Cushman SHUTTLE 2+2 Guide

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: [phone], FAX: [phone]
Service Parts PHONE: [phone], FAX: [phone]
International: PHONE: [phone], FAX: [phone]
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
99
98
120
74
70
71
64
63
65
66
67
121
122
114
119
115
111
73
72
112
118
116
113
62
69
94
96
95
82,87
81,86
84,89
83,88
102,104
105
79
91
92
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
28
22
29
30
22
24 20
15
14
26
25
36
2
3
4
32
34
33
10
9
11
21
19
18
17
16
4
5
7
6
8
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

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page A-2
ACCELERATOR
661605 Service Parts Manual
1 73333G11 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2 - 34) ..................................... 1
2 652241G03 ACCELERATOR PEDAL BRACKET ......................................................... 1
3 01051G01 PAN HEAD PHILLIPS SCREW, #8 - 10 X 1/2" LG.................................... 4
4 25853G01 PEDAL BOX AND COVER ........................................................................ 1
5 00684G6 TRUSS HEAD SCREW (SS), #8 - 32 X 3/4" LG ....................................... 2
6 25861G01 MICRO SWITCH ....................................................................................... 1
7 01050G01 PAN HEAD TORX SCREW, #4 - 20 X 5/8" LG.......................................... 2
8 28444G01 ACCELERATOR ROD CAM...................................................................... 1
9 25854G01 INDUCTIVE THROTTLE SENSOR ........................................................... 1
10 00983G01 SELF THREADING NUT, .38" ................................................................... 2
11 602484 PLUNGER ................................................................................................. 1
12
13
14 17677G1 SPRING RETAINER.................................................................................. 1
15 17979G1 BUSHING, .75" X 2" LG ............................................................................ 1
16 73046G01 COMPRESSION SPRING......................................................................... 1
17 17677G2 SPRING RETAINER, 3/8".......................................................................... 1
18 73332G01 ACCELERATOR ROD............................................................................... 1
19 00532G4 HEX NUT, 5/16" - 24.................................................................................. 1
20 10385G4 CLEVIS YOKE (ADJUSTABLE)................................................................. 1
21 10386G3 CLEVIS PIN, 5/16" X 13/16" LG ................................................................ 1
22 17838G1 NYLON BUSHING, .37" X .31" LG ............................................................ 3
23
24 10387G3 COTTER PIN, 3/32" X 3/4" LG .................................................................. 1
25 74432G01 PEDAL PIVOT PIN .................................................................................... 1
26 12064G6 PUSH NUT, 5/16" ...................................................................................... 1
27 25799G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 28 - 30).......... 1
28 16409G1 OVAL RIVET, 3/16" X 7/16" LG........................................................... 6
29 27512G01 ACCELERATOR PEDAL PAD............................................................. 1
30 652824 ACCELERATOR PEDAL..................................................................... 1
31

Page A-3
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
ACCELERATOR
661605 Service Parts Manual
32 25879G08 PEDAL HARNESS (INCLUDES ITEMS 33 - 34) ...................................... 1
33 17313G1 LOOM FLEX (BULK), 3/8".................................................................. 1
34 17618G1 NYLON CLAMP, 8" LG ....................................................................... 2
35
36 00715G2 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG........................................................... 4

Page A-4
Notes:
ACCELERATOR
661605 Service Parts Manual

661605 Service Parts Manual
Page B-1
BATTERY CHARGER
1
2

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page B-2
BATTERY CHARGER
661605 Service Parts Manual
1 645743 72V BATTERY CHARGER, 1500W ................................................................ 1
2 634567 72V BATTERY CHARGER, 1000W ................................................................. 1

Page B-3
Notes:
BATTERY CHARGER
661605 Service Parts Manual

Page B-4
Notes:
BATTERY CHARGER
661605 Service Parts Manual

661605 Service Parts Manual
Page C-1
BODY
15
11
3
5
2
35 47
36
35
9
13
34
49
14
44
45
11
32
10
43
45
Front of Vehicle
Front of Vehicle
Front of Vehicle
18 INSTRUMENT PANEL ASSEMBLY
includes items 19 - 27
19 INSTRUMENT PANEL ASSEMBLY WITH BALL DEFLECTOR
includes items 20 - 24
40
30
26
23
24 28
29
31
30
21
22
20
4
25 27

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page C-2
BODY
661605 Service Parts Manual
1 641260 UPPER FLOORPAN ........................................................................................ 1
2 14601G11 RIVET (ALUMINUM), 3/16" X 9/16" LG ........................................................... 7
3 70451G01 LOWER FLOORPAN ....................................................................................... 1
4 14601G11 RIVET (ALUMINUM), 3/16" X 9/16" LG ........................................................... 9
5 70452G01 ACCESS COVER............................................................................................. 1
6
7
8
9 613273 FRONT FASCIA............................................................................................... 1
10 617643 COWL GRILL COVER ..................................................................................... 1
11 71597G01 SELF THREADING NUT, 5MM X 10MM X 15MM LG .................................... 2
12
13 15058G1 RIVET (ALUMINUM), .87" LG.......................................................................... 2
14 00414G6 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG ............................................................. 2
15 14390G4 LOCK NUT, 1/4" - 20........................................................................................ 2
16
17
18 662328 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEM 19 - 27)...................... 1
19 71917G01 INSTRUMENT PANEL ASSEMBLY WITH BALL DEFLECTOR
(INCLUDES ITEM 20 - 24) ....................................................................... 1
20 00614G3 PAN HEAD PHILLIPS SCREW, #8 - 15 X 3/8" LG ............................. 4
21 71158G01 BALL DEFLECTOR (PASSENGER SIDE) ......................................... 1
22 71153G01 BALL DEFLECTOR (DRIVER SIDE) ................................................. 1
23 628010 INSTRUMENT PANEL ....................................................................... 1
24 71364G02 SPEED NUT "J" TYPE, #8 ................................................................. 5
25 662223 SAFETY CONSOLE LABEL BRACKET ................................................... 1
26 71158G01 CUP HOLDER INSERT ............................................................................ 1
27 71055G01 RIVET (ALUMINUM), 3/16" X 1" LG ......................................................... 2
28 608290 SELF TAPPING SCREW, #10 - 16 X 3/4" LG.................................................. 5
29 71055G01 RIVET (ALUMINUM), 3/16" X 1" LG ............................................................... 7
30 71115G01 VINYL TRIM ..................................................................................................... 2

Page C-3
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
BODY
661605 Service Parts Manual
31 71055G01 RIVET (ALUMINUM), 3/16" X 1" LG................................................................ 2
32 613036G0XX COWL (See COLOR CODE in HOW TO USE Section of Manual) ................ 1
33
34 654275 FASCIA BRACKET.......................................................................................... 1
35 01038G01 HEX WASHER HEAD SWAGEFORM SCREW
WITH DOGPOINT, 1/4" - 20 X .7" LG ............................................................. 2
36 16469G1 FENDER WASHER, 9/32"............................................................................... 2
37
38
39
40 75459G03 GLOVE BOX DOOR (PASSENGER SIDE) .................................................... 1
41
42
43 614378 FENDER FLARE (DRIVER SIDE)................................................................... 1
44 613274 FENDER FLARE (PASSENGER SIDE) .......................................................... 1
45 71055G01 RIVET (ALUMINUM), 3/16" X 1" LG................................................................ 3
46
47 654276 FRONT SHIELD BRACE ................................................................................ 2
48
49 664610 COWL STRAP ................................................................................................ 2