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Cushman 623525-H Owner's Manual

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Owner's Guide
623525-H
ISSUED JULY 2011
REVISED FEBRUARY 2016

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Summary of Contents for Cushman 623525-H

  • Page 1 Owner’s Guide 623525-H ISSUED JULY 2011 REVISED FEBRUARY 2016...
  • Page 2 WELCOME Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s 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. This manual may cover the operation of several different models or show items that are optional;...
  • Page 3 FOREWORD Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. OWNER’S GUIDE ELECTRIC POWERED VEHICLE HAULER 1200X E STARTING MODEL YEAR 2012 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 specifications.
  • Page 4 FOREWORD Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. This vehicle has been designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless oth- erwise indicated.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SECTION PAGE NO. SAFETY....................................1-1 GENERAL SPECIFICATIONS............................. 2-1 INTRODUCTION.................................. 3-1 OPERATING PROCEDURES.............................. 4-1 MAINTENANCE................................... 5-1 DELCARATION OF CONFORMITY ........................
  • Page 6 TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : Page iv...

  • Page 7: Safety

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SAFETY................................. 1-3 NOTICES, CAUTIONS, WARNINGS, AND DANGERS..................1-3 GENERAL ................................1-4 GENERAL OPERATION ............................1-5 MAINTENANCE ..............................

  • Page 8: Safety

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 1 - 2...
  • Page 9 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SAFETY 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.

  • Page 10: General

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer.

  • Page 11: General Operation

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Refer to GENERAL SPECIFICATIONS for vehicle seating capacity. 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.

  • Page 12: Ventilation

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. • Support the vehicle using wheel chocks and jack stands, NEVER get under a vehicle that is supported by a jack, lift the vehicle in accordance with the manufacturer’s instructions •...

  • Page 13: Labels And Pictograms

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LABELS AND PICTOGRAMS 614121 MIN 150 614121 35962-G01 601781 74322G01 74322G01 74443G01 74443G01 71489G01 AUTHORIZED REPRESENTATIVE IN EC IS: RANSOMES JACOBSEN LTD.
  • Page 14 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL < 14 û 25% READ MANUAL SECURE LOAD AS FAR FORWARD XXX lbs.
  • Page 15 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. CLEAN UP GASOLINE SPILLS WITH DO NOT WATER BEFORE DISPOSE OF STARTING ENGINE BATTERIES IN LANDFILL UNLEADED GASOLINE DO NOT DO NOT...
  • Page 16 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. HEADLIGHTS KEEP ARMS AND LEGS WITHIN VEHICLE UNLOCKED TO OPERATE VEHICLE IN FORWARD: LOCKED Q TURN KEY TO ON Q MOVE DIRECTION SELECTOR TO FORWARD Q PRESS ACCELERATOR PEDAL...
  • Page 17 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 1 - 11...
  • Page 18 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 1 - 12...

  • Page 19: General Specifications

    GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. HAULER 1200X E Vehicle Specifications ........................2 - 3 HAULER 1200X E Vehicle Dimensions ........................... 2 - 4 HAULER 1200X E Vehicle Incline Information and Turning Diameter................
  • Page 20 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 2 - 2...
  • Page 21 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. MODEL: HAULER 1200X TYPE: ELECTRIC 48V POWERED TRUCK MODEL YEAR: 2012 Part No: 619211 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Precision Drive System™...
  • Page 22 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 111.5 in (283.0 cm) 49.5 in 10.5 in (126.0 cm) (27.0 cm) 78.5 in (199.0 cm) 77.0 in (196.0 cm) Front 38.0 in (97.0 cm)
  • Page 23 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER HAULER 1200X E 22.0 ft (6.7 m) 2 - 5...
  • Page 24 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 2 - 6...

  • Page 25: Introduction

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. FEATURES..................................3-3 General Information ....................................3-3 Key Switch / Headlight Switch..................................3-3 State of Charge Meter....................................3-3 Direction Selector......................................
  • Page 26 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 3 - 2...

  • Page 27: Features

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. FEATURES General Information If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’...

  • Page 28: Brake And Park Brake

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. the accelerator inadvertently will release the park brake and will cause the vehicle to move which could cause severe injury or death.

  • Page 29: Horn

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 6. Horn The horn button is located on the driver’s side floorboard; pressing the button will sound the vehicle’s horn. 7.

  • Page 30: Ash Tray

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. RUN/TOW SWITCH The Run/Tow switch should always be returned to the ’TOW’ position after moving a stalled vehicle. If the switch is left in the ’RUN’...

  • Page 31: Utility Bed

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 17. Utility Bed To reduce the possibility of severe injury or death, read, understand and follow the Danger label affixed to the front of the load bed.
  • Page 32 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 3 - 8...

  • Page 33: Operating Procedures

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SERIAL NUMBER LOCATION ............................4-2 BEFORE INITIAL USE ................................ 4-3 PORATABLE CHARGER INSTALLATION ......................... 4-3 Plastic Loadbed......................................

  • Page 34: Serial Number Location

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SERIAL NUMBER LOCATION The serial number and manufacture date code plates are on the vehicle. One (PART C) is placed on the body below the front, driver side of the seat, PART D is placed on the frame weld tube.

  • Page 35: Before Initial Use

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. BEFORE INITIAL USE Read, understand and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle, its equipment as well as how to use it safely.

  • Page 36: Plastic Loadbed

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Provide Protection From Elements Do Not Block Louvered Airways NEMA 15 - 5R Grounded AC Receptacle 110 - 120 VAC.

