Cushman HAULER 1200, Repair Manual

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B
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
9
Repair and Service Manual
653045
BATTERY REMOVAL AND INSTALLA-
TION
Tool List Qty.
Insulated Wrench, 1/2” ................................................ 1
Socket, 1/2” ................................................................. 1
Extension, 12" ............................................................. 1
Ratchet ........................................................................ 1
Torque Wrench, ft. lbs. ............................................... 1
Battery Carrier ............................................................. 1
NOTICE: Hardware that is removed must be
installed in its original position unless otherwise
specified. If the torque values are not specified,
refer to the Torque Specifications table in the GEN-
ERAL INFORMATION AND ROUTINE MAINTENANCE
section.
At the battery, remove the negative (-) cable before
removing the positive (+) cable. Remove the bolt from the
battery hold down and remove the battery.
Installation of the battery is in reverse order of removal.
Connect the positive (+) battery cable first and then con-
nect the negative (-) battery cable.
Be sure to remove all corrosion from the terminals and
hardware. After installing the battery, coat terminals with a
commercially available terminal protectant
Be careful when you use aerosol
containers near battery terminals.
Use an insulated container to
decrease the risk of an explosion.
Fig. 1 Battery Removal
LIFTING THE VEHICLE
Tool List Qty.
Floor Jack ....................................................................1
Jack Stand ...................................................................4
Chocks.........................................................................4
To reduce the possibility of severe
injury or death from a vehicle falling
from a jack:
Place shifter in the P (park) position.
Always place chocks in front and behind the
wheels.
Be sure the vehicle is on a firm and level surface.
Never get under a vehicle while it is supported only
by a jack.
Use jack stands and test the stability of the vehicle
on the stands.
The vehicle is extremely unstable during the lifting
process.
When lifting the vehicle, position jacks and jack
stands only on the areas indicated.
Remove payload from vehicle before lifting. No per-
son(s) should be in or on the vehicle during the lift-
ing process.
Lifting Front of Vehicle
1. Chock the rear wheels to keep the vehicle from roll-
ing backward (Ref. Fig. 3).
2. Put a jack under the center of the vehicle frame at
the center of the front axle (Ref. Fig. 2).
3. Raise the vehicle with the jack.
4. Install a jack stand under each side of the vehicle
frame just behind the front wheels.
5. Lower the vehicle until it rests on the jack stands.
6. Remove the jack.
7. Confirm that the vehicle is stable on the jack stands
before proceeding with any service.
Lifting Rear of Vehicle
1. Chock the front wheels to keep the vehicle from roll-
ing forward (Ref. Fig. 3).
2. Put a jack under the center of the vehicle frame at
the center of the rear crossmember (Ref. Fig. 2).
3. Raise the vehicle with the jack.
4. Install a jack stand under each side of the vehicle
frame just in front of the rear wheels.
5. Lower the vehicle until it rests on the jack stands.
6. Remove the jack.
Battery (-)
Battery (+)
Battery Tray
1
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