Cushman 2012 Hauler 1200 Page 1 Owner'S Manual Download

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622010-M

Owner’s Guide

ISSUED JULY 2011 REVISED FEBRUARY 2016

Summary of Contents for 2012 Hauler 1200

Page 1: ...622010 M 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: ...right 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 revi...

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 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: ...ds 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: ...74093 G0 74093G01 74821G01 14 25 14 25 See Following Pages For Explanation Of These Pictograms 601781 614121 cm MIN 150 R F ON O I O ON O I O F R F ON O I O ON O I O R F ON O I O ON O I O R F 14 25 14...

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

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 N o t e s 2...

Page 21: ...0 cm Cargo Box Capacity 5 9 cu ft 0 17 m3 Cargo Box Material Roto molded polyethylene 37 0 in 94 0 cm 69 5 in 176 0 cm 48 6 in 123 0 cm Top of steering wheel Power Source Vehicle Power Drive Train Con...

Page 22: ...18 x 8 50 8 4 Ply Rated Parking Brake Front Tires Rear Tires Turf Saver 20 x 10 0 8 Dimensions Overall Height No Canopy Overall Height With Canopy Wheel Base Front Wheel Track Rear Wheel Track Gnd Cle...

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 N o t e s 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 N o t e s 2...

Page 27: ...neral Information 3 3 Key Switch Headlight Switch 3 3 Fuel Gauge with Low Oil Pressure Indicator 3 3 Direction Selector 3 4 Accelerator Pedal 3 4 Brake And Park Brake 3 4 Horn 3 4 Front Seats 3 4 Hip...

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: ...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 Indicato...

Page 30: ...e vehicle to move which could cause severe injury or death Pressing the accelerator pedal will release the park brake if it is engaged This is a feature to assure the vehicle is not driven with the pa...

Page 31: ...light turn signal assemblies are located on the rear fenders 12 Glove Box Glove box is offered as an option A separate key is used for the locking glove boxes 13 Cup Holder A cup holder is provided fo...

Page 32: ...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 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: ...s 4 TITLE 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...

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: ...al use Check for correct tire inflation 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 bra...

Page 39: ...pting 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 be...

Page 40: ...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 41: ...ted to no more than the maximum governed speed on level ground see GENERAL SPECIFICATIONS Limit speed by applying service brake FUEL To decrease the risk of severe injury or death from improper fuel h...

Page 42: ...below bottom of filler neck BATTERY Excessive use of accessories may drain the battery and leave insufficient reserve to start the vehicle The vehicle uses a combination starter generator to both sta...

Page 43: ...nd legs inside of vehicle while it is moving 12 VOLT POWER OUTLET Overuse of accessories may drain the battery and leave insufficient reserve to start the vehicle A 12 volt power outlet rated at 15 am...

Page 44: ...4 10 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: ...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 46: ...oughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 5 2 5 LUBRICATION 5 21 SPARK PLUGS 5 21 PROLONGED STORAGE 5 22 PERIODIC SERVICE SCHEDULE 5 23 CA...

Page 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...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 53: ...e Headlight and taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department VEHICLE WITH A DISCHARGED BATTERY To reduce the possibility of sev...

Page 54: ...in this position the direction selector remains locked in the neutral position To unlock the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle...

Page 55: ...urn off all electrical loads from the battery before removing battery wires Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench shorting out a battery which could result in an...

Page 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...ty 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 to the discharge of the battery To...

Page 62: ...d No specific braking distance can be reliably specified The test is conducted by latching the park brake to eliminate different pedal pressures and to include the affects of linkage mis adjustment Es...

Page 63: ...reas shown to prevent engine damage Keep linkages springs and con trols clean Keep area around muffler free of any combustible material At least once a year or more often under adverse conditions the...

Page 64: ...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 65: ...e 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 Service Schedule Spa...

Page 66: ...ish 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 all required routine m...

Page 67: ...URS includes items listed in previous table the following WIRING Check all wiring for loose connections and broken missing insulation ACCELERATOR Check for smooth movement DO NOT LUBRICATE CABLE SERVI...

Page 68: ...al noise and loose or missing mounting hardware 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 mee...

Page 69: ...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 2641...

Page 70: ...5 26 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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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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Page 80: ...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...

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