Textron CUSHMAN ELECTRIC TUG E-Z-GO XI 340 Guide

Manuel de Sécurité, Fonctionnement et de Maintenance
RJ 100 02 2005
AVERTISSEMENT : Risque de blessures graves en
cas d’utilisation incorrecte de la machine. Les
opérateurs et le personnel d’entretien doivent être
formés et conscients des dangers encourus. Ils
doivent lire avec attention le manuel avant d’essayer
demonter, d’utiliser,derégleroumaintenirlamachine.
841463-FR (rev.2)
E-Z-GO XI 340
CUSHMAN ELECTRIC TUGTM
Safety, Operation & Maintenance Manual
WARNING: If incorrectly used this machine can
cause severe injury. Those who use and maintain
this machine should be trained in its proper use,
warned of its dangers and should read the entire
manual before attempting to set up, operate, adjust
or service the machine.

GENERAL INFORMATION
IMPORTANT!
THIS MANUAL WILL AID YOU IN THE SAFE
OPERATIONANDPROPERMAINTENANCEOF
YOUREQUIPMENT.READMANUAL
THOROUGHLYBEFOREATTEMPTING
OPERATION.IFANYPORTIONISNOTCLEARLY
UNDERSTOOD,CONTACTANAUTHORIZED
DEALERFORCLARIFICATION.
Tomakesureyouarefullyawareofsafetyand
serviceinformation,thefollowingtwosymbolsare
usedthroughoutthismanual.
This symbol is used throughout the manual
to alert you to information about unsafe actions or
situations, and will be followed by the word
DANGER,WARNING,orCAUTION.DANGER
indicates immediate hazards that may result in
severeinjuryordeath.WARNINGindicatesunsafe
actions or situations that may cause severe injury,
deathand/ormajorequipmentorpropertydamage.
CAUTIONindicatesunsafe actionsorsituationsthat
maycauseinjury,and/orminor equipment or
propertydamage.
NOTICE This symbol appears next to
informationorinstructionswhichwillhelpyou
operateandmaintainyourequipmentproperly.
Additionalmanualsareavailablethroughyourdealer.
SPECIFICATIONINFORMATION
All information contained in this manual is the latest
availableatthetimeofprinting.RansomesJacobsen
Limited reserves the right to make changes at any
time without notice.
Wheneveranamebrandproductisspecified,an
equivalentproductmaybe usedunlessstated
otherwise.
CHANGEOFOWNERSHIPORADDRESS
RansomesJacobsenLimitedmakeseveryeffortto
keepownersinformedofallsafetyrelated
information.Therefore,changesinownershipand/or
addressshouldbereportedtothemanufacturer.
YourdealerhasREGISTRATIONCHANGEforms
which will be filled out and filed by the dealer for his
records, and a copy will be sent to the manufacturer.
DEALERINFORMATION
Foryournearestdealerlocationwriteto:
RansomesJacobsenLimited
WestRoad,RansomesEuropark
Ipswich,IP39TT,England
ransomesjacobsen.com
The information and instructions included
in this manual alert you to certain things
you should do very carefully. If you do
not, you could:
• injure yourself or others
• injure the next person who
operates the“ equipment“
• damage the equipment.
This manual contains essential operation
and safety information and must remain
with the unit at all times, within easy
access of any operator.
IMPORTANT!
THISEQUIPMENTSHOULDNOTBEMODIFIED
ORADDEDTOWITHOUTTHE
MANUFACTURER'SAUTHORIZATION.
Direct any inquiries to:
RansomesJacobsenLimited
TechnicalDirector
WestRoad,RansomesEuropark
Ipswich,IP39TT,England
Altering this equipment in any manner
which adversely affects the equipments
operation, performance, durability or use,
may cause hazardous conditions.

