Cushman 622020-L, Owner'S Manual

Page 1: ...622020 L Owner s Guide ISSUED JULY 2011 REVISED FEBRUARY 2016...

Page 2: ...ay not be representative of all models Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle...

Page 3: ...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 p...

Page 4: ...onents must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED ST...

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: ...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: ...s UNDER FEDERAL 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 Fed...

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: ...ESULT IN SERIOUS PERSONAL GOVERNOR GOVERNOR TAMPERING CAN RESULT IN SERIOUS PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY INJURY AND WILL VOID THE VEHICLE WARRANTY 74821G01 HO R N OFF ON 71131 G0...

Page 14: ...F GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAVITY MAXIMUM HEIGHT 14 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD B...

Page 15: ...GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE DO NO...

Page 16: ...CTION SELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND PRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SE...

Page 17: ...LOCK DIFFERENTIAL PUSH BOTTOM OF SWITCH TO UNLOCK DIFFERENTIAL 58 REAR DIFFERENTIAL LOCK SWITCH 59 PUSH TOP PART OF SWITCH TO RAISE LOAD BED PUSH BOTTOM PART OF SWITCH TO LOWER LOAD BED 61 54 WARNING...

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: ...oroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TITLE PAGE NO HAULER 1200X Vehicle Specifications 2 3 HAULER 1200X Vehicle Dimensions 2 4 HA...

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: ...sons 900 0 lb 410 0 kg Seating Capacity Dry Weight 800 0 lb 360 0 kg Bed load capacity 500 0 lb 110 0 kg Curb Weight 940 0 lb 430 0 kg Towing Capacity 20 3 ft 6 2 m N A Outside Clearance Circle Inters...

Page 22: ...hicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 4 2 10 5 in 27 0 cm HAULER 1200X 111 5 in 283 0 cm 77 0 in 196 0 cm Front 38 0 in 97 0 cm Rear 38 5 in 98 0 cm 42 5 in 108...

Page 23: ...o become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TURNING CLEARANCE DIAMETER HAULER 1200X 23 5 ft 7 2 m RECOMMENDED MAX RAMP GRADE...

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: ...ion 3 3 Key Switch Headlight Switch 3 3 Fuel Gauge with Low Oil Pressure Indicator Light 3 4 Direction Selector 3 4 Accelerator Pedal 3 4 Brake and Park Brake 3 4 Horn 3 4 Front Seats 3 4 Hip Restrain...

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: ...turned on and off by turning the key To prevent inadvertent operation of the vehicle when left unattended the key should be turned to the OFF position and removed 2 Fuel Gauge with Low Oil Pressure I...

Page 28: ...f it is engaged This is a feature to assure the vehicle is not driven with the park brake engaged Pressing the accelerator pedal is not the preferred method of releasing the park brake Pressing the lo...

Page 29: ...equipped with a 12 volt plug 12 Glove Box A lockable glove compartment is located on each side of the instrument panel 13 Cup Holder A cup holder is provided for convenience of both the driver and pa...

Page 30: ...king up to the edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable surface could result in the vehicle falling backwards 17 Manual Lift Bed Operation Exercise...

Page 31: ...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 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: ...Run in 4 5 Cold Starting 4 6 STARTING AND DRIVING 4 6 Starting The Vehicle 4 6 Coasting 4 7 Fuel 4 7 Fuel Tank 4 8 Early Production Fuel Tank 4 8 Early Production Fuel Tank 4 8 Battery 4 8 Sun Top An...

Page 34: ...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 35: ...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 36: ...tenance may result in damage or decreased performance Read and understand the following warnings before attempting to operate the vehicle To reduce the possibility of severe injury or death resulting...

Page 37: ...Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operating in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehic...

Page 38: ...k brake 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 bac...

Page 39: ...f vehicle control and severe drivetrain damage speeds should be limited to no more than the maximum governed speed on level ground see GENERAL SPECIFICATIONS Limit speed by applying service brake FUEL...

Page 40: ...ks are designed to allow for fuel expansion and do NOT require space below bottom of filler neck BATTERY Excessive use of accessories may drain the battery and leave insufficient reserve to start the...

