Cushman BELLHOP 2 Owner'S Manual And Service Manual Download Page 1

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A Textron Company

OWNER’S MANUAL

AND SERVICE GUIDE

ISSUED OCTOBER 2007 REVISED JUNE 2012

GASOLINE POWERED

PERSONNEL CARRIERS

AND GOLF CAR

606893

Summary of Contents for BELLHOP 2

Page 1: ...A Textron Company OWNER S MANUAL AND SERVICE GUIDE ISSUED OCTOBER 2007 REVISED JUNE 2012 GASOLINE POWERED PERSONNEL CARRIERS AND GOLF CAR 606893...

Page 2: ...tions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe WASH HANDS AFTER HANDLING Battery posts terminals and related accessories contain lead and lead comp...

Page 3: ...revised periodically by the E Z GO Division and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL and the E Z GO Division SPECIFICALLY DIS...

Page 4: ...nor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifica...

Page 5: ...ARTING AND DRIVING 5 STARTING THE VEHICLE ON A HILL 5 COASTING 5 FUEL 6 Fig 8 Fueling 6 BATTERY 6 LABELS AND PICTOGRAMS 6 SUN TOP AND WINDSHIELD 7 VEHICLE CLEANING AND CARE 7 VEHICLE CLEANING 7 REPAIR...

Page 6: ...ng Cooling System with Air 20 REAR AXLE 20 CHECKING THE LUBRICANT LEVEL 20 AIR CLEANER INSPECTION AND REPLACEMENT 20 Fig 30 Add Check and Drain Rear Axle Lubricant 21 Fig 31 Air Cleaner 21 LUBRICATION...

Page 7: ...BE OPER ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the product On behalf of E...

Page 8: ...igher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment Additionally speed should be further moderated by the environmental conditions te...

Page 9: ...s or maintenance All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic Replace damaged or missing warning caution or information labels Keep complete records...

Page 10: ...Owner s Manual and Service Guide Page viii SAFETY INFORMATION NOTES...

Page 11: ...terrain and conditions However improper operation faulty maintenance or poor housekeeping may contrib ute to a condition of instability and defeat the purpose of the standard Some of the conditions w...

Page 12: ...or trailer 6 5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 6 5 1 The user shall require battery changing and charging facilities and procedures to be in accordan...

Page 13: ...1 Personnel and Burden Carrier Operator Qualifications Only persons whoa are trained in the proper operation of the carrier shall be authorized to operate the carrier Oper ators shall be qualified as...

Page 14: ...zed speed limits Under normal traffic conditions keep to the right Maintain a safe distance based on speed of travel from a carrier or vehicle ahead and keep the carrier under control at all times 7 3...

Page 15: ...nd addressed via appropriate hazardous materials regulations 7 3 4 7 Do not operate a carrier with a leak in the fuel system or battery s Battery s shall be charged and serviced per manufacturer s ins...

Page 16: ...ectional controllers limit switches protective devices electrical conductors insulators and connections shall be inspected and maintained per carrier manufacturer s recommendation p Carriers shall be...

Page 17: ...trolling party to implement a golf car safety program It is suggested and recommended that Part II be reprinted in the golf car manufacturer s operation and service manuals to encourage safe operation...

Page 18: ...avoid the hazard 5 2 4 Loose terrain Extreme caution shall be used when driving in areas of loose terrain Loose terrain for example sand or gravel can cause a golf car to lose traction and may affect...

Page 19: ...s instructions for immobilizing golf car before beginning any maintenance b Block chassis before working underneath golf car c Before disconnecting any part of the fuel system drain the system and tu...

Page 20: ...anged accordingly 6 2 6 As required in 6 2 4 the manufacturer shall be contacted to secure new nameplates warnings or safety labels as necessary which shall be affixed in their proper place on the gol...

Page 21: ...t the procedures in 7 1 through 7 4 inclusive are being followed 8 Operating safety rules and practices Operator qualifications 8 1 It is recommended that only persons qualified under the rules of the...

Page 22: ...Owner s Manual and Service Guide Page xx SAFETY INFORMATION NOTES...

Page 23: ...part of the lead acid battery charging process A 4 concentration of hydrogen gas is explosive and could cause severe injury or death Charging must take place in an area that is adequately ventilated m...

Page 24: ...stopped before moving the direction selector Located on the seat support panel this lever permits the selection of either F forward or R reverse Ref Fig 3 on page 2 Vehicle should be left in F when u...

Page 25: ...inadvertently will release the park brake and will cause the vehicle to move which could cause severe injury or death Depressing the accelerator pedal will release the park brake if it is engaged Thi...

Page 26: ...tion selector is in correct position before attempting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in...

