Cushman HAULER 1200X EFI 2019 Owner'S Manual Download

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OWNER’S MANUAL

HAULER 1200X EFI

666002 - A

ISSUED DECEMBER 2018

Summary of Contents for HAULER 1200X EFI 2019

Page 1: ...OWNER S MANUAL HAULER 1200X EFI 666002 A ISSUED DECEMBER 2018...

Page 2: ...y or increase the speed beyond the factory specifications Such modifications can cause serious per sonal injury or death The manufacturer TEXTRON SPECIALIZED VEHICLES TSV Augusta prohibits and disclai...

Page 3: ...ng MODEL YEAR 2019 CONTACT INFORMATION Textron Specialized Vehicles Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 1 800 774 3946 Technical Assistance Warranty 1 888 438 3946 Service Part...

Page 4: ...department These are original instructions as defined by 2006 42 EC Textron Specialized Vehicles Inc maintains the right to change the design of the vehicle without responsibility to make the changes...

Page 5: ...Load Bed P N 74821G01 11 Pinch Warning P N 651671 11 Rear Facing Seat Load Deck Warning P N 651665 11 SAFETY MAXIMUM CARGO LOAD MAXIMUM WEIGHT CAPACITY 13 TIRE PRESSURE 13 OPERATOR SAFETY 13 Unauthor...

Page 6: ...ATOR LIGHT MIL 21 SEAT BOTTOM 21 GLOVE BOX STORAGE COMPARTMENTS 21 FUEL TANK CAP 21 CANOPY TOP AND WINDSHIELD 21 TRUCK BED 22 Manual Bed Release Lever 22 Electric Lift 22 FLIP SEAT LOAD DECK IF EQUIPP...

Page 7: ...37 Initial Service Requirements 37 Severe Use Conditions 37 SCHEDULED MAINTENANCE CHART 38 RECOMMENDED LUBRICANTS AND FLUIDS 40 REPLACEMENT OF MAINTENANCE ITEMS 40 LIFTING THE VEHICLE 41 Lifting Front...

Page 8: ...e Axle Oil Level 49 AIR FILTER 49 LUBRICATION 50 SPARK PLUG 50 MALFUNCTION INDICATOR LIGHT MIL 51 BRAKES 52 Periodic Brake Test 52 BATTERY 53 Battery Cleaning 53 Battery Charging 53 Discharged Battery...

Page 9: ...applicable at the time of manufacture MANUFACTURER S INTENDED USE This vehicle is designed and manufactured for off road use only Use on public streets roads or highways is illegal in most areas and...

Page 10: ...erial such as sand Dis pose in accordance with local state and federal regulations for acid and lead compounds Contact local or state environmental authorized people for the disposal information VEHIC...

Page 11: ...UALLY REVERSE OPERATION KEY IN R PRESS ACCELERATOR GRADUALLY PARK VEHICLE TURN KEY TO OFF FORWARD OPERATION TURN KEY TO ON PUT DIRECTION SELECTOR TO F PRESS ACCELERATOR GRADUALLY REVERSE OPERATION TUR...

Page 12: ...ATTERY SHORTING BATTERY TERMINALS CAN CAUSE EXPLOSION NEGATIVE GROUND BATTERY CLEAN GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE DO NOT SPILL FUEL ON HOT ENGINE NO TAMPERING KEEP HANDS OUT DO NOT...

Page 13: ...BED MAX CENTER OF GRAVITY HEIGHT 5 12 CM ABOVE FLOOR MAX TAILGATE LOAD 100 LBS OR 45 KG MAX 14o 25 MAX 500 lb 227 kg MAX 5 in 12 cm P P MAX 100 lb 45 kg 74821G01 651671 PINCH WARNING KEEP HANDS AND FI...

Page 14: ...12 SAFETY...

Page 15: ...OT approve Distributor Dealer or customer changes that change a TSV product into a Low Speed Vehicle LSV This vehicle meets the current applicable standard for safety and performance requirements MAXI...

Page 16: ...on terrain that is too rough for your vehicle s capabilities and your driving skills Before you drive in the reverse direction make sure the area behind the vehicle is clear Accelerate slowly and avo...

Page 17: ...mmodate the load being carried See Tire Pressure on page 13 for pressure specifications Verify tire pressure and drive slowly and carefully to maintain control of the vehicle if driving under any of t...

Page 18: ...oss of traction loss of control accident or rollover Do not turn quickly or at sharp angles Do not turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Drivin...

Page 19: ...ation for performing maintenance on your vehicle Make sure to read understand and comply with all of this information to decrease the risk of personal injury or death Serious injury or death can occur...

