Cushman 2012 HAULER 1000, Owner'S Manual

Page 1: ...622023 Owner s Guide ISSUED JULY 2011 REVISED JANUARY 2012...

Page 2: ...es in controls will be illustrated Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in a...

Page 3: ...ht to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised...

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

Page 5: ...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...

Page 6: ...Page iv 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 Notes...

Page 7: ...amiliar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 1 TITLE PAGE NO SAFETY 1 3 NOTICES CAUTIONS WARNINGS AND DANGERS 1 3 GENERAL 1 4 GENERAL OPERATION 1 5 M...

Page 8: ...1 2 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1...

Page 9: ...that could result in an unsafe condition Observe these NOTICES CAUTIONS WARNINGS and DANGERS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazar...

Page 10: ...important to the SAFE USE AND OPERATION of the product All customers should adhere to this SAFETY RESTRICTION in connection with the use of all E Z GO products new and used the Distributor or Dealer h...

Page 11: ...sible manner and maintain the vehicle in safe operating condition read and observe all warnings and operation instruction labels affixed to the vehicle follow all safety rules established in the area...

Page 12: ...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...

Page 13: ...ction from golf ballsor other flying objects EGWHL14 WARNING Keep entire body inside car 27653G01 71419G01 71417G01 71415G01 601781 614121 28203 G01 OFF ON 74322G01 cm MIN 150 R F ON OFF I O ON OFF I...

Page 14: ...D LOAD WITH HIGH CENTER OF GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAVITY MAXIMUM HEIGHT x in xx cm MAX LOAD XXX LBS XXX KG WARNING MAXIMUM LOAD CENTER OF GRAVITY KEEP LOAD AS FAR FORWARD AS...

Page 15: ...NALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE LOW OIL PRESSURE 17 18 19 20 21 22 23 24 25 26 27 DO NOT DISPOSE OF BATTERIES IN LANDFILL DO...

Page 16: ...N SELECTOR TO REVERSE Q AN AUDIBLE DEVICE WILL SOUND Q DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK Q APPLY PARKING BRAKE Q TURN KEY TO OFF Q MOVE DIRE...

Page 17: ...1 11 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers SAFETY 1...

Page 18: ...1 12 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1...

Page 19: ...horoughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TITLE PAGE NO HAULER 1000 Vehicle Specifications 2 3 HAULER 1000 Vehicle Dimensions 2 4 HAU...

Page 20: ...2 2 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2...

Page 21: ...nted Forward Neutral Reverse Differential with helical gears 14 7 1 Some items shown may be optional equipment Specifications are subject to change without notice Field installed accessories may requi...

Page 22: ...ghly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 4 2 HAULER 1000 36 0 in 91 0 cm 49 8 in 126 0 cm 10 5 in 27 0 cm 77 0 in 196 0 cm 111 0 in 281 0...

Page 23: ...ual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TURNING CLEARANCE DIA Approx 22 0 ft 6 7 m RECOMMENDED MAX RAMP GRADE 25 or...

Page 24: ...2 6 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2...

Page 25: ...y Switch Headlight Switch 3 3 State of Charge Meter 3 3 Direction Selector 3 3 Accelerator Pedal 3 3 Brake and Park Brake 3 4 Horn 3 5 Front Seats 3 5 Hip Restraint 3 5 Hour Meter 3 5 Weather Enclosur...

Page 26: ...3 2 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3...

Page 27: ...he OFF position and removed 2 State of Charge Meter The vehicle is equipped with a state of charge meter located in the dash panel The state of charge meter indicates the amount of usable power in the...

Page 28: ...d method of releasing the park brake 5 Brake and Park Brake If the vehicle is equipped with factory installed custom accessories some accessories remain operational with the key switch in the OFF posi...

Page 29: ...Cup Holder A cup holder is provided for convenience of both the driver and passenger 13 Steering Wheel The steering wheel located in front of the driver seat is used to steer the vehicle 14 Charger w...

Page 30: ...the Run Tow Maintenance switch to the Tow Maintenance position After connecting a battery or any other wiring wait a minimum of 30 seconds before moving the Run Tow Mainte nance switch to the Run posi...

Page 31: ...re to follow these instructions may result in severe injury damage the vehicle and or cause the vehicle to tip over Use extra care when operating loaded vehicle Do not permit any one to ride in the be...

Page 32: ...3 8 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3...

Page 33: ...5 Understanding the Charger 4 5 LED Operation Codes 4 6 LED Fault Codes 4 6 Maintenance Instructions 4 7 OPERATING THE VEHICLE 4 7 HAULER 1000 48 V PRECISION DRIVE SYSTEM 4 8 General 4 8 Performance...

Page 34: ...rame weld tube The other PART A and PART B is located on the crossmember section of the chassis on the driver side seat back support To access it raise the seat and lift up the flap on the access pane...

Page 35: ...e of battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc Hydr...

Page 36: ...recautions such as recommended rates of charge and removing or not removing cell caps while charging Portable chargers must be mounted on a platform above the ground or in such a manner as to per mit...

Page 37: ...and the DC plug can be removed to permit use of the vehicle Understanding the Charger Plugging the charger into the vehicle s charger receptacle will lock the vehicle out of operation When the charger...

Page 38: ...mperature Fault battery temperature is greater than 122 F 50 C or less than 14 F 10 C TWO RED FLASHES Two flashes a pause and then again two flashes and a pause Battery Voltage Fault Battery pack is l...