GENERALITES
IMPORTANT
LEBUTDECEMANUELESTDEVOUSAIDERA
UTILISERENTOUTESECURITEETA
MAINTENIRCORRECTEMENTLEVEHICULE.IL
FAUTLE LIREAFONDAVANTDE SESERVIR
DUVEHICULEETS’ADRESSERAU
FOURNISSEURPOURCLARIFIERTOUTE
SECTIONDUMANUELS’AVERANTETREMAL
COMPRISE.
Afin de s’assurer de la compréhension des
consignes de sécurité et de service, les deux
symboles suivants sont utilisés dans ce manuel.
Cesymbolefigurepartoutdans le manuel
et sert à signaler des actions ou situations
pouvants’avérerdangereuses ;il
accompagne:DANGER,AVERTISSEMENTou
ATTENTION.DANGERindiquelaprésenced’un
risqueimmédiatpouvantprovoquerdegraves
blessures,voiremortelles.AVERTISSEMENT
indique la présence d’actions ou de situations
dangereusessusceptiblesdeprovoquerdegraves
blessures,voiremortellesetd’endommagerle
véhiculeoulesbiens.ATTENTIONindiquela
présence d’actions ou de situations risquant de
blesseretd’endommagerlégèrementlevéhiculeou
les biens.
AVIS Cesymbole setrouveprèsd’informationsou
deconsignesdestinéesà faciliterlefonctionnement
etlamaintenanceduvéhicule.
S’adresseraufournisseurpourobtenirdescopies
supplémentairesdecemanuel.
SPECIFICATIONS
Lesinformations figurant dans ce manuel sont les
plus récentes au moment de son impression.
RansomesJacobsenLimitedse réserveledroitd’y
apporterdesmodificationssanspréavis.
Quandunemarquedefabriqueestmentionnée,il
est possible de l’utiliser à moins qu’indiqué
différemment.
CHANGEMENTDEPROPRIETAIREOUDE
DOMICILE
RansomesJacobsenLimiteds’efforcederenseigner
les propriétaires des véhicules sur tout ce qui
concerne la sécurité. En cas de changement de
propriétaireduvéhiculeoudedomicile,ilestdonc
recommandéd’enfairepartauconstructeur.
Lefournisseur adesformulairespourtout
CHANGEMENTD’ENREGISTREMENTqu’ilremplit
et classe. Une copie est ensuite envoyée au
constructeur.
FOURNISSEUR
Pourobtenir lescoordonnéesdufournisseurleplus
proche,envoyeruncourrieràl’adressesuivante:
RansomesJacobsenLimited,
WestRoad,Ransomes Europark,
Ipswich,IP39TT,Angleterre
www.ransomesjacobsen.com
Lesinformationsetconsignesfigurant
dans ce manuel signales certaines
actions devant être accomplies
prudemment. Dans la négative, les
risquessontlessuivants :
• Se blesser ou blesser les autres
• Blesser la personne prenant la
relève du véhicule
• Endommager le véhicule.
Ce manuel renferme des informations
importantes sur le fonctionnement et la
sécurité ; il doit, par conséquent, toujours
accompagner le véhicule et doit toujours
être accessible à l’opérateur.
IMPORTANT
ILNE FAUTPASMODIFIERCEVEHICULE SANS
L’AUTORISATIONPREALABLEDU
CONSTRUCTEUR.
Lesdemandesdoiventêtreadresséesà:
RansomesJacobsenLimited,
TechnicalDirector,
WestRoad,Ransomes Europark,
Ipswich,IP39TT,Angleterre
Toute modification apportée au véhicule
affecte négativement son
fonctionnement, sa performance, durée
de service ou utilisation et s’avère
dangereuse.

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E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
PICTORIAL DECALS
Hour Met
er
This decal indicates the
unit is certified for use by
the European community.
.
Brake pedal
Throttle pedal
Forward/Reverse
Indicator
Parking Brake
Headlight
Off
Electrical Power

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SAFETY, OPERATORS & MAINTENANCE MANUAL
PAGE
A
ACCESSORIES ......................................................................5, 14
B
BATTERY:
CHARGING .................................................................. 10
CONDITION METER (ACCESSORY).......................... 5
SERVICE ...................................................................... 10
SPECIFICATIONS ....................................................... 10
BELT ADJUSTMENT ................................................... 13
BRAKE:
PARK ............................................................................. 5
SERVICE ....................................................................... 5
BULBS ....................................................................................... 9
C
CONTROLS, LIGHT, METERS, AND SWITCHES .................. 4
D
DECALS, PICTORIAL ............................................................... 1
DIAGNOSTIC & TROUBLE SHOOTING................................. 11
DIFFERENTIAL ........................................................................ 14
DIRECTION SELECTOR SWITCH ........................................... 4
DRIVING THE VEHICLE ........................................................... 7
F
FRONT AND REAR TIRE/WHEEL REMOVAL ....................... 13
G
GENERAL INFORMATION ............................. INSIDE COVER, 3
H
HORN BUTTONAND HANDLEBAR ........................................ 4
HOUR METER (ACCESSORY) ................................................ 5
I
IDENTIFICATION, VEHICLE..................................................... 3
J
JACKS AND JACKING LOCATIONS ...................................... 14
K“KEY SWITCH ........................................................................ 5
L
LIGHT SWITCH ......................................................................... 5
LUBRICATION:
CHART........................................................................... 9
GUIDE ........................................................................... 9
M
MAINTENANCE GUIDE ............................................................ 9
MODEL NUMBER, VEHICLE ................................................... 3
MOTOR BRUSH REPLACEMENT .......................................... 10
MOTOR TERMINALS............................................................... 10
O
OPERATION, VEHICLE ............................................................ 6
OWNER REGISTRATION ................................... INSIDE COVER
P
PARKING (LEAVING) THE VEHICLE ...................................... 7
R
RATED CAPACITY..................................................................... 7
REARACCESS......................................................................... 10
S
SEAT ADJUSTMENT LEVER ................................................... 4
SEAT SWITCH ........................................................................... 5
SERIAL NUMBER, VEHICLE ................................................... 3
SERVICE AND MAINTENANCE, VEHICLE............................. 8
SERVICE PUBLICATIONS ....................................................... 3
SPECIFICATIONS .................................................................... 15
SPEED CONTROL:
CONTROLLER............................................................. 11
PEDAL ........................................................................... 5
TROUBLE SHOOTING CHART............................... 11-12
STANDARDSAND PUBLICATIONS ........................................ 2
STORAGE ................................................................................. 14
T
THERMAL CIRCUIT BREAKER ............................................... 7
TIRE PRESSURE ..................................................................... 13
TOWING CAPABILITIES .......................................................... 8
TOWING THE VEHICLE ........................................................... 8
TROUBLE SHOOTING CHART............................................... 12
V
VEHICLE SERVICE & MAINTENANCE ................................... 8
W
WARRANTY, CUSHMAN ......................................................... 17
WARRANTY, SERVICE............................................................ 16
WIRING DIAGRAM, VEHICLE .............................................18-21
INDEX

