Cushman 622010, Owner'S Manual

Page 1: ...622010 Owner s Guide ISSUED JULY 2011...

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: ...ehi cle E Z GO Division of Textron Inc reserves the right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously...

Page 4: ...void the warranty Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and repla...

Page 5: ...his 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...

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 5 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: ...ated under the pas senger seat in the Tow position 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...

Page 10: ...ERAL LAW the modified product will be a Low Speed Vehicle LSV subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the...

Page 11: ...eral Motor Vehicle Safety Standards of the United States of America USA and are not equipped for operation on public streets Some communities may permit these vehicles to be operated on their streets...

Page 12: ...le 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 Maintain the vehicle in an area away fro...

Page 13: ...ry Under Seat WARNING Windshieldsdo not provide protection from golf ballsor other flying objects EGWHL14 WARNING Keep entire body inside car 27653G01 DONO AMPERWI HORCHANGE HISAD US MEN OF HE GOVERNO...

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: ...this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TITLE PAGE NO Hauler 800 Vehicle Specifications 2 3 Hauler 1200 Vehicle Specifications 2 4 Hauler 800 1200 Vehicle...

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: ...tice Field installed accessories may require installation charges 103 5 in 265 cm 46 5 in 118 0 cm Overall Length Overall Width 65 5 in 166 0 cm 38 0 in 97 0 cm 44 5 in 113 0 cm 4 3 in 11 0 cm Cargo B...

Page 22: ...Specifications are subject to change without notice Field installed accessories may require installation charges 111 0 in 280 0 cm 49 8 in 126 0 cm Overall Length Overall Width 77 0 in 196 0 cm 38 0...

Page 23: ...Warnings and Dangers 2 7 5 in 19 0 cm 65 5 in 166 0 cm 103 5 in 262 0 cm 48 6 in 123 0 cm Rear 38 0 in 97 0 cm Front 37 0in 94 0 cm HAULER 800 44 5 in 113 0 cm 30 5 in 77 0 cm 10 5 in 27 0 cm 18 0 in...

Page 24: ...oughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 6 2 TURNING CLEARANCE DIA HAULER 800 19 0 ft 5 8 m HAULER 1200 22 0 ft 6 7 m RECOMMENDED MAX R...

Page 25: ...2 7 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS 2...

Page 26: ...2 8 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 27: ...al Information 3 3 Key Switch Headlight Switch 3 3 Low Oil Pressure Indicator Light 3 4 Fuel Gauge 3 4 Direction Selector 3 4 Accelerator Pedal 3 4 Brake And Park Brake 3 4 Horn 3 4 Front Seats 3 5 Hi...

Page 28: ...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 29: ...ries some accessories remain operational with the key switch in the OFF position 1 Key Switch Headlight Switch Located on the dash panel this switch enables the basic electrical system of the vehicle...

Page 30: ...vehicle to move which could result in severe injury or death With the key switch ON depressing the accelerator pedal starts the engine When the pedal is released the engine will stop To stop the vehic...

Page 31: ...each side of the center console 9 Hip Restraint Front The front hip restraints are designed to help keep the occupants properly positioned in the event of sudden vehicle position changes 10 Front Ligh...

Page 32: ...amage the vehicle and or cause the vehicle to tip over Use extra care when operating load ed vehicle Do not permit any one to ride in the load bed Do not drive the vehicle with the load bed raised or...

Page 33: ...3 7 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers INTRODUCTION 3...

Page 34: ...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 35: ...TLE PAGE NO SERIAL NUMBER LOCATION 4 3 BEFORE INITIAL USE 4 4 OPERATING THE VEHICLE 4 4 Run In 4 5 Cold Starting 4 6 STARTING AND DRIVING 4 6 Starting The Vehicle On A Hill 4 6 Coasting 4 7 Fuel 4 7 B...

Page 36: ...4 2 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 37: ...t The other is located on the chassis between the seat back supports To access it raise the seat and lift up the flap on the access panel Design changes take place on an ongoing basis In order to obta...

Page 38: ...inflation See GENERAL SPECIFICATIONS Check for oil or fuel leaks that could have developed in shipment from the factory Determine and record braking distance required to stop vehicle for future brake...

Page 39: ...mpting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in motion coast Check the area behind the vehicle b...

Page 40: ...rake and deter mine the cause of the problem If the vehicle had been running and the engine does not start within 10 seconds use the choke STARTING AND DRIVING To reduce the possibility of roll back w...

Page 41: ...ATIONS Limit speed by applying service brake FUEL To reduce the possibility of severe injury or death from improper fuel handling Do not smoke near the fuel tank Do not refuel near open flame or elect...

Page 42: ...odel but is a starting battery Multiple deep cycling will result in the premature failure of the battery If the vehicle battery has become discharged it must be charged using a 12 volt charger that is...

Page 43: ...s must be reduced to compensate for the trailer and load The range of motion of the trailer is limited by the ball and hitch The trailer should not be used on rough trails or over objects such as logs...

Page 44: ...open tailgate until it is straight down move tailgate panel straight up to remove from pins and remove from the loadbed Reassemble in reverse order ELECTRIC LIFT BED OPERATION Exercise caution while...

