Cushman HAULER 1200X EFI 2019 Owner's Manual
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Cushman HAULER 1200X EFI 2019 Owner's Manual

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OWNER'S MANUAL
HAULER 1200X EFI
666002 - A
ISSUED DECEMBER 2018

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Summary of Contents for Cushman HAULER 1200X EFI 2019

  • Page 1 OWNER’S MANUAL HAULER 1200X EFI 666002 - A ISSUED DECEMBER 2018...
  • 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 WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 OWNER’S MANUAL GASOLINE HAULER 1200x EFI Starting 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 Parts 001-706-798-4311 International www.cushman.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 EXHAUST EMISSIONS ............................7 BATTERY PROLONGED STORAGE ........................8 BATTERY DISPOSAL ...............................8 VEHICLE IDENTIFICATION NUMBERS .......................8 REPAIR AND PARTS MANUALS ..........................8 SAFETY LABELS SAFETY LABELS ..............................9 Operation (P/N 651654) ............................9 Operation (P/N 608529) (If equipped with card holder) ..................9 Negative Ground Label (P/N 28203G01) ......................10 Engine Warning CE (P/N 74093G01) ......................10...
  • Page 6 ABLE OF ONTENTS FEATURES AND CONTROLS KEY SWITCH ................................19 HEADLIGHT SWITCH .............................19 ELECTRIC BED LIFT SWITCH (IF EQUIPPED) ....................19 FUEL GAUGE WITH LOW OIL PRESSURE INDICATOR (IF EQUIPPED) ............19 HORN ..................................19 CUP HOLDER .................................19 12V OUTLET (IF EQUIPPED) ..........................19 USB PORT (IF EQUIPPED) ............................19 STEERING WHEEL .............................20 TURN SIGNAL (IF EQUIPPED) ..........................20...
  • Page 7 ABLE OF ONTENTS PARKING THE VEHICLE ............................28 BATTERY ................................29 HAULING CARGO ..............................29 Maximum Cargo Load / Maximum Weight Capacity ..................29 FLIP SEAT/ LOAD DECK OPERATION (IF EQUIPPED) ..................30 TRUCK BED OPERATION .............................31 Load Bed (P/N 74821G01) ..........................31 DUMPING THE TRUCK BED ..........................31 TOWING ..................................32 WINCH WINCH SAFETY ..............................33...
  • Page 8 ABLE OF ONTENTS CHANGE THE ENGINE OIL ...........................47 Remove the Engine Oil ...........................47 Change the Oil Filter ............................47 Refill Oil ................................48 STARTER/GENERATOR BELT ..........................48 Adjusting the Belt ............................49 AIR INTAKE AND COOLING FINS .........................49 REAR AXLE ................................49 Checking the Axle Oil Level ...........................49 AIR FILTER ................................49 LUBRICATION ................................50 SPARK PLUG ................................50...

  • Page 9: Manufacturer's Intended Use

    All information, including coverage, limitations, exclusions and how to obtain warranty service is included in the litera- ture package with the purchase of the vehicle. It can also be obtained from your CUSHMAN dealer. EXHAUST EMISSIONS The exhaust emissions of this vehicle’s engine complies with regulations set forth by the Environmental Protection Agency (EPA) of the United States of America (USA) at time of manufacture.

  • Page 10: Battery Prolonged Storage

    Record the vehicle identification numbers in the spaces provided below. These identification numbers is required when ordering parts from CUSHMAN. Vehicle Model Number: _________________________________________________________________ Frame PIN: __________________________________________________________________________ REPAIR AND PARTS MANUALS The following manuals can be purchased through your CUSHMAN dealer: • repair manual • parts manual...

  • Page 11: Safety Labels

    AFETY SAFETY LABELS SAFETY LABELS Safety and warning labels are on the vehicle for your protection. Read carefully and comply with the instructions on the labels. If any label shown in this manual is different from the label on your vehicle, always follow the instructions on the vehicle label.

  • Page 12: Negative Ground Label (P/N 28203G01)

    AFETY Negative Ground Label (P/N 28203G01) Located on the seat frame. (For CE vehicles only) NEGATIVE GROUND SHORTING BATTERY TERMINALS CAN BATTERY CAUSE EXPLOSION Engine Warning CE (P/N 74093G01) Located on the truck bed closeout. NO TAMPERING DO NOT EXPOSE GROUND NEGATIVE SHORTING BATTERY TERMINALS...

