Cushman 29175-G01, Owner'S Manual And Service Manual

Page 1: ...ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE ISSUED APRIL 2005 OWNER S MANUAL AND SERVICE GUIDE 29175 G01...

Page 2: ...eeds encountered on a flat surface To pre vent 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...

Page 3: ...this manual is subject to change without notice Cushman Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the mate...

Page 4: ...discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F...

Page 5: ...rn Switch 3 Key Switch 3 Fig 7 Key Switch 4 Direction Selector Switch 4 Fig 8 Direction Selector Switch 4 Power ON Battery Condition Meter 4 Headlight Accessory 4 Service Parking Brake Pedal 4 Fig 9 S...

Page 6: ...LIGHT BULB REPLACEMENT 14 CARE AND CLEANING OF THE VEHICLE 14 TRAILERING 14 HARDWARE 15 Fig 20 Bolt Grades 15 TORQUE SPECIFICATIONS 15 Fig 21 Torque Specifications 15 PERIODIC SERVICE SCHEDULE 16 Fig...

Page 7: ...ture Correction 23 Fig 31 Factory Settings 30 Fig 32 Wiring Diagram 32 Fig 32 Wiring Diagram 33 GENERAL SPECIFICATIONS 29 ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE 30 Fig 33 Vehicle Dimensions and...

Page 8: ...Page vi Owner s Manual and Service Guide TABLE OF CONTENTS Notes...

Page 9: ...SONS 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 Z GO I am directing that...

Page 10: ...icle in a responsible manner and maintain the vehicle in safe operating condition Always read and observe all warnings and operation instruction labels affixed to the vehicle Always follow all safety...

Page 11: ...at could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic Al...

Page 12: ...Owner s Manual and Service Guide SAFETY INFORMATION Page x Notes...

Page 13: ...n which affects capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been...

Page 14: ...vious experience 5 2 3 The user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads...

Page 15: ...brakes It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns re...

Page 16: ...able cleaning fluids for cleaning parts j Properly ventilate the work area k Handle LP gas cylinders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and mak...

Page 17: ...te Inc 1430 Broadway New York New York 10018 USA OR Underwriters Laboratories Inc 333 Pfingsten Road Northbrook Illinois 60062 USA This Electric Vehicle complies with ANSI B56 8 as it applies to OSHA...

Page 18: ...ildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement Never charge a vehicle in an area that is subject to flame or spark Pay particular attention...

Page 19: ...on the dash and the floorboard 1 Key Switch 2 Direction Selector Switch 3 Power On Battery Condition Meter 4 Headlight Switch 1 Service Parking Brake Pedal 2 Speed Control Pedal Ref Fig 6 on page 3 sh...

Page 20: ...te of battery charge The meter illuminates only when power is being supplied The meter scale is a 10 bar LED light emitting diode displaying the state of charge successively bar by bar from full to em...

Page 21: ...lebar Installation If the handlebar is factory installed make sure the retaining nut is tight Otherwise install the fork spindle key handle lockwasher and nut Tighten the nut to 50 ft lbs 68 Nm torque...

Page 22: ...ons EE Units meet all the requirements of E Units and provide addi tional safeguards against inherent fire and electrical haz ards as specified per U L 583 The additional components used on EE vehicle...

Page 23: ...y STARTING THE VEHICLE To start the vehicle Place the key in the key switch and turn to the ON position Move the direction selector to the direction desired release park brake and press the accelerato...

Page 24: ...use the vehicle until the problem is corrected NEVER carry more than one passenger or a pas senger along with a cargo load Passenger must remain seated in rear at all times during transport Passenger...

Page 25: ...e transport LIFTING THE VEHICLE Tool List Qty Required Floor jack 1 Jack stands 4 Chocks 4 Chain hoist 1 Some servicing operations may require the vehicle be raised To prevent possible inju ry or deat...

Page 26: ...tely apply the service and parking brakes to prevent loss of vehicle control Parking The Vehicle To park the vehicle complete the following steps before leaving the operator s seat 1 Stop the vehicle...

Page 27: ...ce with the Periodic Service Schedule Ref Fig 22 on page 16 After the vehicle has been put into service it is recommended that the brakes be checked by performing the following test Test Method To pre...