Page 20: ...18 SAFETY...

Page 21: ...ull tank and E indicates an empty fuel tank The fuel gauge has a low oil pressure indicator A low engine oil pressure condition is shown with a red indicator light HORN The horn switch is the red togg...

Page 22: ...brake will release when you press the accelerator pedal and can cause the vehicle to move suddenly This is a feature to make sure the vehicle is not driven with the parking brake engaged Pressing the...

Page 23: ...re the fuel cap is reinstalled after filling the tank Do not operate the vehicle with out the fuel cap correctly installed and tightened The fuel cap is located on the passenger side of the vehicle Se...

Page 24: ...he switch is located on the cen ter dash console Press and hold the top part of the switch to raise the truck bed Press the bottom part of the switch to lower the truck bed See DUMPING THE TRUCK BED o...

Page 25: ...the table to help ensure safe and reliable operation Item Check Page Brake system pedal travel Check for proper operation 52 Hydraulic brakes if equipped Check for brake fluid level Parking brake Ens...

Page 26: ...ame or electrical items that can cause a spark Wear eye protection to protect from splashed fuel and fuel vapors Never use cigarettes in or near the area where refueling is done or fuel is stored Insp...

Page 27: ...rk ing brake 3 Insert the key and turn the key switch to the ON position 4 Move the direction selector to the appropriate position NOTICE When the direction selector is moved to the reverse position a...

Page 28: ...to the ON position 6 Move the direction selector to the appropriate position 7 With both hands on the steering wheel release the brake and immediately start to apply gradual and steady pressure to th...

Page 29: ...ING HILLSIDES Traversing a hillside is not recommended Improper procedure can cause a loss of control or a rollover Avoid crossing the side of a hill unless absolutely necessary If traversing a hillsi...

Page 30: ...hese guidelines Check that the area behind the vehicle is clear of obstacles and people Check left and right fields of vision before driving in reverse Do not back down a steep hill Drive in reverse s...

Page 31: ...in the truck bed Secure all loads before operating Unsecured loads can shift and create unstable operat ing conditions Operating the vehicle with passengers in the truck bed can result in severe inju...

Page 32: ...follow the steps below Loosen the hand knob under the footrest Slide the handhold away from the vehicle DO NOT remove the handhold from the vehicle Rotate the seat back and seat bottom toward the rear...

Page 33: ...discharge can ignite gasoline vapor and cause an explosion Always put the gasoline container on the ground before filling Never fill a gasoline container in the truck bed Static electricity is built...

Page 34: ...ese guidelines Do not tow more than the recommended towing weight for the vehicle See the following table and the Vehicle Specifications The total capacity of the vehicle operator passenger load bed c...

Page 35: ...ching with the winch cable at an angle to the vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions Be observant of the winch drum Do not allow the win...

Page 36: ...ok Never hook the winch cable to itself Never put your fingers into the hook Doing so could lead to severe injury a Attach the hook onto the load or use a tow strap or chain to secure the load to the...

Page 37: ...enterline c Attach the cable hook to the anchor point or the stuck vehicle frame d Re engage the clutch on the winch e Slowly winch in cable slack f Shift the stuck vehicle to the lowest gear availabl...

Page 38: ...jury or death to anyone in the area When using the winch use the following guidelines To avoid generating high winch cable loads that may exceed the strength of the cable Never use the winching vehicl...

Page 39: ...cle in a safe area that is free from vehicle and person traffic NOTICE To decrease the risk of engine damage do not operate the vehicle at full throttle for more than 5 seconds if the drive wheels are...

Page 40: ...bs as needed 44 Reverse warning alarm Pre ride Check operation Switches Pre ride Check operation Fluid leakages Pre ride Inspect entire vehicle for leaks CVT belt Pre ride Check condition Engine oil a...

Page 41: ...se or missing hardware S E Air filter 125 6 Months Inspect clean as necessary CVT belt 125 6 Months Inspect for cracks fraying and excessive wear Direction selector 125 6 Months Check for wear and smo...

Page 42: ...W 40 Heavy duty use in air temperatures above 40 F 4 C after 100 hour break in period Brake fluid DOT 3 Fuel 6 0 gal 22 7 L Unleaded 87 octane min 10 ethanol content max See page 24 Rear axle oil 51 o...

Page 43: ...round Lifting Front 1 Chock the rear wheels to keep the vehicle from rolling back ward 2 Put a jack under the center of the front axle 3 Raise the vehicle with the jack 4 Install jack stands under the...

