Cushman 612485 User manual

A Textron Company
ELECTRIC POWERED THREE WHEEL
SERVICE VEHICLE
ISSUED JULY 2009
OWNER’S MANUAL
AND SERVICE GUIDE
612485

SAFETY
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
NOTES, CAUTIONS AND WARNINGS
Throughout this guide NOTE, CAUTION and WARNING
will be used.
A NOTE indicates a condition that should be observed.
A CAUTION indicates a condition that may result in
damage to the vehicle.
A WARNING indicates a hazardous
conditionthatcouldresultinsevereinjuryor
death.
Please observe these NOTES, CAUTIONS and WARN-
INGS; be aware that servicing a vehicle requires
mechanical skill and a regard for conditions that could be
hazardous. Improper service or repair may damage the
vehicle or render it unsafe.
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
Wash hands after handling.
NOTICE
Read and understand all labels located on the vehicle. For any questions on any of the information, contact a represen-
tative 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 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.) Limit speed by applying the service brake.
Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situations that could result in an unsafe condition.
Be sure that this manual remains as part of the permanent service record should the vehicle be resold.
WASH HANDS
AFTER HANDLING!
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
BATTERY WARNING
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
BATTERIES
CONTAIN LEAD
AND RELATED PARTS

Page i
Owner’s Manual and Service Guide
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 Divisionof 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.
The CUSHMAN Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the CUSHMAN Division SPECIFICALLY DISCLAIMS LIABILITY FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-CUSHMAN (1-888-438-3946), FAX: [phone]
INTERNATIONAL:
PHONE: [phone], FAX: [phone]
TEXTRON GOLF, TURF & SPECIALTY PRODUCTS
1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page ii
NOTES
Owner’s Manual and Service Guide
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. The rate of self 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 (-60° C).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain, such as the battery charger. Disconnect the battery charger cable
from the vehicle batteries when not charging.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
Refer to the ‘Prolonged Storage’ section within the BATTERIES AND CHARGING section of
this manual.

Page iii
TABLE OF CONTENTS
Owner’s Manual and Service Guide
SAFETY ..................................................................................................................Inside Covers
NOTES.........................................................................................................................................ii
SAFETY INFORMATION ............................................................................................................ v
BEFORE INITIAL USE ...............................................................................................................1
Fig. 1 Initial Service Chart ......................................................................................................................1
On Board Charger ...............................................................................................................................................1
Portable Charger Installation (if equipped) ..........................................................................................................1
Fig. 2 Charger Installation ......................................................................................................................2
Lift Out Battery Trays (if equipped) ......................................................................................................................2
Fig. 3 Charger Distribution Harness ......................................................................................................3
SERIAL PLATE LOCATION .......................................................................................................3
Fig. 4 Serial Plate Location ....................................................................................................................3
CONTROLS AND METERS .......................................................................................................3
Key Switch ...........................................................................................................................................................3
Fig. 5 Controls and Meters ....................................................................................................................3
Direction Selector ................................................................................................................................................4
State of Charge Meter .........................................................................................................................................4
Hour Meter ...........................................................................................................................................................4
Horn .....................................................................................................................................................................4
Accelerator and Brake Combination ....................................................................................................................4
Fig. 6 Combination Accelerator and Brake Pedal ..................................................................................4
Headlights and Taillight .......................................................................................................................................5
BEFORE ENTERING VEHICLE ................................................................................................. 5
OPERATING THE VEHICLE ......................................................................................................5
STARTING THE VEHICLE .........................................................................................................6
COASTING .................................................................................................................................6
SERVICING THE ELECTRIC VEHICLE ....................................................................................6
TOWING .....................................................................................................................................7
LIFTING THE VEHICLE .............................................................................................................7
Fig. 7 Lifting the Vehicle ........................................................................................................................7
ROUTINE MAINTENANCE ........................................................................................................7
Fig. 8 Lubrication Points ........................................................................................................................8
REAR AXLE ...............................................................................................................................8
Checking the Lubricant Level ..............................................................................................................................8
Fig. 9 Rear Axle Lubricant Check and Fill .............................................................................................8
BRAKES .....................................................................................................................................9
Test Method .........................................................................................................................................................9
Fig. 10 Periodic Brake Performance Test ..............................................................................................9
TIRES .......................................................................................................................................10
Tire Repair .........................................................................................................................................................10
Wheel Installation ..............................................................................................................................................10
Fig. 11 Wheel Installation ....................................................................................................................11
LIGHT BULB REPLACEMENT ................................................................................................11
CARE AND CLEANING OF THE VEHICLE .............................................................................11
TRAILERING ............................................................................................................................11
HARDWARE ............................................................................................................................11
Fig. 12 Bolt Grades ..............................................................................................................................12