Page 39: ...of severe injury or death resulting from loss of vehicle control the fol lowing warnings must be observed When driving vehicle consider the terrain traffic conditions and the environmental factors whi...

Page 40: ...is milder The Yellow Plug performance option The vehicle s top speed is sensed and regulated directly by the controller and the pedal up braking is at the strongest level The Red Plug performance opt...

Page 41: ...ic braking will limit speed to approximately 2 mph 3 kph and the warning beeper will sound When the accelerator pedal is depressed the electronic braking and warning beeper will be overridden and norm...

Page 42: ...switch and turn it to the ON N position Move the direction selector to the direction desired Release the park brake by depressing the service brake pedal until the park brake releases Slowly depress...

Page 43: ...eed by releasing the accelerator and applying service brake Severe damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed Damage caused b...

Page 44: ...4 12 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4...

Page 45: ...7 LIGHT BULB REPLACEMENT 5 8 FUSE REPLACEMENT 5 8 TRANSPORTING VEHICLE 5 9 Towing 5 9 Hauling 5 9 SERVICE AND MAINTENANCE 5 9 ROUTINE MAINTENANCE 5 10 Tire Inspection 5 10 Brakes 5 10 PERIODIC BRAKE T...

Page 46: ...5 2 MAINTENANCE 5 AC Voltage 5 19 Troubleshooting 5 19 HYDROMETER 5 20 Using Hydrometer 5 21 PROLONGED STORAGE 5 22...

Page 47: ...mercial plastic polish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied...

Page 48: ...d terrain When driving at full speed on a dirt road loose surfaces or wet grass vehicle stopping distance will increase If the vehicle is fully loaded it will take longer to stop than with no load Whe...

Page 49: ...cle Tool List Qty Tool List Qty Floor jack 1 Jack stands 4 Wheel Chocks 4 Remove payload from vehicle before lifting No person s should be in or on the vehicle while lifting To raise the entire vehicl...

Page 50: ...ld be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for rec ommended tire inflation pressure For outdoor applications with major use on grassy areas the following shoul...

Page 51: ...ve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten the lug nuts 1 in a cross sequence pattern Tighten the lug nuts to 50 to 85 ft lbs 68 to 115 Nm torque in 20 ft lbs 27...

Page 52: ...ilarly replace the turn signal light bulb locate bulb socket on backside of light bar and turn bulb socket a quarter turn counterclockwise to unlock and pull out bulb and socket Insert new bulb and ro...

Page 53: ...he seat bottom secured When transporting vehicle below highway speeds check for tightness of hardware and cracks in sun top at mounting points Always remove windshield when transporting Always check t...

Page 54: ...e owner and service technician to carefully follow the procedures recommended in this manual Preventative maintenance applied at recommended intervals is the best guarantee for keeping the vehicle bot...

Page 55: ...ay or may not lock Observe the vehicle stopping loca tion or measure the vehicle stopping distance from the point at which the brakes were latched The vehicle should stop within the normal range of st...

Page 56: ...ied by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head Metric hardware is marked on the head with 8 8 or 10 9 Unmarked hardware is Grade 2 Lubrication P...

Page 57: ...for loose connections and broken missing insulation CHARGER RECEPTACLE Clean connections keep receptacles free of dirt and foreign matter ACCELERATOR Check for smooth movement SERVICE BRAKE MECHANICAL...

Page 58: ...r approved safety goggles when adding water or charging batteries Any electrolyte spills should be neutralized with a solution of 1 4 cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallon...

Page 59: ...can reduce the life of the battery BATTERY MAINTENANCE Tool List Qty Tool List Qty Insulated Wrench 9 16 1 Battery Carrier 1 Hydrometer 1 Battery Maintenance Kit P N 25587 G01 1 At Each Charging Cycl...

Page 60: ...y Over the life of the battery a considerable amount of water is consumed It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the...

Page 61: ...battery caps are tightly installed To reduce the possibility of damage to vehicle or floor neutralize acid before rinsing battery To reduce the possibility of damage to electrical components while cl...

Page 62: ...placed in the Tow Maintenance position If a power wire battery motor or controller is disconnected for any reason the Run Tow Maintenance switch must be left in the Tow Maintenance position for at lea...

Page 63: ...n area to prevent injury that may result from personnel running over or tripping over the cord set The charger is automatically turned off during the connect disconnect cycle and therefore no electric...

Page 64: ...ase number of 1 000 The concentration of sulfuric acid to water in a new golf car battery is 1 280 which means that the electrolyte weighs 1 280 times the weight of the same volume of water A fully ch...

Page 65: ...low 80 F 27 C Adjust the reading to conform with the electrolyte temperature e g if the reading indicates a specific gravity of 1 250 and the electrolyte temperature is 90 F 32 C add four points 004 t...

Page 66: ...ble and will cause permanent damage to the battery In order to prevent damage the battery should be recharged A hydrometer P N 50900 G1 can be used to determine the specific gravity and therefore the...

Page 67: ...5 23 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers MAINTENANCE 5...

Page 68: ...5 24 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5...

Page 69: ...ad 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 O...

Page 70: ...A 2 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

Page 71: ...A 3 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...

Page 72: ...APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers A 4 DECLARATION OF CONFORMITY CONTINUED...

Page 73: ...A 5 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers APPENDIX A...

Page 74: ...A 6 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

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