Cushman HAULER PRO X Owner's Manual
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Cushman HAULER PRO X Owner's Manual

Cushman HAULER PRO X Owner's Manual

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OWNER'S GUIDE
HAULER Pro X
653036 – A
ISSUED AUGUST 2016

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  • Page 1 OWNER’S GUIDE HAULER Pro X 653036 – A ISSUED AUGUST 2016...
  • Page 2 Read and comply with all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. CALIFORNIA Proposition 65 Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead and lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.
  • Page 3 OWNER’S GUIDE 72V ELECTRIC HAULER Pro X Starting MODEL YEAR 2017 CONTACT INFORMATION Textron Specialized Vehicles, Inc. 1451 Marvin Griffin Road. Augusta, Georgia, USA 30906-3852 North America: Technical Assistance & Warranty PHONE: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts PHONE: 1-800-438-3946, FAX: 1-800-752-6175 International PHONE: 001-706-798-4311, FAX: 001-706-771-4609 cushmancomm@textron.com...
  • Page 4 ELCOME Thank you for purchasing this vehicle. Before driving your new vehicle, read this owner’s manual to familiarize your- self with safe driving practices, operation, features and controls. This manual contains instructions for minor maintenance only. Information about major repairs can be found in the repair manual.

  • Page 5: Table Of Contents

    ABLE OF ONTENTS INTRODUCTION MANUFACTURER’S INTENDED USE ........................7 WARRANTY AND REGISTRATION ......................... 7 BATTERY PROLONGED STORAGE ........................7 BATTERY DISPOSAL ............................... 7 VEHICLE IDENTIFICATION NUMBERS .........................8 REPAIR AND PARTS MANUALS ..........................8 SAFETY SAFETY LABELS ..............................9 Operation (P/N 651654) ............................ 9 Operation (P/N 608529) (If equipped with card holder) ..................10 Bed Latch Warning CE (P/N 74099G01) ......................10 Load Bed (P/N 74821G01) ..........................
  • Page 6 ABLE OF ONTENTS STATE OF CHARGE METER ..........................17 HORN ..................................17 CUP HOLDER .................................17 12V OUTLET (IF EQUIPPED) ..........................17 USB PORT (IF EQUIPPED) ............................17 HOUR METER (IF EQUIPPED) ..........................18 STEERING WHEEL ..............................18 TURN SIGNAL (IF EQUIPPED) ..........................18 BRAKE PEDALS ..............................18 Brake Pedal ..............................18 Parking Brake Pedal ............................18 ACCELERATOR PEDAL ............................19 DIRECTION SELECTOR ............................19...
  • Page 7 ABLE OF ONTENTS STALLING ON A HILL ............................. 29 DRIVING IN REVERSE ............................29 PARKING THE VEHICLE ............................29 HAULING CARGO ..............................30 Maximum Cargo Load / Maximum Weight Capacity ..................30 Flip Seat/ Load Deck Operation (If Equipped) ....................31 TRUCK BED OPERATION ............................. 32 Load Bed (P/N 74821G01) ..........................
  • Page 8 ABLE OF ONTENTS Periodic Brake Test ............................47 BATTERY ................................47 BATTERY DISPOSAL .............................48 BATTERY CLEANING ............................48 BATTERY CHARGING AND MAINTENANCE ......................49 At Each Charging Cycle ..........................49 Monthly ................................49 Electrolyte Level and Water ...........................49 BATTERY REPLACEMENT ............................50 BATTERY STORAGE .............................51 BATTERY CHARGING ............................52 AC Voltage ..............................52 BATTERY FAULT DIAGNOSIS ..........................52 Using A Hydrometer ............................54...

  • Page 9: Manufacturer's Intended Use

    It can also be obtained from your TSVdealer. A registration card is included in the literature package with the purchase of the vehicle. The vehicle can also be reg- istered online at www.cushman.com. BATTERY PROLONGED STORAGE Batteries discharge over time.

  • Page 10: Vehicle Identification Numbers

    NTRODUCTION VEHICLE IDENTIFICATION NUMBERS PART A PART B PART C and D PART B PART A PART C is located on the seat wrap under the charger receptacle. PIN LABEL PART D Record the vehicle identification numbers in the spaces provided below. These identification numbers is required when ordering parts from TSV.

  • Page 11: Safety

    AFETY SAFETY For questions about your vehicle or the material in this manual, see the contact information on page 1 or the back of this publication. Certain replacement parts can be used independently and/or in combination with other accessories to modify a TSV (Augusta) manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph.

