606411 A Textron Company OWNER’S MANUAL AND SERVICE GUIDE ELECTRIC POWERED UTILITY VEHICLES ISSUED NOVEMBER 2006 REVISED OCTOBER 2010
S A FE TY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. See GENERAL SPECIFICATIONS.
OWNER’S MANUAL AND SERVICE GUIDE ELECTRIC POWERED UTILITY VEHICLES COMMANDER™ 280 COMMANDER™ 2100 Starting Model Year 2007 Cushman Division of TEXTRON Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. Cushman Division of TEXTRON Inc.
GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. 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. Overfilling battery may void the warranty. BATTERY PROLONGED STORAGE All batteries will self discharge over time.
TABLE OF CONTENTS SAFETY ................................................................................................................Inside covers GENERAL INFORMATION .......................................................................................................ii SAFETY INFORMATION .........................................................................................................vii GENERAL ...................................................................................................
TABLE OF CONTENTS WHEELS AND TIRES ...................................................................................................................................... 12 Tire Repair ........................................................................................................................................... 12 Wheel Installation ................................................................................................................................. 12 Fig. 15 Wheel Installation .....
TABLE OF CONTENTS Fig. 35 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter ...........31 LABELS AND PICTOGRAMS ............................................................................ Appendix A - 1 LIMITED WARRANTIES ..................................................................................... Appendix B - 1 DECLARATION OF CONFORMITY (EUROPE ONLY) ......................................
TABLE OF CONTENTS Notes: Page vi Owner’s Manual and Service Guide
S A F E T Y I N F O R M ATI O N This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
S A F E T Y I N F O R M ATI O N These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances. Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
S A F E T Y I N F O R M ATI O N • Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire. • Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material.
S A F E T Y I N F O R M ATI O N Notes: Page x Owner’s Manual and Service Guide
S A F E T Y I N F O R M AT I O N GENERAL The following text is provided as recommended by part II of ANSI/ITSDF B56.8 - 2006. The manufacturer strongly endorses the contents of this specification. 6 GENERAL SAFETY PRACTICES 6.1 Introduction 6.1.1 Like other machines, carriers can cause injury if improperly used or maintained. Part II contains broad safety practices applicable to carrier operation.
S A F E T Y I N F O R M AT I O N (1) Arrange for the modification or alteration to be designed, tested, and implemented by an engineer(s) expert in carrier(s) and their safety; (2) Maintain a permanent record of the design, test(s), and implementation of the modification or alteration; (3) Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals; (4) Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been modif
S A F E T Y I N F O R M AT I O N 6.7 Lighting for Operating Area The user, in accordance with his responsibility to survey the environment and operating conditions, shall determine if the carrier requires lights and, if so, shall equip the carrier with appropriate lights. 6.
S A F E T Y I N F O R M AT I O N 7.3.1.1 Read and follow operators’ manual 7.3.1.2 Do not operate carrier under the influence of drugs and alcohol. 7.3.1.3 Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger other persons. 7.3.1.4 Riding on the carrier by persons other than the operator is authorized only on personnel seat(s) provided by the manufacturer. All parts of each person’s body shall remain within the plan view outline of the carrier. 7.3.1.
S A F E T Y I N F O R M AT I O N 7.3.3.2 Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered, operate with extra caution. 7.3.3.3 Handle only loads within the capacity of each cargo area of the carrier as specified by the manufacturer. 7.3.3.4 Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manu- facturer. 7.3.4 Operator Care of Personnel and Burden Carriers 7.3.4.