  • Page 37: Manual Lift Bed Operation

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Failure to follow these instructions may result in personal injury, damage the vehicle and/or cause the vehicle to tip over.

  • Page 38: Operating The Vehicle

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Front of Vehicle Manual Load Bed Latch Pull Up to Release Manual Bed Latch 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.

  • Page 39: Precision Drive System Tm

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Never drive vehicle up, down, or across an incline that exceeds 14° (25% grade). To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings must be observed: Refer to GENERAL SPECIFICATIONS for seating capacity.

  • Page 40: Terrain

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. the pedal-up braking will slow the vehicle (the warning beeper will not sound) until either the vehicle speed is reduced to 8 mph (13 kph), at which it freely coasts between 8 and 3 mph (5 kph), or the accelerator pedal is applied.

  • Page 41: Starting And Driving

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. The controller can be put in diagnostic mode by the technician and the controller will report the failure mode. STARTING AND DRIVING To reduce the possibility of roll - back which could result in severe injury or vehicle damage, do not release the service brake until motor has started.

  • Page 42: Labels And Pictograms

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 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 sur- face.
  • Page 43 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 4 - 11...
  • Page 44 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 4 - 12...

  • Page 45: Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. VEHICLE CLEANING AND CARE ............................5-3 Vehicle Cleaning ......................................5-3 REPAIR ....................................5-3 Lifting the Vehicle......................................5-3 WHEELS AND TIRES................................
  • Page 46 MAINTENANCE AC Voltage ........................................ 5-18 Troubleshooting......................................5-18 HYDROMETER ..................................5-19 Using Hydrometer...................................... 5-20 PROLONGED STORAGE ..............................5-22 5 - 2...

  • Page 47: Vehicle Cleaning And Care

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. VEHICLE CLEANING AND CARE Vehicle Cleaning To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.

  • Page 48: Wheels And Tires

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. When lifting the vehicle, position the jacks and jack stands at the areas indicated only. Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while lifting.

  • Page 49: Wheel Installation

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. only sockets designed for impact wrench use. Use caution when inflating tires. Overinflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause severe injury.

  • Page 50: Light Bulb Replacement

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Tire/wheel style may vary 'Cross Sequence' 'Cross Sequence' Wheel Installation LIGHT BULB REPLACEMENT Inside of Cowl Headlight Casing To reduce the possibility of premature bulb failure, do Screw...

  • Page 51: Transporting Vehicle

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TRANSPORTING VEHICLE Towing This vehicle is not designed to be towed. It is recommended that the vehicle be moved by placing the entire vehicle on a trailer, flatbed truck or other suitable transport.

  • Page 52: Routine Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicar- bonate (baking soda) dissolved in 1 quart (1 liters) of water and flushed with water. Aerosol containers of battery terminal protectant must be used with extreme care.

  • Page 53: Periodic Brake Test For Mechanical Brakes

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PERIODIC BRAKE TEST FOR MECHANICAL BRAKES The purpose of this test is to compare the braking performance of the vehicle to the braking performance of new or ‘known to be good’...

  • Page 54: Lubrication

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LUBRICATION Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components.

  • Page 55: Capacities And Replacemant Parts

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table. Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific torque val- ues.

  • Page 56: Periodic Service Schedule

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PERIODIC SERVICE SCHEDULE    Check Clean, Adjust, etc. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representa- tive or see the Repair and Service Manual for this vehicle.

  • Page 57: Battery Charging And Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)  DIRECTION SELECTOR Check for wear and smooth movement (lubricate shaft with light oil if required) ...

  • Page 58: Battery

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. metal container to prevent can from contacting battery terminals which could result in an explosion. Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ’shorting out’...
  • Page 59 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. DO NOT overfill batteries. The charging cycle will expel electrolyte and result in component damage. A battery being charged will ’gas’ with the majority of the gassing taking place at the end of the charging cycle. This gas is hydrogen with is lighter than air.

  • Page 60: Battery Cleaning

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. The watering device should only be used if the electrolyte level is less than 1/2” (13 mm) above top of plates. WATERING GUN SIMILAR TO THE TYPE INCLUDED IN THE E-Z-GO BATTERY MAINTENANCE KIT VALVE...

  • Page 61: Battery Replacement

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. cial attention should be paid to metal components adjacent to the batteries which should also be sprayed with the solution.

  • Page 62: Battery Charging

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Use care to connect the battery wires as shown. Tighten the battery post hardware to 90 - 100 in. lbs. (6 -8 Nm) torque Front of Vehicle not over-torque the terminal stud nut, this will cause a “mushroom”...

  • Page 63: Hydrometer

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. HYDROMETER BULB FLOAT CYLINDER A hydrometer is used to test the state of charge of a battery THERMOMETER cell.

  • Page 64: Using Hydrometer

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular 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.

  • Page 65: Prolonged Storage

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PROLONGED STORAGE Battery charger, controller and other electronic devices need to be disconnected since they will contribute to the pre- mature discharge of batteries.
  • Page 66 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 5 - 22...
  • Page 67 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TABLE OF CONTENTS FOR APPENDIX A TITLE PAGE NO. DECLARATION OF CONFORMITY ................................. A - 3 A - 1...
  • Page 68 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : A - 2...
  • Page 69 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. DECLARATION OF CONFORMITY A - 3...
  • Page 70 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. DECLARATION OF CONFORMITY (CONTINUED) A - 4...
  • Page 72 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...

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