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E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
Cushman electric vehicles comply with ansi b56.8 as
it applies to osha for powered industrial trucks under
the type e classification. The electric tuge vehicle
has been approved by factory mutual research
corporation. To meet the manufacturer portions of
the osha requirements (as stated in section
1910.178, paragraph a3) powered industrial trucks
must bear the approval mark of either ul
(underwriters laboratory) or fm (factory mutual) or
other nationally recognized testing laboratories.
SERVICE PUBLICATIONS
Additional operator's manuals and parts manuals are
available for a minimum charge at this address:
Ransomes Jacobsen Limited
West Road, Ransomes Europark
Ipswich, IP3 9TT, England
GENERAL INFORMATION
Your cushman electric tuge vehicle is powered by a
36 volt d.c. Traction type motor. Three (3) heavy
duty v-belts transmit the power to the differential.
A key type switch turns off the control system,
preventing all electrical functions when the key is in
vertical off position.
Standard equipment includes an electronic speed
controller, handlebar steering, three (3) wheel
hydraulic service brakes, hand operated parking
brake, horn, stoplight, taillight, battery condition
meter.
The range of this vehicle is up to 35 miles (56 km).
Determining factors affecting the range are: Battery
condition and size, payload, the number of stops, tire
pressure, acceleration and operating terrain.
• altering this vehicle in any manner which
adversely affects the vehicle's operation,
performance, durability or use may cause
hazardousconditions.“
• never attach any electrical device or accessory
to this vehicle which is grounded to the vehicle
frame.

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SAFETY, OPERATORS & MAINTENANCE MANUAL
VEHICLE IDENTIFICATION
These identification numbers must appear on all
correspondence concerning this vehicle.
Model number
The vehicle model number, model year and serial
number are stamped on the decal attached to the
left kick panel.
The complete ten (10) digit number is required to
identify certain parts.
5201
Model number, model year and
serial number on decal
VEHICLE SERIAL NUMBER
the vehicle serial number and model number is also
stamped on the right wheel well under the deck.
4022
Serial number and model number onwheel well
CONTROLS, LIGHT, METERS AND SWITCHES
1. Battery condition meter
2. Key switch
3. Headlight switch
4. Direction selector switch
5. Horn button and handlebar (not shown)
6. Speed control pedal
7. Brake pedal
8. Parking brake lever
9. Master cylinder cap
10. Headlight (accessory) (not shown)
11. Hour meter (accessory)
12. Quick disconnect (ec model only)
13. Tail light (not shown)
14. Backup alarm (not shown)
5202
1
2
3
4
5201
6
7
8
9
10

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SAFETY, OPERATORS & MAINTENANCE MANUAL
11
12
5207
SEAT ADJUSTMENT LEVER
3536
Seat adjustment lever
To adjust seat, move lever to the left side of the
vehicle, and slide the seat to desired position,
release lever.
HORN BUTTON AND HANDLEBAR
The horn button switch is attached to the handlebar
on the standard equipment vehicle.
A vehicle equipped with optional wheel type
steering will have the horn button located in the
center of the steering wheel.
Depress to sound horn. The horn will not sound
when the key is in "off" position.
DIRECTION SELECTOR SWITCH
The direction selector switch, located on the
instrument panel, operates the contactors that
control the direction of vehicle movement.
Depressing the top portion of the switch will select
forward direction, depressing the bottom of the
switch will select reverse.
Backup alarm will sound when direction selector is
placed in the reverse position.
KEY SWITCH
1
2
This is a two position switch:
1. Off position - interrupts the vehicle's electrical
control system.
2. On position - key is in this position for
operation.
BRAKE PEDAL AND PARKING BRAKE
Depress the brake pedal (push down) to slow or
stop the vehicle.
Parking brake may be adjusted, by turning the end
of the lever clockwise.
Pull the lever up to apply brake - push down to
release.
1
2
5201
1. Parking brake released position
2. Parking brake applied position
ALWAYS APPLY THE PARKING BRAKE
WHENEVER THE VEHICLE IS LEFT
UNATTENDED. THE PARKING BRAKE IS
NOT AUTOMATICALLY APPLIED.