  • Page 12: Operation (P/N 608529) (If Equipped With Card Holder)

    AFETY Operation (P/N 608529) (If equipped with card holder) Located on the steering wheel. OPERATING INSTRUCTIONS 608529 BEFORE OPERATING READ all warning labels and the owner’s manual. Contact an authorized dealer or go the the manufacturer’s website for a replacement manual. This vehicle is equipped for personal use in most communities.

  • Page 13: Load Bed (P/N 35980G02)

    AFETY Load Bed (P/N 35980G02) HIGH CENTER WARNING SECURE LOAD PASSENGERS OF GRAVITY MAY READ THE MANUAL MAX BED WEIGHT IN LOAD BED CAUSE TIP OVER 500 lb. 226 kg 5 in. 12 cm / 25% 35980G02 DO NOT FILL GAS MAX CENTER OF MAX SIDE CAN IN LOAD BED...

  • Page 14: Run/Tow Switch Operation (P/N 633950)

    AFETY Run/Tow Switch Operation (P/N 633950) Located on the run/tow switch. 633950 MAXIMUM CARGO LOAD / MAXIMUM WEIGHT CAPACITY Exceeding the weight capacities can cause loss of vehicle control and possible injury or death. Maximum Cargo Load Capacity 500 lbs. (255 kg) Maximum Vehicle Weight Capacity 900 lbs.

  • Page 15: Unauthorized Operation

    AFETY • Inspect the vehicle before each use to make sure it is in safe operating condition. Perform the pre-ride inspection described in this manual. See page 23. • Always have the vehicle checked by an authorized dealer if it is involved in an accident. •...

  • Page 16: Before Operating

    AFETY Before Operating Perform the PRE-RIDE INSPECTION on page 23 before each use to make sure the vehicle is in safe operating con- dition. Failure to inspect and confirm that the vehicle is safe to operate increases the risk of an accident. Follow all inspection and maintenance procedures and schedules described in this owner’s manual.

  • Page 17: Stalling On A Hill

    AFETY Stalling on a Hill A rollover can result from stalling or rolling backward while climbing a hill. Drive uphill at a constant speed. See proce- dure on page 29 for maintaining control of your vehicle if it stalls on a hill. Tires Operating the vehicle with incorrect tires or with incorrect or uneven tire pressure can cause loss of control or an acci- dent.
  • Page 18 AFETY •When you service the vehicle, always wear eye protection. Be careful when working around batter- ies, using solvents or compressed air. •Use insulated tools within the battery area to prevent sparks or battery explosion. •To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks away from the battery.

  • Page 19: Features And Controls

    EATURES AND ONTROLS FEATURES AND CONTROLS NOTICE: Some accessories continue to operate with the key in the OFF position. Leaving these accessories activated after the vehicle is shut down can cause the battery to discharge. 12V accessories must be connected to the DC to DC converter. Converter is rated for 390 Watt out- put.

  • Page 20: Hour Meter (If Equipped)

    EATURES AND ONTROLS HOUR METER (If Equipped) The hour meter is located under the driver’s seat and indicates the vehicle’s total hours of operation. STEERING WHEEL Steering Wheel Steering Wheel The steering wheel allows the driver to Turn Signal Switch Turn Signal Switch control the direction of travel.

  • Page 21: Accelerator Pedal

    EATURES AND ONTROLS ACCELERATOR PEDAL The accelerator pedal is the right pedal on the floorboard. It activates the engine and controls the acceleration of the vehicle. Apply slow and steady pressure to the accelerator pedal to increase vehicle speed. DIRECTION SELECTOR Direction The direction selector is the key switch.

  • Page 22: Canopy Top And Windshield

    EATURES AND ONTROLS Rear passengers must stay in the seat and hold both hip restraints and the rear hand hold when the vehicle is in motion. Always make sure that all passengers are seated and holding on before operating the vehicle. Do not allow passengers to ride on the load deck.
  • Page 23 EATURES AND ONTROLS...
  • Page 24 EATURES AND ONTROLS...

  • Page 25: Operation

    PERATION OPERATION SAFETY Failure to operate the vehicle correctly can result in a collision, loss of control, accident or rollover, and cause serious injury or death. Follow all operation procedures in this section of the manual. Read and comply with all safety warnings in the safety section of this owner’s manual.

  • Page 26: Environmental Awareness

    PERATION ENVIRONMENTAL AWARENESS When driving the vehicle, be careful of potential environmental hazards like steep slopes, rocks, tree branches, etc. that could cause an incident that could result in vehicle damage, personal injury or death. There is a risk of fire when the vehicle is operated near combustible material. Always be respectful of the environment.

