N

DECALS AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P

NOTES

Page iv 661605 Service Parts Manual

Page v

HOW TO USE THE SERVICE PARTS MANUAL

661605 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.

USE OF THE MANUAL

To use this manual, consult the TABLE OF CONTENT to locate the information or illustration required.

Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of

components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your

situation and then contact the Service Parts Department. It is important that the serial number of your vehicle and its

model number be supplied to Service Parts when ordering any replacement components.

Page vi

HOW TO USE THE SERVICE PARTS MANUAL

661605 Service Parts Manual

1. WHEN THE PART NUMBER IS NOT KNOWN

•Determine the function and application of the part required. Turn to the TABLE OF CONTENT and select the

most appropriate title.

•Turn to the page number indicated and locate the desired part on the illustration.

•From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying

description for specific information regarding the part.

2. IF YOU KNOW THE PART NUMBER

•Locate the part number or description in the appropriate column on the parts list page.

NOTE: Confirm the part selected is correct by verifying it with the illustration.

If an asterisk (*) appears in the part number column on the parts list page, read upward until a part number is found. The

part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates the part depicted is not available

for purchase.

NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the

assembly that it is used on. This process is repeated until the highest final assembly is reached.

To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is

available from the Service Parts Department.

Title Title

Left hand

illustration page Parts list (continued on

rear of page if required)

Front of Vehicle

123

101

100

120

121

122

114

119

115

111

112

118

116

113

82,87

81,86

84,89

83,88

102,104

105

107

106

62 - Includes Items 63 - 66, 69 - 74

70 -Incl

udes Items 71 - 74

81- Includes Items 82 - 84

86 - Includes Items 87 - 89

94 - Includes Items 95, 96

111 - Includes Items 112 - 114

118 - Includes Items 119 - 121

126 - Includes Items 127 - 131

103

*See Body Section for

decal information

127

128129

130

131

126

Page vii

HOW TO USE THE SERVICE PARTS MANUAL

661605 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.

CODE # DESCRIPTION

11 BLACK

19 PATRIOT BLUE PEARL

20 INFERNO RED METALLIC

26 STEEL BLUE PEARL

31 METALLIC CHARCOAL

35 SAFETY YELLOW

36 IVORY

37 FOREST GREEN

38 BRIGHT WHITE

39 FLAME RED

41 ELECTRIC BLUE

42 PLATINUM

43 BURGUNDY

44 ALMOND

51 SUNBURST ORANGE

52 BRITISH RACING GREEN

79 JACOBSEN ORANGE 172

A5 OCEAN GRAY

661605 Service Parts Manual

Page A-1

ACCELERATOR

BLK

24 20

RED

GRN

To harness

from direction

selector

Part of Frame

WHT

1PEDAL BOX ASSEMBLY

includes items 2 - 34

27 ACCELERATOR PEDAL ASSEMBLY

includes items 28 - 30

32 PEDAL HARNESS

includes items 33 - 34

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