Page 41: ...st falling objects nor does the windshield protect against flying objects and tree limbs Keep arms and legs inside of vehicle while it is moving 12 VOLT POWER OUTLET Overuse of accessories may drain t...

Page 42: ...When using winch under a load operate the remote control from as far to the side of the vehicle as possible Do not operate winch while sitting in passenger seat Read the following section WINCH APPLIC...

Page 43: ...g severe injury or death to anyone in the area The winch cable could also become overstressed and break causing severe injury or death to anyone struck by the cable If the vehicle becomes stuck or hun...

Page 44: ...l out and rotate the knob If the cable is under any load the clutch may not release easily Jog out some of the cable to release the tension and operate clutch Pull out the desired amount of cable and...

Page 45: ...rking on the winch drum in order to prevent inadvertent operation When operating winch take up slack slowly Stop winch before cable becomes tight and inspect all winching connections Check winch attac...

Page 46: ...uld result in severe injury or death to the operator or passengers LOAD BED To reduce the possibility of severe injury or death read understand and follow the Warning label affixed to the front of the...

Page 47: ...ep the bed raised Over time the gas strut may allow the load bed to slowly lower If this condition is evident replacement of gas strut is required To lower the manual lift bed grasp the bed handle and...

Page 48: ...e remove the side cables from the load bed and open tail gate until it is straight down move tail gate panel straight up to remove from pins and remove from the load bed Reassemble in reverse order Ga...

Page 49: ...4 17 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 50: ...4 18 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 51: ...NT 5 10 FUSE REPLACEMENT 5 10 VEHICLE DISCHARGED BATTERY 5 10 TRANSPORTING VEHICLE 5 11 Towing 5 11 Neutral Lock 5 11 Hauling 5 11 SERVICE AND MAINTENANCE 5 12 ROUTINE MAINTENANCE 5 13 Tire Inspection...

Page 52: ...familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 5 2 5 TITLE PAGE NO LUBRICATION 5 22 SPARK PLUGS 5 22 PROLONGED STORAGE 5 23 PERIODIC SERVICE SCHEDULE...

Page 53: ...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 54: ...5 4 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 55: ...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 56: ...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 57: ...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 58: ...List Qty Lug 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...

Page 59: ...ecommendations must be fol lowed in order to reduce possibility of severe injury Wheel Installation To reduce the possibility of component damage do not tighten lug nuts to more than 85 ft lbs 115 Nm...

Page 60: ...o replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new automotive type fuse Headlight and taillight bulbs and fuses are available from a local Distri...

Page 61: ...pin will snap into the hole in the direction selector mounting bracket preventing any move ment When in this position the direction selector remains locked in the neutral position To unlock the direct...

Page 62: ...ir To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads from the battery before removing battery wires Wrap wrenches with viny...

Page 63: ...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 64: ...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 65: ...sture 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 de g...

Page 66: ...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 67: ...Ratchet 3 8 drive 1 Socket 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 At no time during installation of belt should...

Page 68: ...ea of the vehicle or storage facility where it will attack the metal structure or the concrete asphalt floor Additionally a resi due will be left on the battery which is conductive and will contribute...

Page 69: ...ace condition actual vehicle weight accessories installed and vehicle speed No specific braking distance can be reliably specified The test is conducted by latching the park brake to eliminate differe...

Page 70: ...ling fins Dirt and debris may clog the engine s air cooling system Clean areas shown to prevent engine damage Keep linkages springs and con trols clean Keep area around muffler free of any combustible...

Page 71: ...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 72: ...ive ft lbs 1 Use care not to over tighten the plug Over tightening can cause damage to the aluminum cylinder head threads Remove and inspect the spark plug at intervals indicated in the Periodic Servi...

Page 73: ...nt a build up of varnish and gum in the carburetor and corrosion in the engine Turn the Key Switch to OFF position and leave the Forward Reverse switch in the NEUTRAL position during storage Perform a...

Page 74: ...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 75: ...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 76: ...Min 1 4 US qt 1 3 liters 51 oz 1 5 liters SAE 30 2 oz 60 mL P N 625753 15 amp P N 18392G1 P N 619101 P N 619100 P N 619102 P N 607454 P N 28463G01 NGK BPR2ES P N 607462 028 031 7 mm 8 mm Gap P N 26414...

Page 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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...

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