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E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
SEAT SWITCH
The seat switch, located under the operator's seat,
allows the speed controller to function only when
the operator is properly seated.
OPERATION
The safety warning decal is located on the upper
portion of the right kick panel. All information on
the decal is of the utmost importance. This decal
and all others must remain on the vehicle.
TO PREVENT UNEXPECTED VEHICLE
MOVEMENT, NEVER OPERATE THE
VEHICLE IF THE SEAT SWITCH IS NOT
FUNCTIONING PROPERLY.
SPEED CONTROL PEDAL
This pedal is located on the floorboard. Operation
with the pedal fully depressed gives maximum
speed but is recommended only when the vehicle
can be operated safely.
when slower speeds are desired, depress the pedal
as required.
TO PREVENT LOSS OF VEHICLE
CONTROL, NEVER EXCEED SAFE
OPERATING SPEED. ALWAYS ADJUST
SPEED TO CONDITIONS.
Battery "fuel" gauge
A 10-bar led display shows state of charge from full
to empty.““at 70% discharge "energy reserve" alert
is signaled by a flashing light.““at 80% discharge a
double flashing light indicates an "empty charge".““
ACCESSORIES
Headlight
The headlight can be pivoted on the mounting as
required. Push switch to turn on or off.
Hour meter
This meter records the number of hours the vehicle
has been operated in a forward direction.
FAILURE TO OBEY A SAFETY WARNING
MAY RESULT IN INJURY TO YOU OR
OTHERS
BEFORE OPERATING VEHICLE
READ AND UNDERSTAND OPERATORS MANUAL
(LOCATED UNDER SEAT).
DO NOT CARRY PASSENGER.
SWITCHES SPARK, DO NOT OPERATE IN
EXPLOSIVE OR COMBUSTIBLE ATMOSPHERE.
WHILE OPERATING VEHICLE
KEEP BODY INSIDE VEHICLE, STAY IN SEAT.
SUDDEN SHARP TURNS, UNBALANCED OR TOP
HEAVY LOADS CAN CAUSE UNSTABLE
CONDITIONS.
ADJUST SPEED TO CONDITIONS.
CARGO MUST BE SECURED TO PLATFORM.
AVOID SUDDEN STARTS AND STOPS TO AVOID
SHIFTING LOADS AND JACKKNIFE OF VEHICLE
ANDTRAILERS.
BEFORE LEAVING VEHICLE
SET DIRECTION INDICATOR TO "OFF".
TURN KEY TO VERTICAL "OFF" POSITION AND
REMOVE.
IF MALFUNCTION OCCURES, OR ADJUSTMENT IS
NEEDED, DO NOT USE.
WARNING
- APPLY HAND BRAKE OR FOOT BRAKE-
PARKING BRAKE NOT AUTOMATICALLY
APPLIED.
Read this section carefully and thoroughly in order
to become familiar with proper operating
procedures. Be sure to obtain an operating
demonstration from your authorized cushman
dealer before attempting to drive the vehicle.
YOUR SAFETY AND THE SAFETY OF
THOSE AROUND YOU DEPEND ON YOUR
CARE AND GOOD JUDGMENT IN
OPERATING AND MAINTAINING THIS
VEHICLE