Page 28: ...se caution when inflating tires Due to the low volume of these small tires overinflation can occur in a matter of seconds Overinflation could cause the tire to separate from the wheel or cause the tir...

Page 29: ...afety warnings provided by the mounting demounting machine manufacturer Wheel Installation Do not tighten lug nuts to more than 85 ft lbs 115 Nm torque It is important to follow the cross sequence pat...

Page 30: ...t proper techniques and cleaning mate rials be used Normal cleaning of the vinyl backrest and plastic or rub ber trim requires the use of a mild soap solution applied with a sponge or soft brush and w...

Page 31: ...Fig 20 Bolt Grades Grade 2 Grade 5 Fig 21 Torque Specifications ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten al...

Page 32: ...s items listed in previous table the following BATTERIES Clean batteries terminals with 1 4 cup 60 ml baking soda to 1 1 2 gallons 6 liters water solution rinse with clear water Check charge condition...

Page 33: ...Technician s Repair and Service Manual Check brake shoe linings see Technician s Repair and Service Manual BODY Clean body components and wax all painted surfaces STEERING Lubricate use wheel bearing...

Page 34: ...with water Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle Expelled electrolyte may cause personal injury and damage to the vehicle and storage...

Page 35: ...charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas however this loss is minimal If the battery...

Page 36: ...special attention should be paid to metallic components adjacent to the batteries which should also be sprayed with the sodium bicarbon ate baking soda solution Allow the solution to sit for at least...

Page 37: ...avity of 1 275 and the battery is allowed to sit unused it will become partially discharged When it reaches 1 240 which it will do in less than twenty days it should be recharged If a battery is left...

Page 38: ...e does not perform adequately Performance problems may result in a vehicle that runs slowly or in a vehicle that is unable to operate for the time required A new battery must mature before it will dev...

Page 39: ...10 F 6 C the electrolyte temperature is above or below 80 F 27 C Adjust the reading to conform with the electrolyte temperature e g if the reading indicates a specific gravity of 1 250 and the electro...

Page 40: ...0 1 200 indicates a problem with the low reading cell s As a battery ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the battery providing all...

Page 41: ...rrent during ramp start in low speed Acceleration Rate 0 3 1 0 8 Sec Time to reach full output from zero output Quick Start 0 6 1 4 0 2 Output will respond to rate of throttle change Throttle type typ...

Page 42: ...Y W BL OR 11 Y 7 W 6 BL 5 TAILLIGHT 892676 CONTROLLER 892789 A2 B B M P3 P16 P11 P5 P6 P7 REAR LIGHT P2 REVERSE P3 FORWARD P4 MAIN CONTACT P5 POT HIGH P6 0 5V INPUT P7 POT LOW P11 REVERSE INPUT P12 F...

Page 43: ...40679 B RB W B W B B R CIRCUIT BRKR MINUTE MISER 829164 TUG 824800 R R B R B B B BL 6V MINUTE MISER BRAKE LIGHT SW 6V MAIN CONTACT 0R 2 4 1 CCW 0V 5V DIRECTION SWITCH TUG BRAKE LIGHT SW HEADLIGHT SWIT...

Page 44: ...RIC THREE WHEEL SERVICE VEHICLE Page 28 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...

Page 45: ...Page 29 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS...

Page 46: ...r connected directly to front fork SEATING Driver and rear facing passenger TOTAL LOAD CAPACITY 550 lbs 250 kg including operator accessories cargo SPEED 10 1 2 mph 17 kph CHASSIS Welded tubular steel...

Page 47: ...Guide Fig 33 Vehicle Dimensions and Incline Specifications RECOMMENDED MAXIMUM RAMP GRADE 25 or 14 MAXIMUM RECOMMENDED MAXIMUM SIDE TILT 25 or 14 MAXIMUM 22 75 in 58 cm 28 5 in 73 cm 30 in 76 cm 25 8...

Page 48: ...rvice Guide GENERAL SPECIFICATIONS Fig 34 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance TURNING CLEARANCE DIAMETER 54 in 137 cm 54 in 137 cm INTERSECTING AISLE CLEARANCE 130 in 3...

Page 49: ...components will eventually fail to perform properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each...

Page 50: ...XTRON Inc Technical Communications Department 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...