  • Page 27: Performance Features

    PERATION PERFORMANCE FEATURES NOTICE: The vehicle operates when the Run/Tow switch is in the RUN position. The speed of the motor is sensed and controlled by the controller. Speed Control The speed control system is not an alternative for the brake. Use the brake to control speed and decrease the risk of injury.

  • Page 28: High Pedal Disable Feature

    PERATION the Anti-Stall feature senses a stalled motor condition and removes power from the motor. When the brake pedal is released, the vehicle will move backward slightly before power is returned to the motor. High Pedal Disable Feature High Pedal Disable prevents acceleration of the vehicle if the direction selector is changed or the key is turned on while the accelerator is pressed.

  • Page 29: Braking

    PERATION Apply slow, steady pressure to the accelerator pedal to increase vehicle speed. When you release the accelera- tor pedal, the motor decreases the speed of the vehicle. NOTICE: On mechanical brake vehicles, if the key switch is in the ON position and the parking brake is engaged, the brake releases when you press the accelerator pedal and can cause the vehicle to move suddenly.

  • Page 30: Slippery Surfaces

    PERATION • Handling characteristics can change with the added weight of a passenger. Allow more time and distance for brak- ing. SLIPPERY SURFACES Skidding or sliding can cause loss of control. Skidding or sliding can cause rollover if tires have lost traction, then regain traction suddenly. When operating on slippery sur- faces, travel at reduced speed to help maintain control of the vehicle.

  • Page 31: Stalling On A Hill

    PERATION • Never drive down hills with excessively slippery or loose surfaces. • Drive slowly. • Drive straight down the hill. Avoid descending the hill at an angle that could cause the vehicle to lean sharply to one side. • Apply light and constant pressure to the brakes to maintain slow speed and control of the vehicle. STALLING ON A HILL A rollover can result from stalling or rolling backward while climbing a hill.

  • Page 32: Hauling Cargo

    PERATION HAULING CARGO Hauling cargo incorrectly can alter vehicle handling characteristics and cause loss of control, brake instability, and possibly lead to serious injury or death. Never exceed the maximum weight capacity of the vehicle. The total load (operator, pas- senger, accessories, cargo and load on hitch) must never exceed the maximum weight capacity of the vehicle.

  • Page 33: Flip Seat/ Load Deck Operation (If Equipped)

    PERATION Flip Seat/ Load Deck Operation (If Equipped) To reduce the possibility of severe injury or death never operate vehicle without the rear handhold installed in the proper position. When rear seat is used the handhold must be positioned in the setting closest to the footrest and secured with the hand knob. Some vehicles are equipped with a rear facing seat that pivots to form a load deck.

  • Page 34: Truck Bed Operation

    PERATION TRUCK BED OPERATION Failure to follow these instructions can cause personal injury, damage the vehicle or cause the vehicle to tip over. Be aware of the load when you operate the vehicle. Read, understand and follow the warning label attached to the front of the truck bed. Do not allow passengers to ride in the truck bed.

  • Page 35: Towing

    PERATION Put the direction selector in forward (F). Exit the vehicle. Make sure the cargo is positioned evenly or located at the front of the truck bed. Release the tailgate latches. Manual bed lift vehicles: Stand clear and pull the release handle. Lift up on the truck bed to dump the cargo.
  • Page 36 PERATION...

  • Page 37: Winch

    INCH PERATION WINCH The safety warnings and information in this section apply if your vehicle has a winch. Improper or irresponsible use of the winch can result in severe injury or death. Always follow all winch instructions and warnings in this manual. WINCH SAFETY •...

  • Page 38: Winch Operation

    INCH WINCH OPERATION Read all of the Winch Safety beginning page 35 before operating your winch. NOTICE: Practicing operation and use of the winch before it is needed to perform a job is recommended. Improper or irresponsible winch use can result in severe injury or death. Comply with all winch instructions and warnings in this manual.

  • Page 39: Winch Cable Care

    INCH Pull out as much cable as possible to maximize the winch’s pulling capac- ity. Maintain at least five full turns of winch cable wrapped around the winch drum at all times. The friction provided by the wrapped cable allows Minimum five (5) the drum to pull on the winch cable and move the load.

  • Page 40: Shock Loading

    INCH • Always inspect the winch cable before each use. Inspect for wear or kinks in the cable. – A kinked winch cable made of wire rope is shown at right. Even after being straightened out, this cable has been permanently and severely damaged.

  • Page 41: Maintenance

    AINTENANCE MAINTENANCE MAINTENANCE SAFETY To prevent serious injury or death, follow the procedures and comply with the safety information in this manual while performing vehicle service or maintenance. Use the tools shown in the tool list and wear the specified safety equipment when per- forming vehicle service or maintenance.

  • Page 42: Severe Use Conditions

    AINTENANCE Severe Use Conditions Vehicles subjected to heavy or severe use must be inspected and serviced more frequently than those of normal use patterns.The following conditions are considered severe use: • frequent or prolonged use in a dusty environment • frequent use in mud, water or sand •...

  • Page 43: Recommended Lubricants And Fluids

    AINTENANCE Interval (perform at interval Item Remarks Page that comes first) Hours Calendar Brakes Monthly Check for smooth operation and acceptable stopping distance. Front wheel alignment 3 Months Check for unusual tire wear. Check for shock oil leakage, worn bushings, loose or missing Rear Suspension 3 Months hardware.

  • Page 44: Lifting The Vehicle

    AINTENANCE LIFTING THE VEHICLE Read and comply with all of the following warnings and lifting procedures to prevent the possibility of the vehicle falling and causing serious injury or death. For some maintenance procedures, it is necessary to lift the vehicle. Comply with the following warnings and follow the lifting procedure to ensure the safety of you, your vehicle and surroundings.

  • Page 45: Vehicle Cleaning And Care

    AINTENANCE VEHICLE CLEANING AND CARE Keeping your vehicle clean is not only beneficial to its appearance, but can also help extend the life of various compo- nents. Washing the Vehicle NOTICE: Do not use a pressure washer to wash your vehicle. High water pressure can damage components. Some products, including insect repellents and chemicals, will damage plastic surfaces.

  • Page 46: Tire Pressure

    AINTENANCE Tire Pressure Maintaining correct tire inflation pressure is essential for safe vehicle operation. You can vary the inflation pressure, within the recommended range to suit the condition of the terrain. TIRE PRESSURE RANGE TERRAIN CONDITIONS RECOMMENDATION Inflate to higher pressure within the range; never exceed hard surfaces or pavement maximum pressure indicated.

  • Page 47: Wheel Installation

    AINTENANCE Wheel Installation Lug Nut Torque 65 - 85 ft.lbs. (88 - 115 Nm) NOTICE: To decrease the risk of component damage, do not tighten the lug nuts Lug Nut Tightening Pattern to more than the specified torque. Always install lug nuts using a cross sequence pattern to ensure even seating of the wheel against the hub.

  • Page 48: Fuse Replacement

    AINTENANCE FUSE REPLACEMENT The fuse block is under the driver seat. NOTICE: Have the vehicle inspected by your dealer if fuses continue to blow after they have been replaced. Lift the seat bottom to access the fuses. Remove the old fuse and replace with a new fuse of the same type and size. Fuses are available from a local Distributor, an authorized Branch or the Service Parts Department.

  • Page 49: Brakes

    AINTENANCE BRAKES Always inspect the pedal travel before you operate a vehicle to confirm some brake func- tion is present. All driving brake tests must be done in a safe location with regard for the safety of all personnel. NOTICE: Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.

  • Page 50: Battery Disposal

    AINTENANCE slower in cold conditions. Temperature is important when conducting tests on a battery and test results must be cor- rected to adjust for temperature differences. An older battery can perform adequately except that its capacity is decreased. Capacity describes the time that a bat- tery can continue to supply its design amperes from a full charge.

  • Page 51: Battery Charging And Maintenance

    AINTENANCE To decrease the risk of damage to electrical components surrounding the battery while cleaning, do not use a pressure washer. When you clean the battery cases and terminals, do not use a water hose without neutralizing any acid deposits first. The water hose moves the acid from the top of the batteries to another area of the vehicle or storage facility, where it can cause damage.

  • Page 52: Battery Replacement

    AINTENANCE and surface below the vehicle. Sulphuric acid loss will weaken the amount of acid within the electrolyte and decrease the life of the battery. Over the life of the battery, a large amount of water is used. The water added to the batteries must be clean and with- out contamination.

  • Page 53: Battery Storage

    AINTENANCE If the batteries have been cleaned and the acid in the battery rack area is neutralized as recommended, no cor- rosion to the battery racks or surrounding area should be present. If any corrosion remains, remove it with a putty knife and a wire brush.

  • Page 54: Battery Charging

    AINTENANCE In high temperatures the chemical reaction is fast, while low temperatures cause the chemical reaction to slow. A vehicle that is stored at 90° F (32° C) will lose.002 of spe- cific gravity each day. If a completely charged battery has a specific gravity of 1.275, and the battery is not used, it will become partially discharged.
  • Page 55 AINTENANCE • Find the reason a vehicle does not perform adequately. Performance problems can cause a vehicle to run slowly or can not operate for the time needed. A new battery must mature before it develops its maximum capacity. Maturing can take 100 or more charge and dis- charge cycles.

  • Page 56: Using A Hydrometer

    AINTENANCE Using A Hydrometer ELECTROLYTE Draw electrolyte into the hydrometer and release it sev- TEMPERATURE eral times to permit the thermometer to adjust to the °F °C electrolyte temperature and note the reading. Examine the color of the electrolyte. A brown or gray coloration +.032 indicates a problem with the battery and is a sign that +.030...

  • Page 57: Transporting The Vehicle

    AINTENANCE TRANSPORTING THE VEHICLE Do not ride or allow other people on a vehicle being transported on a trailer or being towed with another vehicle. Towing the Vehicle Do not try to tow the vehicle with ropes, chains or any device different from a tow bar approved by the manufacturer.
  • Page 58 AINTENANCE...

  • Page 59: Specifications

    PECIFICATIONS SPECIFICATIONS HAULER PRO-X - VEHICLE SPECIFICATIONS • Solid State continuously variable AC • Full torque, reduced speed reverse speed controller • Seatwrap mounted direction selector • Inductive throttle sensor switch (Forward-Neutral-Reverse) • Anti-roll back, walkway braking and • Diagnostic indicator alarm •...
  • Page 60 PECIFICATIONS Drive Train Motor Shaft Direct Drive Transaxle Differential with helical gears Gear Selection Seatwrap Mounted Forward-Neutral-Reverse Rear Axle Ratio 17:1 Seating Capacity 2 Person or 4 person with optional flip seat Dry Weight 948 lb. (430 kg) (Without Batteries) Curb Weight 1513 lb.

  • Page 61: Maintenance Log

    AINTENANCE MAINTENANCE LOG Record periodic maintenance in the following maintenance log. MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 62 AINTENANCE MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 63 AINTENANCE MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 64 AINTENANCE MILES (KM) SERVICE PERFORMED DATE TECHNICIAN AND HOURS COMMENTS...
  • Page 65 PPENDIX APPENDIX A DELTA-Q USER’S GUIDE...

  • Page 66: Safety Instructions

    PPENDIX 8VHU·V *XLGH SAVE THESE IMPORTANT INFORMATIONS IMPORTANTES DE SÉCURITÉ SAFETY INSTRUCTIONS Ce manuel contient des instructions importantes This manual contains important safety and operating concernant la sécurité et le fonctionnement. instructions – read before using charger. Attention: Utiliser le chargeur seulement avec un algorithme Warning: Use charger only with an algorithm selected that is approprié...
  • Page 67 PPENDIX 4. Optional Charger Single-LED Display (internal or external) LED Colour Indication (following “Power-On Self Test”) Green Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short: <80% Charge. Long: >80% Charge. When battery is not connected: Algorithm Number display. Amber Flashing: Reduced Power Mode: Low AC Voltage or High internal charger temperature.
  • Page 68 PPENDIX...
  • Page 69 NDEX INDEX hitch weight capacity 33 horn switch 17 auxiliary outlet, 12V 17 key switch 17 battery disposal 7 battery maintenance 47 bed lift switch, electric 17 labels, safety 9 brakes 47 lifting, vehicle 15, 42 lubricants, recommended 41 cable, winch 37 capacity maintenance cargo load 12, 30...
  • Page 70 NDEX safety symbols 7 scheduled maintenance chart 40 seat bottom 19 serial number labels 8 shock loading, winch 38 slippery surfaces 28 specifications, vehicle 55 steering wheel 18 storage compartments 19 switches bed lift, electric 17 horn 17 key 17 tires 43 pressure 12, 44 repair 44...
  • Page 71 Normal use, age and wear on vehicle components can affect the safe operation and reliability of the vehicle. The rec- ommended Inspection and maintenance procedures are crucial for safety, performance, reliability and maximum lon- gevity of your vehicle. A damaged vehicle, or a vehicle that is not functioning properly is dangerous and must not be operated until repairs are made.
  • Page 72 CUSHMAN 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA TO CONTACT US: North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-438-3946, FAX: 1800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 Website: www.cushman.com Service Parts Manuals and Repair and Service Manuals are available from a local Distributor, or an authorized Branch.

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