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E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
You, the operator, must take time to familiarize
yourself with the function of all vehicle controls as
well as the operating characteristics of the vehicle.
This is best accomplished through careful
application of proper operating procedures.
• This vehicle is heavy equipment that could
cause serious injury or death to you the
operator or bystanders if improperly used or
overturned.
• Never operate this vehicle until the operator's
manual is read and understood.
• Only trained and authorized persons shall
operate this vehicle.
• Never allow children to operate the vehicle.
• the following steps tell you how to use this
vehicle properly and what may happen if you
do not.
1. Before using the equipment, always check all
parts of the vehicle and any attachments. If
something is wrong, stop using it. Make sure
the problem is fixed before the equipment is
used again.
2. Always make sure the area of operation is
clear of trash, litter and other objects.
3. This vehicle is designed to carry only you, the
operator, in the seat provided by the
manufacturer. Never carry any other
persons on the vehicle.
4. Always keep both hands on the handle bar
wheneverpossible.
5. Always use extreme care when backing and
make sure no one is behind you. The
reverse speed is half of forward speed. To
maintain vehicle control, always back the
vehicle carefully at reasonable speed.
Backup alarm will sound when direction
selector is placed in the reverse position. Do
not operate if backup alarm is not functioning
properly.
6. Always keep arms and legs inside of the
vehicle while it is moving. Sit only in the seat
provided by the manufacturer. Any body
parts extending past the confines of the
vehicle could be struck by nearby objects.““
7. Never use the vehicle in, or near, an area
where there is explosive dust or fumes. The
electrical system of this vehicle will make
sparks which can ignite explosive materials.
8. Always signal that you are going to turn or
stop early enough so that other persons
know that you plan to do so. Obey all traffic
rules and regulations.
9. Always watch for and avoid low overhang
such as tree limbs, door jambs, overhead
walkways, etc. Make sure there is enough
room overhead for your vehicle and your
head to clear easily.
10. Always use good judgment when operating
on or near an incline, ramp, grade, slope or
other surface.
11. Always adjust your speed to conditions(dry,
moist, icy, etc.).
12. Never start or stop suddenly. You may
cause unstable vehicle operating conditions.
13. Never change direction of vehicle abruptly or
make sharp turns on an incline, ramp, grade,
slope or other surface.
14. Always stay a safe distance away from
pedestrians, ramp edges, platforms, other
equipment, etc.
15. Always drive straight up and down the face of
an incline, ramp, grade or slope, never
across the face.
While driving down an incline, especially with
a heavily loaded vehicle, always remove the
foot from the speed control switch pedal to
avoid increasing the vehicle speed beyond
level ground maximum speed. Always use
foot brake to slow the vehicle.
Never park the vehicle with loaded trailers on
incline or ramps.
Never leave the vehicle without applying the
park brake and removing the switch key.
16. Never overload your vehicle, or trailers. The
maximum rated capacity is: 450 lbs. (204
kg) includes 200 lbs. (91 kg) for operator;
tows up to 3000 lbs. (1361 kg); up to 15000
(6804 kg) with additional trailer brakes. See
towing capacities on page 8.
Always position loads carefully so they can't
shift or tip over suddenly. Distribute loads

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E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
evenly over rear area.
Always keep loads low (not top heavy) so
vehicle does not get top heavy when driven.
17. Always slow down when turning the vehicle
with trailers.
18. Always allow sufficient space when turning
corners with trailers.
DRIVING THE VEHICLE
1. You, the operator, must be properly seated
on the vehicle seat.
2. Insert key in switch, turn to on position.
3. Position the direction selector switch for
direction of vehicle movement desired.
4. Release the parking brake.
5. Slowly depress the speed control pedal to
achieve the desired vehicle speed.
While driving down an incline, release the speed
control switch pedal to conserve battery power and
avoid increasing the vehicle speed beyond level
ground maximum speed. Use foot brake to slow
the vehicle.
NOTICE
• To avoid motor damage, do not cause the
motor to exceed normal operating speed.
• The vehicle electrical circuit includes a
protective component.““
Thermal circuit breaker
This switch prevents overloading of the drive motor.
should the vehicle be stopped by the opening of the
circuit breaker, the breaker will automatically reset
in about 20 seconds. An audible click will be heard
when circuit breaker resets. If the circuit breaker
continues to open, a problem exists within the
circuit, or vehicle is overloaded. Do not operate the
vehicle.
Consult your authorized cushman dealer for any
service required.
PARKING (LEAVING)“THE VEHICLE
Before you leave the operator's seat, do the
following:
• Always apply/set the parking brake.
• Always place the direction selector switch in
"off" (center) position.
• Always turn the switch key to vertical "off"
position and remove the key to prevent
unauthorized people from operating the
vehicle.
When parking the vehicle only on an incline, the
front wheel should be curbed whenever possible.
Seeillustration.
TOWING THE VEHICLE
Attach towing equipment to the front kick panel
outer edges near the floorboard.“refer to the
chassis lubrication chart for towing equipment
attaching locations (page 9).
• Always attach towing equipment to the
vehicle at the towing points. Never attach
towing equipment under the vehicle. You
may damage steering, brake lines, or other
parts.
• Always remove the load before towing the
vehicle. Towing a loaded vehicle could
cause either vehicle to lose proper steering
control.
• Never tow vehicle faster than 5 m.p.h. (8 km/
h). Towing at excessive speed could cause
either vehicle to lose proper steering control.

