Cushman 625615 Manuals

Manuals and User Guides for Cushman 625615. We have 1 Cushman 625615 manual available for free PDF download: Technician's Repair And Service Manual

Cushman 625615 Technician's Repair And Service Manual

Cushman 625615 Technician's Repair And Service Manual (189 pages)

ELECTRIC POWERED UTILITY VEHICLES

Brand: Cushman | Category: Utility Vehicle | Size: 15.95 MB

Table of Contents

Safety
2
- Notice
  2
- Battery Prolonged Storage
  4
- Battery Disposal
  4
General Information
4
- Table of Contents
  5
- General
  7
Safety Information
7
- General Operation
  8
- Maintenance
  8
Safety
8
- Ventilation
  9
- General Information & Routine Maintanence
  11
- Hauling
  13
- Serial Number Location
  13
- Servicing the Electric Vehicle
  13
- Towing
  13
- Transporting Vehicle
  13
- Brakes
  14
- Light Bulb Replacement
  14
- Rear Axle
  14
- Routine Maintenance
  14
- Tires
  14
- Vehicle Cleaning and Care
  14
- Sun Top and Windshield
  15
- Vehicle Care Products
  15
- Hardware
  16
- Torque Specifications
  16
- Periodic Service Schedule
  17
- Before Servicing the Vehicle
  21
- General Maintenance
  21
- Important Safety Warning
  21
- Modifications to Vehicle
  21
- Notices, Cautions Warnings and Dangers
  21
- Additional Warnings
  22
- Battery Removal & Installation
  23
- Fig. 1 Battery Connections
  23
- Lifting the Vehicle
  24
View from Underside of Vehicle
24
Body
27
- Section Title
  27
- Body Component Replacement
  29
- Drill out Metal Rivet
  29
- Front Body Components
  30
- Floor Mount Gun Holder
  31
- Ashtray
  31
- Floor Mount Gun Holder and Ashtray
  31
- Larger Scratches
  33
- Complete Panel Repair
  33
- Minor Scratches
  33
- Painting
  33
Wheels and Tires
35
- Wheel and Tire Service
  37
- Tire Repair
  37
- Wheel Installation
  38
- Wheel and Tire Installation
  38
Front Suspension and Steering
41
- Fig. 2 Lubrication Points
  41
- Axle Mounted Steering and Front Suspension
  43
- Lubrication
  44
- Maintenance
  44
- Wheel Bearing and King Pin Bushing Inspection
  44
- Wheel Bearing Packing
  44
- Wheel Alignment
  45
- Wheel Bearing Adjustment
  45
- Front Shock Absorber Replacement
  47
- Front Suspension
  47
- Front Suspension Components
  47
- Axle Linkage Rod Replacement
  48
- Front Axle Replacement
  48
- Front Spring Replacement
  49
  - To Detach Driver Side Spring
    49
  - To Detach Passenger Side Spring
    49
- Hub Replacement
  50
  - Seal Installation
    50
  - Tool List
    50
- Wheel Bearing and Race Replacement
  50
- Wheel Bearing Replacement
  51
- Rack Ball Joint Replacement
  52
- Steering
  52
  - Steering Components
    52
  - Rack Ball Joint Installation
    53
- Tie Rod Inspection/Replacement
  53
  - Tie Rod Replacement
    53
  - Bellows Replacement
    54
  - Pinion Seal Replacement
    54
  - Removing Brake Caliper
    55
  - Spindle Replacement
    55
  - Rack and Pinion Unit Disassembly
    56
  - Rack and Pinion Unit Disassembly and Inspection
    56
  - Checking/Adjusting Rack Extension-To-Rack
    57
  - Rack and Pinion Unit Replacement
    57
  - Checking Gap
    58
  - Clipboard Removal
    58
  - Spindle Contact with Front Axle
    58
  - Steering Wheel Replacement
    58
  - Steering Shaft and Column
    59
  - Steering Shaft and Column Replacement
    59
  - Small Retaining Ring Orientation
    60
  - Electronic Speed Control - Tct
    63
- Changing Performance Options
  65
- General
  65
- Trucourse Technology System
  65
- Operation
  66
  - Run-Tow/Maintenance Switch
    66
  - Access to Pedal Box
    67
- Controller
  67
- Pedal Box
  67
- Speed Sensor
  67
- Battery Reference Voltage
  68
- Continuity Check
  68
- General Troubleshooting
  68
- Symptoms
  68
- Testing Battery Voltage
  68
- Testing a Solenoid for Continuity
  69
- Testing a Switch for Continuity
  69
- Continuity Check of Solenoid
  69
- Troubleshooting Diagrams
  70
- 1206HB-5201 Controller Faults and Troubleshooting
  70
- Controller Connectors and Connections
  72
- Controller Wiring Diagram
  73
- Inductive Throttle Sensor (Its)
  74
- ITS and Plunger
  74
- ITS Adjustment
  75
- Controller Replacement
  77
- Solenoid Replacement
  77
- Solenoid Wiring
  78
Motor
81
- Disconnect Battery Cable
  83
- Motor
  83
- Motor Disassembly
  83
- Motor Removal
  83
- Motor Components
  84
- Bearing Replacement
  85
- Brush Replacement