Page 45: ...4 11 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers OPERATING PROCEDURES 4...

Page 46: ...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 47: ...E REPLACEMENT 5 9 TRANSPORTING VEHICLE 5 10 Towing 5 10 Neutral Lock 5 10 Hauling 5 10 SERVICE AND MAINTENANCE 5 11 ROUTINE MAINTENANCE 5 12 Tire Inspection 5 11 Rear Axle 5 11 FOUR CYCLE ENGINE 5 12...

Page 48: ...oughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 5 2 5 LUBRICATION 5 22 SPARK PLUGS 5 22 PROLONGED STORAGE 5 23 PERIODIC SERVICE SCHEDULE 5 24 CA...

Page 49: ...5 3 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 50: ...cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc wi...

Page 51: ...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 52: ...and jack stands at the areas indicated only Lifting The Vehicle 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 i...

Page 53: ...wrench 3 4 1 Impact socket 3 4 1 2 drive 1 Impact wrench 1 2 drive 1 Torque wrench 1 2 drive 1 Use caution when inflating tires Due to the low volume of the small tires overinflation can occur in seco...

Page 54: ...hored to floor Wear OSHA approved safety equipment when mounting demounting tires If the tire is to be removed or mounted the tire changing machine manufacturer s recommendations must be fol lowed in...

Page 55: ...dware securing lens and remove lens Install replacement bulb FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new automo tive typ...

Page 56: ...e so that the pointed portion of the handle is to the side of the direction selector cam Move direction selector towards the area between F and R Dur ing that motion the pin will snap into the hole in...

Page 57: ...re when work ing around batteries or using solvents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads fro...

Page 58: ...t five years is the periodic inspection of the rear axle for lubricant leakage Unless leakage is evident the lubricant need only be replaced after five years Refer to the Service and Repair Man ual fo...

Page 59: ...t gets hot Do not overfill Check that the oil cap is firmly in place When adding oil between oil changes do not mix brands and viscosity grades of oil The oil dipstick fill cap must be in place before...

Page 60: ...isture that has accumulated during storage Be aware that engine fluids may be hot and contact to the skin may cause severe burns Wear rubber gloves to protect skin from exposure to the old oil and deg...

Page 61: ...n lbs 7 0 Nm torque Apply engine oil to the oil filter seal and install oil filter onto the engine until the seal contacts mounting surface of the engine Then turn the filter 2 3 to 3 4 rotations by H...

Page 62: ...ket 3 4 3 8 drive 1 The starter generator belt tension should be checked after the first 15 20 hours and set to 75 80 lbs 34 36 kg A loose belt can cause audible vibration and squeal Tighten a new sta...

Page 63: ...water Use of a water hose without first neutralizing any acid will move acid from the top of the battery to another area of the vehicle or storage facility where it will attack the metal structure or...

Page 64: ...ith low pressure clear water Do not use a pressure washer BRAKES To reduce the possibility of severe injury or death always evaluate pedal travel before operating a vehicle to verify some braking func...

Page 65: ...e test area and remove foot from pedal The vehicle should stop aggres sively The wheel brakes may or may not lock Observe the vehicle stopping location or measure the vehicle stop ping distance from t...

Page 66: ...evel check plug located on the driver side at the rear of the housing Unless leakage of rear axle lubricant is evident an annual lubricant check is sufficient Checking The Lubricant Level Tool List Qt...

Page 67: ...to clean the air filter doing so will damage the filter which may result in damage to the engine The air cleaner element is accessible by unsnapping the clips on the air canister and removing the cove...

Page 68: ...Tool List Qty Spark plug socket 13 16 1 2 drive 1 Ratchet 1 2 drive 1 Plug gauge wire type 1 Anti seize compound AR Torque wrench 1 2 drive ft lbs 1 Use care not to over tighten the plug Over tighteni...

Page 69: ...possible eye injury from gasoline or gasoline vapor Keep hands clothing and jewelry away from moving parts Use care not to contact hot objects Raise the rear of the vehicle and support on jack stands...

Page 70: ...n previous table the following WIRING Check all wiring for loose connections and broken missing insulation ACCELERATOR Check for smooth movement DO NOT LUBRICATE CABLE SERVICE BRAKE MECHANICAL BRAKES...

Page 71: ...rdware AIR FILTER ELEMENT Check filter element clean replace as required OIL FILTER Replace at oil change ENGINE OIL Replace with SAE 10W 30 or 10W 40 that meets or exceeds SF SG CC oil DO NOT OVERFIL...

Page 72: ...5 liters 87 Octane Min 1 4 US qt 1 3 liters 51 oz 1 5 liters SAE 30 15 amp P N 18392 G1 P N 619101 P N 619100 P N 619102 P N 26591 G01 P N 28463 G01 NGK BPR2ES P N 25523 G3 020 030 71 75 mm Gap P N 6...

Page 73: ...5 27 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 74: ...5 28 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 75: ......

Page 76: ...of Textron Inc Technical Communications Department 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 ar...