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E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
NOTICE
• Towing the vehicle at excessive speed could
cause damage to the drive train components,
such as the drive motor which could cause the
towed vehicle to stop abruptly.
TOWING TRAILERS/EQUIPMENT, ETC.
NOTICE
• coasting the vehicle at excessive speed
could cause damage to the drive train
components, such as the drive motor which
could cause the vehicle to stop abruptly.
•do not exceed 3,000 lbs. (1362 kg)
gross weight towing capability of
vehicle. Failure of brakes/steering
may occur, injuring operator or
bystanders.
• never use the vehicle on floors,
ramps or other surfaces that are not
strong enough to support the
vehicle when loaded with maximum
rated payload and any towed trailer
with payload.
• to prevent possible loss of control
and collision or vehicle upset when
towing, the operator must
determine that the vehicle has
adequate braking capacity to stop
either a loaded or unloaded vehicle
and the towed unit(s) on the type(s)
of surface(s) and grade(s) on which
the units will be operated. Sudden
stops may cause trailers and
vehicle to jackknife.
Also, the load must be positioned
on the towed unit(s) so the trailer
tongue weight on the vehicle will
not cause instability or loss of
vehicle steering control.
•this vehicle can tow heavier loads
than can be stopped under some
conditions.
Recommended maximum gross towed
load
1 trailer: 3000 lbs. (1362 kg)
2 trailers: 1500 lbs. Each (681 kg)
3 trailers: 1000 lbs. Each (454 kg)
NOTICE
• towing a load greater than 3000lbs. (1361 kg)
up to 15000 (6804 kg) requires additional
trailer brakes.
VEHICLE SERVICE AND“ MAINTENANCE
•when replacement parts are
required, use genuine cushman
parts. Failure to do so may result in
product malfunction and possible
injury to the operator and/or
bystanders.
Never attempt to perform service or maintenance
functions on this vehicle if you are untrained or
unauthorized. Improper maintenance can cause
hazardous conditions. See your authorized cushman
dealer for necessary maintenance and service.
When it is necessary to raise the vehicle for any
repair or service, use jackstands to provide adequate
support. Do not rely on hydraulic or mechanical
jacks.
It is advisable that your vehicle be equipped with an
hour meter (set #884737) to record hours of
operation. A good maintenance schedule can then
be established.
The following maintenance guide provides a check
list for servicing your vehicle. The guide is set up for
average use on clean, paved surfaces. Vehicles
used in dusty areas, or operated in mud, snow or
water or for winter driving require more frequent
service.

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E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
MAINTENANCE GUIDE
Check tire pressure.
Fill batteries to proper level and check specific gravity.
Wash battery tops free of dirt and electrolyte.
Remove and clean corroded wire terminals, battery terminals
and batteries. Reinstall wire terminals.
Use metal parts protector (Part No. 841192) to cover all elec-
trical connections and battery terminals.
AS REQUIRED
NOTICE
• Be sure to make all connections prior to
using the metal parts protector, since it will
coat all open surfaces.
Perform previous services
Lubricate chassis*
Check differential lube level (EP)
Check master cylinder fluid level ± use DOT 3 brake fluid
EVERY 200 HOURS
EVERY 1000 HOURS OR YEARLY
Perform previous services
Change differential lube (EP)
Clean and repack front wheel bearings (PG)
Check motor brushes
PG ± Pressure gun grease
(lithium base)
EP ± Extreme pressure lube
SAE ± 80±90 Multigrade
BF ± Brake fluid DOT (3)
LUBRICATION CODE
CHASSIS LUBRICATION CHART
Perform every 200 hours
LUBRICATION AREA NUMBER OF
LUBRICATION POINTS
OR FITTINGS*
1. Brake pedal pivot crank 1
2. Fork tube upper bushing & lower bearing 2
3. Fork pivot bushing 2
* Use a lithium based pressure gun grease on all
grease fittings and lubrication points.
CHASSIS LUBRICATION GUIDE
IMPORTANT
* TOW LINE ATTACHING POINTS
X JACKING LOCATIONS
BULBS
Description Specification or Trade No. Cushman No.
BULBS
Headlight (accessory) 35 Watt No. 4411 820594
(3000 CP)
Light, Stop, Tail 32±4 CP No. 1157 822049
or
No. 2057

GB-11
E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
BATTERY SPECIFICATIONS, SERVICE AND
CHARGING
Specifications
This vehicle requires six (6) deep cycle 6 volt
batteries each with a minimum capacity of 180 a.h.
(Ampere-hours at the sae 20-hour rate) and 5/16"
(8 mm) stud posts.
The maximum case dimensions are:
W length 10 3/8" (264 mm)
W width 7 3/16" (183 mm)
W height 11 5/8" (295 mm) (including posts)
Service and charging
NOTICE
Do not attempt to recharge the batteries with a
charger not designed for this vehicle.
• untrained/unauthorized persons
should never attempt to service or
recharge the batteries of this
vehicle.
• to avoid injury, use an adequate
lifting device to lift the batteries
and/or accessory lift out battery
rack.
• never use metal chains, etc., to lift
the batteries and/or accessory lift
out battery rack. They can cause
electrical arcing resulting in battery
explosion.
• stay clear when lifting, lowering or
moving the batteries and/or
accessory lift out battery rack.
See your authorized cushman dealer for information
about lifting devices.““
Battery location
The batteries are located under the seat deck.
5204
Standard battery arrangement
5205
Ec battery arrangement
ACCESSORY LIFT OUT BATTERY RACK
The batteries and rack weigh approximately 400
lbs. (183 kg). Use an adequate lifting device to lift
batteries. ““
Battery charger
The standard vehicle is equipped with a built in 36
volt, 25 amp dc, 120 volt ac, 60 hz, fully automatic
charger located under the vehicle seat. The battery
charger will shut off automatically. If the battery
condition meter indicates a full charge has not been
achieved, check batteries and/or charger. Battery
condition meter is reset to indicate a full charge at
the end of charge cycle.
Rear access
The cargo area floor may be removed to service
the brakes, differential, drive motor and belts.