Page 27: ...erator pedal to start the engine Release service brake when engine starts When the accelerator pedal is released the igni tion circuit is de energized and the engine stops To stop the vehicle more qui...

Page 28: ...operating symptoms occur use gasoline with a lower percentage of alcohol or ether Use fresh regular grade unleaded fuel Ethanol blend fuels upto 10 is permissible Fig 8 Fueling BATTERY Excessive use...

Page 29: ...r electrical sys tem Do not use pressure in excess of 700 psi to wash exterior of vehicle Clean windshield with lots of water and a clean cloth Minor scratches may be removed using a commercial plasti...

Page 30: ...k stand under the outer ends of the rear axle Lower the jack and test the stability of the vehicle on the two jack stands Place the jack at the center of the front axle Raise the vehicle enough to pla...

Page 31: ...but under no condition should inflation pressure be higher than recommended on tire sidewall All four tires should have the same pressure for opti mum handling characteristics Be sure to install the...

Page 32: ...e with a new auto motive type fuse Headlight and taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department Fig 11 Headlight Turn Signal Mark...

Page 33: ...ays remove windshield before transport ing Maximum speed with sun top installed is 50 mph 80 kph If the vehicle is to be transported at highway speeds the sun top must be removed and the seat bottom s...

Page 34: ...mended intervals is the best guarantee for keeping the vehicle both dependable and economical This vehicle will give years of satisfactory service provid ing it receives regular maintenance Refer to t...

Page 35: ...p vent is free of dirt COOLING FAN 9 Check for build up of foreign matter inside blower housing and fins clean if required ENGINE OIL 9 Check and add if required DO NOT OVERFILL STARTER GENERATOR BELT...

Page 36: ...sive play and tightness of retaining nuts STEERING ASSEMBLY 9 Check bellows and pinion seal for damage or grease leakage RACK END BALL JOINT Lubricate use wheel bearing grease REAR AXLE 9 Check for un...

Page 37: ...l to enter the air filter enclosure The oil should be checked with the engine warm The vehicle should be on a level surface with the parking PARK brake engaged Allow adequate time for oil to drain int...

Page 38: ...The oil should be changed as part of spring maintenance This will remove any moisture that has accumulated during storage Be aware that engine fluids may be hot and contact to the skin may cause seve...

Page 39: ...k Oil should be slightly below H to allow for expansion If necessary continue to add oil slowly and allow time for oil to flow down into engine Check oil level on dipstick Do not overfill Do not overf...

Page 40: ...a solution of sodium bicarbonate baking soda and water to neutralize any acid deposits before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from the t...

Page 41: ...r time Periodic Brake Test For Mechanical Brakes The purpose of this test is to compare the braking perfor mance of the vehicle to the braking performance of new or known to be good vehicles or to an...

Page 42: ...y off road use allow to cool and then check for a build up of dirt and debris in the air intake and cooling fins Dirt and debris may clog the engine s air cooling system Clean areas shown to prevent e...

Page 43: ...ning arrow on cover is pointing upward and all clips are fastened securely If the element is in acceptable condition loose dirt may be removed by tapping the filter lightly Do not use oil on the filte...

Page 44: ...axle cable mount Lubricate the direction selector linkage and related moving parts periodically PROLONGED STORAGE To reduce the possibility of severe injury or death resulting from a possible explosi...

Page 45: ...by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head Unmarked hardware is Grade 2 Ref Fig 34 on page 23 Fig 34 Torque Specifications and Bolt Grades ALL T...

Page 46: ...ig 35 Capacities and Replacement Parts Fuel Tank Fuel Engine Oil Oil Filter Air Filter Spark Plugs Starter Generator Belt Clutch Belt Rear Axle Oil Fuse Headlight Sealed Beam Turn Signal Bulb Tail Lig...

Page 47: ...ATION AND SERVICE INFORMATION Page 25 Owner s Manual and Service Guide Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings NO...

Page 48: ...ATION AND SERVICE INFORMATION Page 26 Owner s Manual and Service Guide Read all of Manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings NO...

Page 49: ...Page 27 Owner s Manual and Service Guide GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS...

Page 50: ...Cooled Overhead Valve Pressurized Lubrication with replaceable Oil Filter Internal Balance Shaft Solid State Ignition Replaceable Dry Cartridge Air Filter Remote Intake Fixed Jet Bowl Carburetor Pulse...

Page 51: ...Air Cooled Overhead Valve Pressurized Lubrication with replaceable Oil Filter Internal Balance Shaft Solid State Ignition Replaceable Dry Cartridge Air Filter Remote Intake Fixed Jet Bowl Carburetor...

