612485 A Textron Company OWNER’S MANUAL AND SERVICE GUIDE ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE ISSUED JULY 2009
SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact a representative for clarification. 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 vehicle specification.
OWNER’S MANUAL AND SERVICE GUIDE ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE VEHICLES CUSHMAN INDUSTRIAL 640 CUSHMAN STOCK CHASER Starting Model Year 2009 The CUSHMAN Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by the CUSHMAN Division, and therefore is subject to change without notice.
NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, an authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Overfilling of batteries may void the warranty. BATTERY PROLONGED STORAGE All batteries will self discharge over time.
TABLE OF CONTENTS SAFETY .................................................................................................................. Inside Covers NOTES .........................................................................................................................................ii SAFETY INFORMATION ............................................................................................................ v BEFORE INITIAL USE ...............................................................
TABLE OF CONTENTS TORQUE SPECIFICATIONS .................................................................................................. 12 Fig. 13 Torque Specifications .............................................................................................................. 12 PERIODIC SERVICE SCHEDULE .......................................................................................... 13 Fig. 14 Periodic Service Schedule .......................................................................
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. This manual has been designed to assist the owner-operator 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.
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. This vehicle conforms to the current applicable standard for safety and performance requirements. These vehicles do not conform to Federal Motor Vehicle Safety Standards and are not equipped for operation on public streets. With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Always check the polarity of each battery terminal and be sure to rewire the batteries correctly. Always use specified replacement parts. Never use replacement parts of lesser quality. Always use recommended tools.
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS.
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. GENERAL The following text is provided as recommended by part II of ASME/ANSI B56.8-1988. CUSHMAN strongly endorses the contents of this specification. manual without the manufacturer’s prior written authorization.
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. 4.8 Control of Noxious Gases and Fumes turer; 4.8.
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. 5.4.9 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles, access to stairways, or fire equipment. 5.5 Traveling 5.5.1 Observe all traffic regulations, including authorized speed limits. Under normal traffic conditions keep to the right.
SAFETY INFORMATION Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. 6.2 Maintenance Procedures 6.2.1 Maintenance and inspection of all carriers shall be performed in conformance with the manufacturer’s recommendations and the following practices. (a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Thank you for this purchase. The vehicle is equipped with an electronic speed control unit that is the most advanced in the industry. Before driving the vehicle, we ask you to spend some time reading this Owner’s Manual and Service Guide. This guide contains information that will assist you in maintaining your highly reliable vehicle.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. cut or bend the ground post. Provide Protection From Elements To disconnect charger before the charging cycle is completed, disconnect the AC cord from the AC outlet first and then disconnect the DC cord from the vehicle. The charging (DC) cord is equipped with a polarized connector which fits into a matching receptacle on the vehicle.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Use a hoist with a minimum working rating of 150 lbs. (70 kg). The hoist must be fitted with insulated lifting hook and chain or cable to prevent any possibility of shorting exposed battery terminals or connections. As an added precaution, cover the batteries to further prevent the possibility of shorting battery terminals or connections.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. sure is COMPLETELY removed. Depressing the rear (heel) portion of the pedal further activates the service brake. NOTICE If the vehicle is equipped with manufacturer installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’ position.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. brakes. Apply pressure to the heel of the pedal to stop more quickly. When vehicle is to be left unattended, release pedal completely, move direction selector to neutral position, turn key to ‘OFF’ position and remove key.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. reach. To prevent inadvertent movement when the vehicle is to be left unattended, release pedal completely, move direction selector to neutral position, turn key to ‘OFF’ position and remove key. driving the vehicle above specified speed.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. TOWING Turn wheel as shown to permit jack placement This vehicle is not designed to be towed. Detail It is recommended that this vehicle be moved by placing the entire vehicle on a trailer, flatbed truck or other suitable transport. LIFTING THE VEHICLE Tool List Qty. Required 1 2 2 Place jack along the flat edge of footrest Floor jack .........