S A F E T Y I N F O R M AT I O N k) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s recommendations. l) Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved safe operating features.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Manual and Service Guide. This guide contains the information that will assist you in maintaining this highly reliable vehicle. Some illustrations may show items that are optional for your vehicle.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Provide Protection From Elements Looping the DC cord through the steering wheel when charging, serves as a good reminder to store the cord out of the way when finished with charging. The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings DIRECTION SELECTOR If vehicle is to be charged with a non E-Z-GO charger, refer to the instructions supplied with the charger.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ACCELERATOR PEDAL OPTIONAL FRONT DISC BRAKES Unintentional movement of the accelerator pedal will release the park brake and may cause the vehicle to move which could result in severe injury or death. With the key switch ‘ON’, depressing the accelerator pedal starts the motor. When the pedal is released, the motor will stop (Ref Fig.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Horn Always select PARK WARNIN 'TOW / RUN TOWING G MAINTE l NANCE' posit ion befo re towing. TOW MAIN TENA Possibilit MAINT STORAGE NCE y of elec ENANCE Before trical arc rem and batt turn swit oving/conne ery exp ct ing ch to 'TOW losion.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Before operating, check to ensure no one is behind the vehicle. To lower the manual lift bed, grasp the bed handle and lower the bed to the rest position. Be sure hands are not trapped by the bed. TAILGATE OPERATION Never fill a gas can in the bed of a vehicle. Static discharge could ignite gasoline vapor and cause an explosion.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OPERATING THE VEHICLE Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance. Read and understand the following warnings before attempting to operate the vehicle.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 1. The No Plug performance option: The vehicle’s top speed is sensed and regulated directly by the controller and the pedal-up braking is at the strongest level. 2. The Blue Plug performance option: The vehicle’s top speed is sensed and regulated directly by the controller and the pedal-up braking feel is milder. 3.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Example: If all of the following events occur... a) the system senses that the accelerator pedal is depressed (power applied to motor) b) the brake is engaged so as to prevent vehicle motion the PDS system will sense a stalled motor condition and remove power from the motor.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings TOWING A TRAILER Some PDS models are equipped with a feature (pedal-up braking) which slows the vehicle’s speed when the accelerator pedal is released. On steep hills, it is possible for non-PDS vehicles to coast at faster than normal speeds that may be encountered on a flat surface.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings WHEELS AND TIRES Tire Repair Tool List Qty. Required Lug wrench, 3/4" ......................................................... 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Impact wrench, 1/2" drive ............................................ 1 Torque wrench, 1/2" drive............................................
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To replace the tail and brake light bulb, roll the rubber bezel from around the edge of the taillight and remove lens. Install replacement bulb and replace lens. Roll Rubber Bezel Away From Body Tire/wheel style may vary 'Cross Sequence' 1 3 3 4 Tail/Brake Light 'Cross Sequence' 1 4 Rear Fender 2 5 2 Ref Whi 2 Fig.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Always remove windshield before transporting. 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 secured. When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To access powertrain for routine maintenance, lift or remove seat. For major repair, refer to appropriate Technician’s Repair and Service Manual. Some service procedures may require the vehicle to be lifted. Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE 3 Check Clean, Adjust, etc. S Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 3 Check for bent/binding linkage rod 3 Check for damage or wear to latch arm or catch bracket Lubricate as required, use light oil.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings vehicle should stop aggressively. The wheel brakes may or may not lock. Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched. The vehicle should stop within the ‘normal’ range of stopping distances. If the vehicle stops more than 4 ft. (1.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified 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. 24 on page 20). CAPACITIES AND REPLACEMENT PARTS Ref Raf 1 Check/Fill Plug Fig.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings releases stored chemical energy in the form of electrical energy. The chemical reaction takes place faster in warm conditions and slower in cold conditions. Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Battery Cleaning To prevent battery damage, be sure that all battery caps (if equipped) are tightly installed. To reduce the possibility of damage to vehicle or floor, neutralize acid before rinsing battery. Wpt 1S Fig.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Battery Replacement of sodium bicarbonate (baking soda) and brush clean if required. Before any electrical service is performed on PDS model vehicles, the Run-Tow/Maintenance/Storage switch must be placed in the ‘Tow/Maintenance/Storage’ position.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Prolonged Storage BATTERY CHARGING Battery charger, controller and other electronic devices need to be disconnected since they will contribute to the premature discharge of batteries.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • The charger connector/cord set is protected from damage and is located in an area to prevent injury that may result from personnel running over or tripping over the cord set. • The charger is automatically turned off during the connect/disconnect cycle and therefore no electrical arc is generated at the DC plug/receptacle contacts.
OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Cylinder reading of 1.254. Similarly if the temperature was 70° F (21° C), subtract four points (.004) from the 1.250 to give a corrected reading of 1.246 (Ref Fig. 33 on page 26).
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 27
GENERAL SPECIFICATIONS COMMANDER™ 280 STANDARD EQUIPMENT: WEIGHT (without batteries) TIRES TIRE PRESSURE LOAD CAPACITY GROUND CLEARANCE MAXIMUM HEIGHT CHASSIS BODY AND FINISH SAFETY STEERING WHEEL BRAKES FRONT SUSPENSION REAR SUSPENSION STEERING DASH PANEL SEATING MOTOR DRIVE TRAIN ELECTRICAL SYSTEM SPEED CONTROL TRANSAXLE SPEED CHARGER NOISE VIBRATION, WBV VIBRATION, HAV 675 lbs. (306 kg) 18 x 8.50 x 8 (4 ply rated)* 18 - 22 psi (120 - 150 kPa)* 800 lbs.