  • Page 13: Load Bed (P/N 74821G01)

    AFETY Load Bed (P/N 74821G01) Located on the truck bed. SECURE LOAD HIGH CENTER WARNING MAX BED WEIGHT OF GRAVITY MAY PASSENGERS READ THE MANUAL 500 LBS or 227 KG CAUSE TIP OVER IN LOAD BED 500 lb. 227 kg 5 in.
  • Page 14 AFETY...

  • Page 15: Maximum Cargo Load / Maximum Weight Capacity

    AFETY SAFETY For questions about the 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 manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph.

  • Page 16: Unauthorized Operation

    AFETY Serious injury or death can occur if you do not follow the instructions and procedures shown in this owner’s manual. • Read this entire manual and all product labels carefully. Follow the safety information and operating procedures described. • Operate your vehicle responsibly to prevent dangerous conditions for the operator, passengers and other people in the area of operation •...

  • Page 17: Alcohol Or Drugs

    AFETY Alcohol or Drugs Operation of the vehicle during or after consuming alcohol or drugs can adversely affect operator judg- ment, reaction time, balance and perception. Never drink alcohol or use drugs or medications before or during operation of the vehicle. Passenger All passengers must be at least 59 in.

  • Page 18: Driving In Reverse

    AFETY Driving in Reverse Make sure the area behind the vehicle is clear before operating in reverse. After making sure it is clear and safe to operate in reverse, accelerate slowly. Avoid making sharp turns in reverse. Refer to Driving in Reverse on page 28 for operational information.

  • Page 19: Hot Exhaust Systems

    VEHICLE MODIFICATION Do not install any accessory not approved by CUSHMAN. Do not modify the vehicle to increase the speed or power. Any modifications or installation of accessories not approved by TSV can create a safety hazard and increase the risk of injury.
  • Page 20 AFETY...

  • Page 21: 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. KEY SWITCH Fuel Horn Light Electric Lift Gauge Switch...

  • Page 22: Steering Wheel

    EATURES AND ONTROLS STEERING WHEEL Steering Wheel Steering Wheel The steering wheel allows the driver to Turn Signal Switch Turn Signal Switch control the direction of travel. Cup Holder Cup Holder TURN SIGNAL (If Equipped) The turn signal switch is located on the steering column and is used to activate the turn signals.

  • Page 23: Efi Malfunction Indicator Light (Mil)

    EATURES AND ONTROLS EFI MALFUNCTION INDICATOR LIGHT (MIL) The MIL is located on the rear of the seat frame. Lift the truck bed to view the MIL.The MIL can be used to diagnose a prob- lem and whether a technician will be required to service the vehicle.

  • Page 24: Truck Bed

    EATURES AND ONTROLS TRUCK BED To prevent injury and property damage, follow all warnings, pro- cedures, and weight capacities described on the label in the truck bed as well as the ones in this owner’s manual. See HAULING CARGO on page 29 and DUMPING THE TRUCK BED on page 31.

  • 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: Engine Break-In

    PERATION ENGINE BREAK-IN Correct operation of the engine during the break-in period is essential to the performance, reliability, and life of the engine. The engine break-in period is: • the first 50 operating hours of a new engine • the first 50 operating hours of an engine that has been completely disassembled •...

  • Page 27: 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 28: Accelerating

    PERATION ACCELERATING Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause severe injury or death. Make sure the key is in the OFF position and the parking brake is engaged any time the vehicle is parked. Apply slow, steady pressure to the accelerator pedal to increase vehicle speed.

  • Page 29: Slippery Surfaces

    PERATION SLIPPERY SURFACES Skidding or sliding can cause a loss of control. Skidding or sliding can cause a 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. When operating in conditions such as ice, water, muddy trails, loose gravel or freezing temperatures, follow these guidelines: •...

  • Page 30: Stalling On A Hill

    PERATION STALLING ON A HILL A rollover can result from stalling or rolling backward while climbing a hill. Drive uphill at a constant speed. If your vehicle completely stalls while climbing a hill: Apply the brakes. Verify that the area behind you is clear. Put the transmission in R (reverse).

  • Page 31: Battery

    PERATION BATTERY NOTICE: Heavy use of accessories or leaving accessories turned on when the vehicle is not being used can drain the battery and leave insufficient reserve to start the vehicle. The vehicle uses a starter/generator to start the engine and charge the battery. The engine does not idle; so the bat- tery does not charge while the vehicle is stopped.

  • Page 32: 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 the vehicle without the rear handhold installed in the proper position. When the 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 33: 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 operating 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 34: 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 35: 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 36: Winch Operation

    INCH WINCH OPERATION Read all of the Winch Safety beginning on page 33 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 37 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 38: Winch Cable Care

    INCH WINCH CABLE CARE For your safety, use factory approved replacement parts. Replace the winch cable at the first sign of damage to prevent severe injury or death in the event of failure. • Always inspect the winch cable before each use. Inspect for wear or kinks in the cable. –...

  • Page 39: Vehicle Maintenance

    Refer to the SCHEDULED MAINTENANCE CHART on page 38 for detailed requirements. Inspect, clean, lubricate, adjust, and replace parts as necessary. Use CUSHMAN or equivalent replacement parts. Record the maintenance items performed along with details in the MAINTENANCE LOG beginning on page 59.

  • Page 40: Scheduled Maintenance Chart

    AINTENANCE SCHEDULED MAINTENANCE CHART Perform all services at the maintenance interval reached first. S – Indicates operations that need to be performed on vehicles subjected to severe use. E – Indicates emission-related services (Failure to do this maintenance will not void the emissions warranty but may affect emissions). D –...
  • Page 41 AINTENANCE Interval (perform at interval Item Remarks Page that comes first) Hours Calendar General lubrication 3 Months Lubricate all fittings, pivots, cables, etc. where required. Throttle/governor linkage 3 Months Check operation and governed speed. Fuel system 3 Months Check for leakage at tank, cap, lines, filters, pump, carburetor. Front axle 3 Months Check for damage, loose or missing hardware.

  • Page 42: Recommended Lubricants And Fluids

    Grease fittings Universal joint grease or equivalent of grease in each fitting. REPLACEMENT OF MAINTENANCE ITEMS These items or their equivalents can be purchased through an authorized dealer, directly from CUSHMAN or any other qualified source. Item Part Number Oil Filter...

  • Page 43: 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 44: 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 the vehicle. High water pressure can damage components. Some products, including insect repellents and chemicals, will damage plastic surfaces.

  • Page 45: Tire Pressure

    Fully inflate the tire. 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 inflated, improper sized, or incorrectly installed tires will affect vehicle handling and could cause an accident resulting in severe injury or death.

  • Page 46: 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 the even seating of the wheel against the hub.

  • Page 47: Taillight

    AINTENANCE Taillight Roll rubber bezel Roll the rubber bezel from around the edge of the taillight and remove the away from body. lens. Install the new bulb. Taillight Replace the lens. Brake Light FUSE REPLACEMENT The fuse block is under the driver seat. NOTICE: Have the vehicle inspected by an authorized dealer if fuses continue to blow after they have been replaced.

  • Page 48: Four Cycle Engine

    AINTENANCE FOUR CYCLE ENGINE The engine is an air cooled, 4-stroke, OHV, single cylinder gasoline engine. It has a pressure fed lubrication positive displacement oil pump with a cartridge type full flow oil filter and a counter rotating balance shaft. NOTICE: The engine uses more oil during the first hours of operation, than after the internal parts are run-in.

  • Page 49: Change The Engine Oil

    AINTENANCE CHANGE THE ENGINE OIL Change the engine oil at the initial service and then intervals indicated in the SCHEDULED MAINTENANCE CHART on page 38. Tools • ratchet • universal strap wrench • socket, 19 mm • funnel • Extension, 8” •...

  • Page 50: Refill Oil

    AINTENANCE Inspect the new oil filter for any defects. Apply engine oil to the oil filter o-ring (5). Install the oil filter onto the engine until the o-ring con- tacts the mounting surface of the engine. Turn the filter 2/ 3 to 3/4 rotations by HAND(S).

  • Page 51: Adjusting The Belt

    AINTENANCE Adjusting the Belt Loosen the starter/generator pivot bolt. While holding the lower adjusting nut with a wrench, loosen the upper jam nut with another wrench. Move the lower nut up or down the adjustment bolt until the correct belt tension is achieved. Hold the lower nut in place and tighten the upper jam nut against it.

  • Page 52: Lubrication

    AINTENANCE A lightly soiled filter can be cleaned by tapping out dust. Do not use compressed air on the filter. If the filter is heavily soiled, it must be replaced. Reinstall or replace the filter, making sure it is fully seated in the housing. Replace the housing and secure with the latches on the air cleaner cover.

  • Page 53: Malfunction Indicator Light (Mil)

    AINTENANCE MALFUNCTION INDICATOR LIGHT (MIL) The EFI system uses Diagnostic Trouble Codes to report issues. Both active and stored faults are reported by the Engine Control Module (ECM). • Active Faults – These are faults that have been triggered since the key switch was last turned to the ON position. •...

  • Page 54: Brakes

    AINTENANCE BRAKES Always inspect the pedal travel before operating 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. It is, therefor, important to establish the standard with a new vehicle.

  • Page 55: Battery

    AINTENANCE BATTERY The vehicle has a sealed battery, which requires no maintenance except to keep it corrosion-free, and to test for func- tionality. The sealed battery is filled with electrolyte and sealed at the factory. Never pry the seal strip off, or add fluid to the bat- tery.

  • Page 56: Discharged Battery

    AINTENANCE Discharged Battery To decrease the risk of severe injury or death from accidental movement, do not use jumper cables to start a vehicle. The vehicle has a starter/generator and does not idle. When you start the engine, the starter/generator functions as a starter and with the engine running, it functions as a generator.

  • Page 57: Towing The Vehicle

    When in this position, the direction selector remains locked in the neutral position. Attach the vehicle to the towing vehicle with a tow bar that is approved by CUSHMAN. Release the parking brake if it is engaged. After the vehicle has been towed, unlock the direction selec- tor.

  • Page 58: Remove From Storage

    AINTENANCE Clean the vehicle. See VEHICLE CLEANING AND CARE on page 42. Turn the key switch to the OFF position and put the direction selector in the NEUTRAL position. Chock the wheels to prevent the vehicle from rolling. Do not engage the parking brake. Perform all required routine maintenance indicated in the SCHEDULED MAINTENANCE CHART on page 38.

  • Page 59: Specifications

    PECIFICATIONS SPECIFICATIONS HAULER 1200X - VEHICLE SPECIFICATIONS Item Specification Overall Length 119.0 in (302 cm) Overall Width 49.4 in (125 cm) Overall Height (No Canopy) 53.0 in (135 cm) (Top of steering wheel) Overall Height (With Canopy) 77.0 in (196 cm) Wheel Base 77.5 in (197 cm) Front Wheel Track...
  • Page 60 PECIFICATIONS Speed (Level Ground) 16.5 mph ± 0.5 mph (26.58 kph ± 0.80 kph) Maximum Drawbar 500 lbs (2225 N) Towing Capacity 1200 lbs (544 kg) max load Steering Self-compensating reduction rack and pinion Front Suspension Leaf springs with hydraulic shock absorbers Rear Suspension Leaf springs with hydraulic shock absorbers Brakes...
  • Page 61 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 DECLARATION OF CONFORMITY...
  • Page 66 PPENDIX...
  • Page 67 PPENDIX...
  • Page 68 PPENDIX...
  • Page 69 NDEX INDEX capacity 40 recommended 40 accelerator pedal 20 auxiliary outlet, 12V 19 fluids capacities 40 battery disposal 8 recommended 40 battery maintenance 53 fuel bed lift switch, electric 19 add 24 brakes 52 gauge 19 pedal, mechanical 20 handling guidelines 15 break-in specifications 24 CVT belt 24...
  • Page 70 NDEX capacity 32 speeds 32 PIN plate 8 towing, vehicle 55 pre-ride inspection 23 transporting the vehicle 54 truck bed 22 registration information, vehicle 7 dumping 31 safety USB port 19 carbon monoxide 15 cargo 13, 29 vehicle driving downhill 16 hauling 54 driving in reverse 16 removing from storage 56...
  • 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 TEXTRON SPECIALIZED VEHICLES 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA 1-800-774-3946 Technical Assistance & Warranty 1-888-438-3946 Service Parts www.cushman.com Service Parts Manuals and Repair and Service Manuals are available from a local Distributor or an authorized Branch. Copyrighted Material...

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