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Fig. 14). Refer to Lubrication Points for appropriate lubrication locations (Ref Fig. 8). Grease Fitting NOTICE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions. Grease Fitting Use maximum of three pumps of grease for each grease fitting - Overgreasing may damage grease seals.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Check/Fill Plug Dry, Level, Clean, Paved Surface Fig. 9 Rear Axle Lubricant Check and Fill BRAKES Service brakes in accordance with the Periodic Service Schedule (Ref Fig. 14).
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. TIRES Tools List Qty. Required Impact wrench, 1/2" drive ............................................ 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Torque wrench, 1/2" drive, ft. lbs. ................................ 1 Wrench, 1 1/8".............................................................
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. with lukewarm or cold water is the best method of preserving the painted surfaces. NOTICE It is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will assure even seating of the wheel against the hub. With the valve stem to the outside, mount the wheel onto the hub with lug nuts.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Grade 2 Grade 5 Fig. 12 Bolt Grades TORQUE SPECIFICATIONS 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.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. PERIODIC SERVICE SCHEDULE ✓ Check ♦ Clean, Adjust, etc.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. BATTERIES AND CHARGING Safety NOTICE Always observe the following warnings when working on or near batteries: To prevent burns or battery explosion that could result in severe personal injury or death, keep all smoking materials, open flame or sparks away from the batteries. Hydrogen gas is formed when charging batteries.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. At Each Charging Cycle equal importance is too much water which will result in electrolyte being forced out of the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it does not exceed the impurity levels specified in the table. Automatic watering devices such as the one included in the Battery Maintenance Kit can be used with an approved water source (Ref Fig. 17).
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Battery Replacement Remove battery hold downs and cables. Lift out batteries with a commercially available lifting device. Inspect all wires and terminals. Clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate (baking soda) and brush clean if required.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. In high temperatures the chemical reaction is faster, while low temperatures cause the chemical reaction to slow down. A vehicle that is stored at 90° F (32° C) will lose .002 of specific gravity each day. If a fully charged battery has a specific gravity of 1.275, and the battery is allowed to sit unused, it will become partially discharged.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. TROUBLESHOOTING In general, troubleshooting will be done for two distinct reasons. First, a battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturer’s warranty. Different manufacturers have different requirements.
ELECTRIC THREE WHEEL SERVICE VEHICLE Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS. Using A Hydrometer 1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading. Examine the color of the electrolyte. A brown or gray coloration indicates a problem with the battery and is a sign that the battery is nearing the end of its life.
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 21
GENERAL SPECIFICATIONS ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE BATTERIES....................................................................... Four 6 volt deep cycle (105 minute minimum, 220 amp-hour @ 20 hour discharge rate) SPEED CONTROLLER..................................................... Solid state, 275 amp capacity with potentiometer throttle sensor MOTOR ............................................................................. 24 VDC, series wound 1.5 hp (1.1 kW) @ 2800 rpm & 4.3 hp (3.
GENERAL SPECIFICATIONS 17.5 in. (44 cm) 29 in. (74 cm) 48 in. (122 cm) 98 in. (248 cm) 78 in. (198 cm) 48 in. (122 cm) 22.5 in. 21.5 in. (57 cm) (55 cm) 29.5 in. (75 cm) 5 in. (13 cm) 48 in. (122 cm) 77.5 in. (197 cm) 84 in. (213 cm) RECOMMENDED MAXIMUM RAMP GRADE 25% or 14˚ MAXIMUM RECOMMENDED MAXIMUM SIDE TILT 25% or 14˚ MAXIMUM Fig.
GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER 10.5 ft. (3.2 m) 56 in. (142 cm) INTERSECTING AISLE CLEARANCE 56 in. (142 cm) Fig.
NOTICE 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, release pedal completely, 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 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-CUSHMAN (1-888-438-3946), FAX: 1-800-7526175 International: Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 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.