Page 52: ...on with replaceable Oil Filter Internal Balance Shaft Solid State Ignition Replaceable Dry Cartridge Air Filter Remote Intake Fixed Jet Bowl Carburetor Pulse Fuel Pump VALVE TRAIN Overhead valve LUBRI...

Page 53: ...ide GENERAL SPECIFICATIONS Fig 36 Vehicle Dimensions 46 5 in 118 cm 122 in 310 cm 132 5 in 337 cm 134 5 in 342 cm 93 5 in 237 cm BELLHOP 4 BELLHOP 6 Lowest Clearance At Differential NA All Models Not...

Page 54: ...Page 32 Owner s Manual and Service Guide GENERAL SPECIFICATIONS Fig 37 Vehicle Dimensions Continued 93 5 in 237 cm 122 in 310 cm 138 in 351 cm 44 5 in 113 cm BELLHOP 2...

Page 55: ...IONS Fig 38 Vehicle Dimensions and Incline Specifications RECOMMENDED MAX RAMP GRADE 25 or 14 MAX RECOMMENDED MAX SIDE TILT 25 or 14 MAX Rear 38 in 97 cm w o Front Brake 33 5 in 85 cm With Front Brake...

Page 56: ...s Manual and Service Guide GENERAL SPECIFICATIONS Fig 39 Turning Clearance Diameter Intersecting Isle Clearance 94 in 240 cm 94 in 240 cm INTERSECTING AISLE CLEARANCE TURNING CLEARANCE DIAMETER 25ft...

Page 57: ...Page 35 Owner s Manual and Service Guide GENERAL SPECIFICATIONS NOTES...

Page 58: ...Page 36 Owner s Manual and Service Guide GENERAL SPECIFICATIONS NOTES...

Page 59: ...Page 37 Owner s Manual and Service Guide VEHICLE WARRANTIES VEHICLE WARRANTIES...

Page 60: ...LE WARRANTIES DOMESTIC WARRANTY U S AND CANADA To obtain a copy of the limited warranty applicable to the vehicle call or write a local distributor authorized Branch or the Warranty Department with ve...

Page 61: ...ator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance ret...

Page 62: ...s not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF...

Page 63: ...r the lack of receipts As the vehicle owner you should be aware that E Z GO may deny you war ranty coverage if your vehicle or a covered part has failed due to abuse neglect or improper maintenance un...

Page 64: ...nted parts caused by the use of add on or modified part HOW TO FILE A CLAIM If you have questions regarding your warranty rights and responsibilities you should contact your nearest authorized service...

Page 65: ...Page 43 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY...

Page 66: ...Owner s Manual and Service Guide Page 44 DECLARATION OF CONFORMITY NOT AVAILABLE AT THE TIME OF PUBLICATION...

Page 67: ...Appendix A 1 Owner s Manual and Service Guide LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS...

Page 68: ...r Seat 35493 G01 71489G01 See Following Pages For Explanation Of This Pictogram 1 2 1 To Prevent Roll Back On a Hill From a Stopped Position 2 Apply Service Brake With Left Foot 3 Fully Release Park B...

Page 69: ...14 25 WAR NING READ MANU AL FOR MA XIMUM LOA D BED CAP ACI TY MAXIMUM RA MP HILL SECURE LO AD AS FAR F ORW ARD AS POSSIBLE MAXIMUM LO AD BED CAP ACI TY DO NO T RIDE IN LOA D BED DAN GER OF EXPLOSION D...

Page 70: ...O GROUND SHORTING BA TT ERY TERMINALS M AY CAU SE EXPLOSION DO NO T EXPOSE TOFLAME WAR NING COR ROS IVE WAR NING LETHAL VOLT AGE WAR NING EXPLOSIVE DO NO T DISPOSE OF BAT TERIES IN LANDFILL DO NO T D...

Page 71: ...EDAL AND A CC ELERA TE SMOO THLY TOLEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY P ARKING BR AKE TURN KEY TOOFF MOVE DIRECTION SELECT OR T O FORW ARD P N TOLEAVE A N ELECTRIC POWERED VEHICLE IN PARK...

Page 72: ...Manual and Service Guide Appendix A 6 LABELS AND PICTOGRAMS MAXIMUM TAI LGA TE LOA D 51 52 Ref Pic 1 4 53 DEPRESS PEDAL RELEASE DEPRESS PEDAL SIMULT ANEOUSLY NOTE All Pictograms may not apply to your...

Page 73: ...refore should be considered potentially hazardous Use extreme care when working on any vehicle When diagnosing removing or replacing any components that are not operat ing correctly take time to consi...

Page 74: ...nical Communications Department E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US North America Technical Assistance Warranty Phone 1 800 774 3946 FA...

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