GENERAL SPECIFICATIONS COMMANDER™ 2100 STANDARD EQUIPMENT: WEIGHT (without batteries) TIRES (4 ply rated) TIRE PRESSURE LOAD CAPACITY GROUND CLEARANCE MAXIMUM HEIGHT CHASSIS BODY AND FINISH SAFETY STEERING WHEEL BRAKES FRONT SUSPENSION REAR SUSPENSION STEERING DASH PANEL SEATING MOTOR DRIVE TRAIN ELECTRICAL SYSTEM SPEED CONTROL TRANSAXLE SPEED CHARGER NOISE VIBRATION, WBV VIBRATION, HAV 809 lbs. (374 kg) 18 x 8.50 x 8 (4 ply rated)* 18 - 22 psi (120 - 150 kPa)* 1000 lbs.
GENERAL SPECIFICATIONS 10 in (25 cm) 47 in (119 cm) 66 in (168 cm) 103 in (262 cm) (Front) 38 in (97 cm) (Rear) 38 in (97 cm) 35 in (89 cm) 47 in (119 cm) COMMANDER ™ 280 18 in (46 cm) 47 in ( 119 cm) 11.5 in (29 cm) (Front) 38 in (97 cm) 77 in (196 cm) 111 in (282 cm) (Rear) 38 in (97 cm) 50 in (127 cm) COMMANDER ™ 2100 42.5 in (108 cm) Fig.
GENERAL SPECIFICATIONS RECOMMENDED MAX SIDE TILT 25% or 14o MAX RECOMMENDED MAX RAMP GRADE 25% or 14o MAX TURNING CLEARANCE DIAMETER COMMANDER ™ 280 COMMANDER ™ 2100 19 ft (5.8 m) 22 ft (6.7 m) Fig.
GENERAL SPECIFICATIONS Notes: Page 32 Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1
LABELS AND PICTOGRAMS I ON R F cm I ON F O OFF R I ON R O OFF F O OFF MIN 150 See Following Pages For Explanation Of These Pictograms I ON < 14° 25% < 14° 25% O OFF F I ON O OFF F I ON O OFF R 614121 614121 ! ! P F ! < 14˚ 25% < 14˚ 25% R F 601781 See Following Pages For Explanation Of These Pictograms OFF ON 71129-G02 71129G02 On Battery Under Seat See Following Pages For Explanation Of This Pictogram 35493-G01 28203-G01 74099G01 28203-G01 Pb 35493G01 28203G01 See Foll
LABELS AND PICTOGRAMS 1. ! WARNING 9. 2. READ MANUAL < 14û 25% WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL SECURE LOAD MAX AS FAR FORWARD XXX lbs. AS POSSIBLE. XXX kg MAXIMUM LOAD BED 10. 3. WARNING USE CAUTION IN INCLEMENT WEATHER CAPACITY ! 4. WARNING DO NOT OPERATE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL 5. MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED MAX 14û/ 25% 12.
LABELS AND PICTOGRAMS 15. 17. 18. H 2O PP 16. PP 3 2 1 PP 28. 29. GROUND FUEL PUMP 30. 19. 20. 21. DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND 22. SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION 24. 25. 26. 27. WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS NO TAMPERING. KEEP HANDS OUT WARNING CORROSIVE WARNING EXPLOSIVE 31. BATTERIES ARE HEAVY. USE CARE LIFTING 32. USE INSULATED TOOLS 33. 34. WEAR EYE PROTECTION NO SMOKING 35. HOT SURFACE 36.
LABELS AND PICTOGRAMS 45. HEADLIGHTS KEEP ARMS AND LEGS WITHIN VEHICLE 37. UNLOCKED 46. 38. F TO OPERATE VEHICLE IN FORWARD: Q TURN KEY TO ON Q MOVE DIRECTION SELECTOR TO FORWARD Q DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE: Q TURN KEY TO ON Q MOVE DIRECTION SELECTOR TO REVERSE Q AN AUDIBLE DEVICE WILL SOUND Q DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY 39. R P 40.
LABELS AND PICTOGRAMS Appendix A - 6 Owner’s Manual and Service Guide
WARRANTY LIMITED WARRANTIES Owner’s Manual and Service Guide Appendix B - 1
WARRANTY 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 vehicle serial number and manufacturer date code.
DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Appendix C - 1
DECLARATION OF CONFORMITY Appendix C - 2 Owner’s Manual and Service Guide
DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Appendix C - 3
DECLARATION OF CONFORMITY Appendix C - 4 Owner’s Manual and Service Guide
Read and understand the following warnings before attempting to operate the vehicle: To prevent personal injury or death, observe the following: When vehicle is to be left unattended, engage parking (PARK) brake, move direction selector to neutral, turn key to ‘OFF’ position and remove key. Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain and traffic conditions. Consider environmental factors which effect the terrain and the ability to control the vehicle.
A Textron Company CUSHMAN 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, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc.