Page 44: ...not apply wax or polish to matte finish surfaces Use clean or new cloths and pads for polishing Old or reused cloths and pads can contain dirt particles that will scratch the finish TIRES Follow the...

Page 45: ...re See Tire Pressure on page 13 Tire Replacement Tire replacement requires a tire mounting machine and must be done by a qualified tire center or an authorized CUSHMAN dealer WHEELS Worn improperly in...

Page 46: ...s are available from a local Distributor an authorized Branch or the Service Parts Department Halogen Headlight Bulb Replacement Light components can get hot if they have been in operation Allow the l...

Page 47: ...ver seat NOTICE Have the vehicle inspected by an authorized dealer if fuses continue to blow after they have been replaced 1 Lift the seat bottom to access the fuses 2 Remove the old fuse and replace...

Page 48: ...free cloth 5 To get an accurate level reading wipe oil from the dipstick and insert back into the opening 6 Remove the dipstick again and check the level The oil level must be in the area between L an...

Page 49: ...he key to OFF and engage the parking brake 2 Wipe the top of the engine clean with a cloth to remove debris that could fall in the engine 3 Remove the oil fill cap 4 Place a drain pan under the oil dr...

Page 50: ...level ground Oil increases in volume when warm The H mark on the dipstick is calibrated for an engine at operating temperature When the engine is cold the oil will be below the full mark The engine ca...

Page 51: ...can be used for routine cooling system maintenance Clean the cooling system at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 38 REAR AXLE The rear axle has an oil level check fil...

Page 52: ...when the engine is cold 2 Inspect and replace the spark plug at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 38 3 Apply a light coat of anti seize compound to the spark plug thre...

Page 53: ...des display as a combination of 0 3 second flashes for the tens place and 1 second flashes for the ones place c Active faults are displayed first then stored faults are displayed d Active faults are d...

Page 54: ...vehicle weight and speed No specific braking distance can be reliably specified so it is important to establish a base to test with The test is conducted by engaging the park brake instead of the bra...

Page 55: ...asher 1 Remove corrosion with a wire brush 2 Wash the top and sides of the battery with a solution of 1 tsp 5 ml baking soda 1 cup 236 ml water Wash all metal components near the battery 3 Rinse with...

Page 56: ...is going to be out of operation for three 3 months or longer do the following 1 Remove the battery from the vehicle 2 Make sure the battery is fully charged 3 Store it out of the sun in a cool dry pl...

Page 57: ...ng a vehicle for 30 days or more requires proper preparation to prevent a build up of varnish and gum in the fuel system and corrosion in the engine The following procedure will prepare the vehicle fo...

Page 58: ...e the tires See Tire Pressure on page 43 6 Add fuel stabilizer 4 oz for a full tank of fuel to the fuel and install the cap securely 7 Remove the spark plug and pour approximately 1 2 oz 15 ml of SAE...

Page 59: ...1 kW Exceeds SAE J1940 Standard Cooling System Air Cooled Balancer Internal Counter Rotating Balance Shaft Ignition Electronic Inductive Spark Magneto Electrical System Starter Generator Solid State...

Page 60: ...and Rear Tires K500 20 x 8 10 6 ply rated Frame Welded steel with DuraShieldTM powder coat Front Body and Finish Injection Molded TPO Rear Body and Finish Injection Molded TPO Standard Color Forest Gr...

Page 61: ...MAINTENANCE LOG 59 MAINTENANCE LOG Record periodic maintenance in the following maintenance log DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 62: ...60 MAINTENANCE LOG DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 63: ...MAINTENANCE LOG 61 DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 64: ...62 MAINTENANCE LOG DATE MILES KM AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 65: ...APPENDIX A A APPENDIX A DECLARATION OF CONFORMITY...

Page 66: ...B APPENDIX A...

Page 67: ...APPENDIX A C...

Page 68: ...D APPENDIX A...

Page 69: ...erse 28 slippery surfaces 27 stalling on hill 28 traversing hillsides 27 uphill 27 E engine break in 24 starting 25 engine oil capacity 40 recommended 40 F fluids capacities 40 recommended 40 fuel add...

Page 70: ...serial number labels 8 shock loading winch 36 slippery surfaces 27 spark plugs 50 specifications vehicle 57 steering wheel 20 storage compartments 21 switches bed lift electric 19 horn 19 key 19 T ti...

Page 71: ...or pedal Decrease speed before and during turns Bring the vehicle to a complete stop before you move the direction selector See GENERAL SPECIFICATIONS for the vehicle load and seat capacity NOTICE Rea...

Page 72: ...anuals are available from a local Distributor or an authorized Branch Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of Textron Specialized V...

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