GB-12
E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
MOTOR BRUSH REPLACEMENT
At regular maintenance intervals, each motor brush
should be checked to determine if excessive wear
or damage is evident. If a brush is broken,
cracked, chipped or worn to a length of less than 5/
8" (15.9 mm), measured on the short side of the
brush, all brushes should be replaced. Never
replace a single brush.
see your authorized cushman dealer for service
required.
Motor terminals
Motor wire to motor terminal connections should be
clean and tight for maximum motor efficiency. Use
metal parts protector spray (part no. 841192).
• the cargo area floor is a machinery
guard and its removal exposes the
operator to moving parts. Keep
hands, hair and clothing away from
belts and pulleys
NOTICE
• motor terminals should not be turned from
original position.“hold terminal stud nut while
torquing the wire terminal retaining nuts 50 to
70 in.-lbs. (5.5 to 8 n·m).
Speed controller
The vehicle is equipped with an electronic speed
controller that does not require servicing.
5203
Controller led status indicator
3
4
LED DIAGNOSTICS
OFF
012
MAIN PLUG
CURRENT LIMIT
ACCEL. CREEP LOW
SPEED LIMIT
3
4
OFF
012
3
4
OFF
0123
4
OFF
012
3
4
OFF
012
D
uring normal operation, with no faults present, the Status LED flashes a singl
e
f
lash at approximately 1 flash/second. If the controller detects a fault, a 2±digi
t
c
ode (see Table) is flashed continuously until the fault is corrected. For exam-
p
le, code ª3,2º ±welded direction contactor ± appears as:
(3,2) (3,2) (3,2)
STATUS
PROGRAMMER ACCESSORY
A Controller Programmer is available, Part No. 893052

GB-13
E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
TROUBLESHOOTING CHART
LED
CODE PROGRAMMER
LCD DISPLAY EXPLANATION POSSIBLE CAUSE
1,2 HW FAILSAFE hardware fail±safe error 1. Controller defective.
1,3 M±FAULT M±output shorted 1. M±output shorted to ground.
2. Direction contactor not closing.
3. Direction contactor not closing fast enough
.
4. Internal motor short to ground.
1,4 SRO SRO fault 1. Improper sequence of KSI, brake and
direction inputs.
2. Wrong SRO type selected.
3. Brake or direction switch circuit open.
4. Sequencing delay too short.
2,1 THROTTLE FAULT 1 5kΩ±0 or wiper fault 1. Throttle input wire open.
2. Throttle input wire shorted to ground or B+
.
3. Throttle pot defective.
4. Wrong throttle type selected.
2,2 BB WIRING CHECK emer. reverse wiring fault 1. BB wire open.
2. BB check wire open.
2,3 HPD HPD sequencing fault 1. Improper seq. of KSI, brake, throttle inputs
.
2. Wrong HPD type selected.
3. Misadjusted throttle pot.
2,4 THROTTLE FAULT 2 Pot Low broken or shorted 1. Pot Low wire open.
2. Pot Low wire shorted.
3. Wrong throttle type selected.
3,1 CONT DRVR OC driver output overcurrent 1. Direction contactor coil shorted.
2. Shunt field shorted.
3,2 DIR CONT WELDED welded direction contactor 1. Direction contactor stuck closed.
3,4 MISSING CONTACTOR missing contactor or shunt 1. Direction contactor coil open.
2. Direction contactor missing.
3. Shunt field open.
4. Wire to shunt or direction contactor open.
4,1 LOW BATTERY VOLTAGE low battery voltage 1. Battery voltage <16 volts.
2. Corroded battery terminal.
3. Loose battery or controller terminal.
4,2 OVERVOLTAGE overvoltage 1. Battery voltage >45 volts.
2. Vehicle operating with charger attached.
4,3 THERMAL CUTBACK over/under±temp. cutback 1. Temperature >855C or <±25 5C.
2. Excessive load on vehicle.
3. Improper mounting of controller.
4. Operation in extreme environments.