Page iv Owner’s Manual and Service Guide
TABLE OF CONTENTS
TORQUE SPECIFICATIONS ..................................................................................................12
Fig. 13 Torque Specifications .............................................................................................................. 12
PERIODIC SERVICE SCHEDULE ..........................................................................................13
Fig. 14 Periodic Service Schedule ...................................................................................................... 13
BATTERIES AND CHARGING .................................................................................................14
Safety ................................................................................................................................................................ 14
BATTERY .................................................................................................................................14
BATTERY MAINTENANCE ......................................................................................................14
At Each Charging Cycle .................................................................................................................................... 15
Monthly ............................................................................................................................................................. 15
Electrolyte Level and Water .............................................................................................................................. 15
Fig. 15 Correct Electrolyte Level ......................................................................................................... 15
Fig. 16 Water Purity Table .................................................................................................................. 15
Cleaning Batteries ............................................................................................................................................. 16
Fig. 17 Automatic Watering Gun ......................................................................................................... 16
Fig. 18 Preparing Acid Neutralizing Solution ....................................................................................... 16
Battery Replacement ........................................................................................................................................ 17
Fig. 19 Battery Connections ................................................................................................................ 17
Prolonged Storage ............................................................................................................................................ 17
Fig. 20 Freezing Point of Electrolyte ................................................................................................... 20
Battery Charging ............................................................................................................................................... 18
AC Voltage ........................................................................................................................................................ 18
TROUBLESHOOTING ..............................................................................................................19
Hydrometer ....................................................................................................................................................... 19
Fig. 21 Hydrometer ............................................................................................................................. 19
Using A Hydrometer .......................................................................................................................................... 19
Fig. 22 Hydrometer Temperature Correction ...................................................................................... 20
GENERAL SPECIFICATIONS...................................................................................................21
ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE.......................................................................... 22
Fig. 23 Vehicle Dimensions and Incline Specifications......................................................................... 23
Fig. 24 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance ................................... 24

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page v
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. To reduce the chance of personal injury and/or property damage, the following instructions
must be carefully observed:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an
CUSHMAN-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an CUSHMAN-man-
ufactured vehicle is modified an any way by the Distributor, Dealer or customer to operate at or in excess of 20mph,
UNDER FERERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and require-
ments of Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or
Dealer MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifica-
tions for LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance
with the requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applica-
ble in the places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be
the Final Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
CUSHMAN will NOT approve Distributor, Dealer or customer modifications converting CUSHMAN products into LSV’s.
The Company, in addition, recommends that all CUSHMAN products sold as personal transportation vehicles BE
OPERATED 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 CUSHMAN, I am directing that CUSHMAN Branch personnel, Distributors and Dealers advise all customers to
adhere to this SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or
Dealer has reason to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or
through the Internet at the website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
GENERAL
Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. The manufacturer strongly suggests that the owner-operator read this entire manual paying
particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees
and other operators be encouraged to do the same.
If you have any questions, contact your closest representative or write to the address on the back cover of this publica-
tion, Attention: Product Service Department.
TEXTRON Golf, Turf & Specialty Products 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.
TEXTRON Golf, Turf & Specialty Products is not liable for errors in this manual or for incidental or consequential dam-
ages that result from the use of the material in this manual.

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page vi
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.
Never use the chassis or body as a ground connection.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and
disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the
vehicle.
GENERAL OPERATION
Always use the vehicle 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 rules established in the area where the vehicle is being operated.
Always reduce speed to compensate for poor terrain or conditions.
Always apply service brake to control speed on steep grades.
Always maintain adequate distance between vehicles.
Always reduce speed in wet areas.
Always use extreme caution when approaching sharp or blind turns.
Always use extreme caution when driving over loose terrain.
Always use extreme caution in areas where pedestrians are present.
MAINTENANCE
Always maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
Always ensure that mechanics performing repairs are trained and qualified to do so.
Always follow the manufacturer’s directions if you do any maintenance on your 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.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by short-
ing the battery terminals or associated wiring. Remove the batteries or cover exposed terminals with an insulating
material.

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page vii
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.
Always determine that tools and procedures not specifically recommended by the manufacturer will not compromise
the safety of personnel nor jeopardize the safe operation of the vehicle.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a
jack. Lift the vehicle in accordance with the manufacturer’s instructions.
Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that 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.
Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of
both vehicular and pedestrian traffic.
Always replace damaged or missing warning, caution or information labels.
Always keep complete records of the maintenance history of the vehicle.
VENTILATION
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because
hydrogen gas is lighter than air, it will collect in the ceiling of buildings 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 to natural gas or propane
gas water heaters and furnaces.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the recepta-
cle when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable
electrical code (whichever is more restrictive).

Owner’s Manual and Service Guide
SAFETY INFORMATION
Page viii
Read all of manual to become familiar with this vehicle. Pay particular attention to all NOTICES, CAUTIONS,WARNINGS and DANGERS.
NOTES: