Cushman HAULER 1200X, Owner'S Manual

Page 1: ...622020 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: ...le 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 The i...

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 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: ...RAL 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: ...14 WARNING Keep entire body inside car 27653G01 DONOTTAMPERWITHORCHANGETHISADJUSTMENTOFTHE GOVERNOR FAILURETOCOMPLYCOULD RESULTINSERIOUS PERSONALINJURYAND WILLVOID THEVEHICLEWARRANTY WARNING 24880G01...

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 DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION...

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: ...l Width 77 0 in 196 0 cm 38 5 in 98 0 cm 44 0 in 112 0 cm 5 3 in 15 0 cm Cargo Box Length inside 36 0 in 91 0 cm Cargo Box Depth inside 10 5 in 27 0 cm Cargo Box Capacity 9 6 cu ft 0 27 m3 Cargo Box M...

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 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 4 Hip Restraint...

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: ...lectrical system of the vehicle to be 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...

Page 28: ...dvertently will release the park brake and will cause the vehicle to move which could cause severe injury or death Depressing the accelerator pedal will release the park brake if it is engaged This is...

Page 29: ...light switch It provides constant power for accessories equipped with a 12 volt plug 13 Glove Box A lockable glove compartment is located on each side of the instrument panel 14 Cup Holder A cup holde...

Page 30: ...load bed raised or with the tailgate unsupported When using a load bed be sure to avoid backing up to the edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable...

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: ...TIAL USE 4 4 OPERATING THE VEHICLE 4 4 Run in 4 5 Cold Starting 4 6 STARTING AND DRIVING 4 6 Starting The Vehicle 4 6 Coasting 4 7 Fuel 4 7 Battery 4 8 Sun Top And Windshield If Equipped 4 8 12 Volt P...

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: ...oper maintenance 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 r...

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 vehi...

Page 38: ...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 back...

Page 39: ...TIONS 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 electr...

Page 40: ...ut 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 rated...

Page 41: ...e rocks or holes The vehicle should not be used to cross water OPTIONAL WINCH The ST 400 may be equipped with an optional winch Read understand and follow all of the following information on the opera...

Page 42: ...se hand saver bar to keep tension on the cable while activating remote When winding cable make sure the cable winds tightly and evenly onto the drum leaving no gaps that could cause premature wear to...

Page 43: ...to anyone struck by the cable If the vehicle becomes stuck or hung up on an obstruction the vehicle may be moved using the winch The winch may be installed in either the front or rear receiver and hel...

Page 44: ...area while operating winch Never allow anyone to remain in the vehicle To prevent damage to the wire cable never hook the cable to itself Always use a nylon sling Stay clear of the winch the cable an...

Page 45: ...ght only Do Not Pull at Angle If the vehicle is being used as an anchor to winch a load it should have the park brake set and chocks installed on all wheels Never use the winch to lift people or other...

Page 46: ...o not permit any one to ride in the load bed Do not drive the vehicle with the load bed raised or with the tailgate unsupported When using a load bed be sure to avoid backing up to the edge of a drop...

Page 47: ...no one is behind the vehicle Electrical Bed Latch TAIL GATE OPERATION To open the tail gate lift tail gate straight up with a sharp upward pull to lift out of the closed position and pivot out for op...

Page 48: ...4 16 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 49: ...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 50: ...familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 5 2 5 TITLE PAGE NO LUBRICATION 5 23 SPARK PLUGS 5 23 PROLONGED STORAGE 5 24 PERIODIC SERVICE SCHEDULE...

Page 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...rdware 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 ty...

Page 59: ...irection selector To operate Turn key switch to OFF and lift seat Pull out and rotate the neutral lock pin handle so that the pointed portion of the handle is to the side of the direction selector cam...

Page 60: ...cting battery at negative terminal before servicing Wear eye protection when working on the vehicle Use extra care when work ing around batteries or using solvents or compressed air To reduce the poss...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...edal The vehicle should stop aggressively The wheel brakes may or may not lock Observe the vehicle stopping location or measure the vehicle stopping dis tance from the point at which the brakes were l...

Page 69: ...er 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 Qty Socket 13 mm 3 8 drive 1 Ratchet...

Page 70: ...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 71: ...ing failure SPARK PLUGS 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 tighte...

Page 72: ...ible 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 befo...

Page 73: ...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 74: ...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 75: ...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 76: ...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...

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Page 78: ...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...