GB-14
E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
BELT ADJUSTMENT
The motor mount assembly pivots to provide belt
adjustment. Turn the adjusting nuts as required.
When properly adjusted, the belts will be tight
enough to prevent slippage. Do not overtighten.
The motor base is slotted to allow the motor to be
moved on the mounting plate, should the pulleys
become misaligned.
The belts should always be replaced in matched
sets of three.
NOTICE
• to avoid unnecessary belt wear and load on
the motor, do not overtighten the belts or
operate with misaligned pulleys.
FRONT TIRE REMOVAL
12
5
7
6
3
4
1. Front axle lock 5. Washer
2. Lockwasher 6. Wheel retaining nut
3. Axle nut 7. Valve stem“
4. Side arm NOTICE
• install the wheel assembly with the valve
stem on the right side.
• make sure the fork side arm reaction pin is
inserted in slot of the brake dust shield.
1
2
1. Dust shield slot
2. Reaction pin
• when it is necessary to raise the
vehicle for any repair or service,
use jackstands to provide adequate
support. Do not rely on hydraulic or
mechanical jacks.
Remove and reinstall as follows:
• loosen the axle nuts and lower entire wheel,
hub and axle assembly from front fork.
Remove the four wheel retaining nuts.
• reinstall tire and wheel by reversing above
sequence and tighten wheel retaining and
axle nuts to 70 to 100 ft. - Lbs.(95 to 140
Nm) torque.
• position the large flat washer located on
ends of the axle, on the inside of the fork
side arm assembly.
• when reinstalling the front wheel
assembly to the fork side arm,
always place the axle locks over the
side arm (as shown) and tighten the
axle nuts. Failure to follow the
procedure may allow the axle to
drop out of the fork side arm and
result in loss of vehicle control.
• the fork side arm reaction pin must
be inserted in the brake dust shield
slot to prevent the shield from
turning when the brakes are
applied.

GB-15
E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
REAR TIRE REMOVAL IMPORTANT
Drain differential after first 100 hours of service and
refill with EP 80-90 multigrade extreme pressure
lubricant. Thereafter lubricant should be changed
per maintenance guide.
Repairing this rear axle is a major service operation
and should be performed by your authorized
cushman dealer who has the necessary equipment
and information.
3546
1
2
1. Filler plug
2. Drain plug
JACKS AND JACKING LOCATIONS
A scissors type jack with a 1 1/2 ton (minimum)
capacity is required. Use jackstands to support
vehicle, do not rely on scissor, hydraulic or
mechanical jacks.
The jacking locations are shown on the chassis
lubrication chart illustration (page 9). Raise the
vehicle only enough to perform maintenance
required.
STORAGE
If the vehicle is to be stored, remove the connecting
wires and batteries. Clean as required. Clean
battery racks.
Battery electrolyte is an acidic solution and should
be handled with care. If electrolyte is spilled or
splashed on any part of the body, immediately flush
the exposed area with liberal amounts of water and
obtain medical aid immediately.
Reinstall the batteries and wires. Make sure the
batteries are fully charged.
Check the state of charge of the batteries every 30
days and recharge as necessary to maintain the
specific gravity above 1.230 (corrected for
electrolytetemperature*).
• when it is necessary to raise the
vehicle for any repair or service,
use jackstands to provide adequate
support. Do not rely on hydraulic or
mechanical jacks.
Remove and reinstall as follows:
• remove the wheel retaining nuts and remove
wheel assembly from hub.
• reinstall the tire and wheel by reversing
above sequence and tighten wheel retaining
nuts to 70 to 75 ft.-lbs. (95 to 102 n·m)
torque.
• make sure the valve stem is located toward
the outside.
Tire air pressure
Tire Size
4.00 ±4.80 x 8
Maximum
Cold Inflation Pressure
60 PSI (414 kPa)
Fill tires with care. Use a pressure gauge before
connecting an air hose to a partly inflated tire. Due
to the low air volume needed, over-inflation may be
reached in a matter of two or three seconds.
NOTICE
• proper inflation will improve the life of your
tiresconsiderably.
• never exceed maximum air pressure
indicated on tire.
• if the vehicle is operated on any surface
other than smooth and level, the use of foam
filled or solid tires could cause premature
failure of tires, axles and suspension
components.
• the tires are to be used on the welded one
piece wheel only.
• use replacement tires equivalent to or
exceeding original equipment specifications.
DIFFERENTIAL
The filler plug and the drain plug are illustrated.
Check oil level frequently. It should always be up to
the level of the filler hole.

GB-16
E-Z-GO XI 340 / CUSHMAN TUG
SAFETY, OPERATORS & MAINTENANCE MANUAL
Hydrometer readings should be increased .004 for
every 10 degrees f. (5.55c) above 80 degrees f.
(275c) and decreased .004 for every 10 degrees f.
(5.55c) below 80 degrees f. (275c).
NOTICE
• batteries should not be allowed to freeze. A
cool dry storage area will help prevent self
discharge.““
ACCESSORIES ARE AVAILABLE FOR USE ON
THIS VEHICLE
Accessories include literature concerning
installation, operation, and safety information about
the accessory. Such literature should be kept with
this manual for future reference.
Read and understand all literature before
attempting to operate this vehicle or any attached
equipment.