  85
- Brush Wear
  85
- Motor Assembly
  86
- Motor Installation
  86
- Motor Tests
  86
- Securing Brushes
  86
- Batteries and Charging
  89
- Battery Maintenance
  91
- Safety
  91
- At each Charging Cycle
  92
- Electrolyte Level and Water
  92
- Monthly
  92
- Automatic Watering Gun
  93
- Battery Replacement
  93
- Cleaning Batteries
  93
- Preparing Acid Neutralizing Solution
  93
- Battery Charging
  95
- Freezing Point of Electrolyte
  95
- Prolonged Storage
  95
- Specific Gravity Electrolyte Freezing Point
  95
- AC Voltage
  96
- Hydrometer
  96
- Troubleshooting
  96
- Using a Hydrometer
  97
- Hydrometer Temperature Correction
  97
Electrical System
99
- Digital Volt Ohm Meter
  101
- Accessory Wiring Diagram
  102
- Main Harness Wiring Diagram
  103
- Check Fuse
  104
- Main & Accessory Wiring
  104
- Check Battery Condition
  104
- Power Supply
  104
- Electrical Accessories
  105
- Mechanical Brakes
  109
- Brake System Overview
  111
- How the Service Brake Works
  111
- Mechanical Brake System
  111
- Equalizer Link
  112
- Automatic Adjuster Mechanism
  112
- How the Parking Brake Works
  112
- Wheel Brake Adjustment
  112
- Parking Brake and Kick-Off Mechanism
  113
- Kick-Off Actuating Linkage
  113
- Compensator Assembly
  113
- Troubleshooting Flowchart
  114
- New Vehicles
  118
- Troubleshooting and Inspection Procedures
  118
- Brake Pedal Bumper Inspection
  118
- Brake Pedal Inspection
  118
- Checking for Excessive Free Travel
  119
- Equalizer and Compensator
  119
- Parking Brake Pedal Hinge Inspection
  120
- Kick-Off Cam Inspection
  120
- Periodic Brake Performance Test (PBPT)
  120
- Aggressive Stop Test
  121
- Periodic Brake Performance Test
  121
- Wheel Brake Inspection
  122
- Equally Load Vehicle
  122
- Adjuster Mechanism
  123
- Brake Shoe Wear
  123
- Parts Replacement Vs. Repair
  124
- Maintenance and Repairs
  124
- Orientation of Brake Shoe Springs
  124
- Adjusting Brake Pedal Free Travel
  124
Brakes
124
- Checking Parking Brake Latching Pressure
  125
- Check Clevis Pins
  125
- Free Travel Adjustment
  125
- Brake Drum Removal and Installation
  125
- Wheel Brake Service
  126
- Brake Assembly
  126
- Backing Plate/Entire Wheel Brake Assembly
  127
- Backing Plate Removal and Installation
  127
- Wheel Brake Lubrication Points
  127
- Brake Shoe and Adjuster Replacement
  127
- Setting Adjuster Screw
  128
- Brake Shoes and Springs
  128
- Brake Cable and Equalizer Assembly
  128
- Brake Cable, Equalizer and Compensator
  129
- Brake Pedal Removal and Installation
  129
- Catch Bracket and Latch Arm
  130
- Parking Brake Kick-Off Cam Removal
  130
- Pedal Bumper Adjustment
  130
Battery Charger
133
- Charger Description
  135
- Portable Charger Installation
  135
- Charger Installation
  135
- Maintenance Instructions
  136
- Led Display Information
  136
- LED Fault Code
  136
- Understanding the Charger
  136
Rear Suspension
139
- Shock Absorber Installation
  141
- Rear Spring Removal
  141
- Rear Spring Installation
  141
- Shock Absorber Removal
  141
Rear Axle
145
- Rear Axle Maintenance
  147
- Checking the Lubricant Level
  147
- Axle Shaft Removal and Disassembly
  147
- Rear Axle Disassembly
  147
- Removing Seal
  148
- Removing/Installing Inner Snap Ring
  148
- Axle Shaft Seal Removal and Replacement
  148
- Removing/Installing Axle Shaft
  148
- Axle Shaft Replacement
  149
- Installing Seal
  149
- Cut Away of Outer Bearing and Brake Drum
  149
Weather Protection
151
- Top and Windshield
  153
- Front Strut
  153
- Sun Top
  153
- Trailering
  153
- Split Windshield
  155
- Full Windshield
  156
Handheld Diagnostics
159
- Primary Connection: 4 Pin Tyco
  161
- Alternate Connection: 4 Pin Molex
  161
- Navigation
  161
- Curtis Handheld Programmer
  161
- Changing Data Value
  162
- Bookmark
  162
- Main Menu Definitions
  162
Troubleshooting
167
- Lightning Protection and Grounding
  173
- Equipment Fault and Personal Safety System
  175
- Ground Network Requirements
  175
- Ground Systems
  175
- External Grounding Requirements
  176
- Lightning Protection System
  176
- Materials
  176
- 10. Equipment Fault and Personal Safety System
  177
General Specifications
179

Advertisement

Advertisement

Related Products

Cushman Categories

Utility Vehicle Offroad Vehicle Golf Cars Electric Vehicles Tractor

More Cushman Manuals