Cushman HAULER 1200 Manuals

Cushman HAULER 1200 Manuals

Manuals and User Guides for Cushman HAULER 1200. We have 1 Cushman HAULER 1200 manual available for free PDF download: Repair Manual

Cushman HAULER 1200 Repair Manual

Cushman HAULER 1200 Repair Manual (177 pages)

Brand: Cushman | Category: Utility Vehicle | Size: 23 MB

Table of Contents

Battery Disposal
2
Battery Prolonged Storage
2
Safety Information

5
- General
  5
- Safety Information
  5
- General Operation
  6
- Maintenance
  6
- Ventilation
  6
- Table of Contents
  7
General Information and Routine Maintenance

19
- Serial Number Label Location
  19
- Vehicle with a Discharged Battery
  19
- Starting Vehicle on a Hill
  19
- Servicing the Vehicle
  20
  - Initial Service Chart
    20
  - Warnings on Fuel
    20
- Fuel Tank
  20
- Fuel Tank View
  21
- Powertrain Maintenance
  21
- Battery
  21
- Routine Maintenance
  21
- Brakes
  21
- Tires
  21
- Light Bulb Replacement
  21
  - Towing
    22
  - Neutral Lock
    22
- Hauling
  22
- Winter or Prolonged Storage
  22
- Transporting Vehicle
  22
- Canopy and Windshield
  22
- Vehicle Cleaning and Care
  23
  - Vehicle Care Production
    24
  - Torque Specifications
    24
- Hardware
  24
- Before Servicing the Vehicle
  25
Safety

25
- Notices, Cautions, Warnings and Dangers
  25
- Important Safety Warning
  25
- Modifications to Vehicle
  25
- General Maintenance
  25
- Battery Removal and Installation
  27
  - Lifting Front of Vehicle
    27
  - Lifting Rear of Vehicle
    27
  - Lowering Vehicle
    28
- Body Component Replacement
  31
- General
  31
  - Front Body Components
    32
  - Instrument Panel Replacement
    32
  - Brush Guard Replacement
    33
  - Cowl Replacement
    33
  - Front Bumper Replacement
    34
  - Rocker Panel Replacement
    34
  - Side Panel Replacement
    34
  - Tool List Quantity
    34
  - Drill
    34
  - Drill Bit
    34
  - Punch, Small
    34
  - Pop Rivet Tool
    34
  - Hammer
    34
  - NOTICE: the Cowl (2) Can be Removed Along with
    34
  - Seat Filler Panel Replacement
    35
  - Rear Body Panel Replacement
    35
- Painting
  36
  - Rear Fender Replacement
    36
  - Minor Scratches
    36
  - Larger Scratches
    36
  - Item Torque Specification
    36
  - Tool List Quantity
    36
  - Ratchet
    36
  - Torque Wrench, Ft. Lbs
    36
  - Complete Panel Repair
    37
  - Truck Bed Replacement (Optional Electric Lift)
    39
- Truck Bed Removal
  40
Speed Control

43
- Pedal Box Operation
  43
- Governor Operation
  43
  - Ccelerator and Speed Control System View
    43
  - Speed Control Fault Testing
    44
- Accelerator Cable Removal at Pedal Box
  44
- Pedal Box Adjustments
  45
  - Accelerator Cable Installation
    45
  - Throttle Rod Removal
    45
  - Accelerator Pedal Arm Adjustment
    45
  - Micro Switch Adjustment
    46
    
    Accelerator Pedal Arm Adjustment
    46
    
    Pedal Box Micro Switch
    46
  - Road Test
    46
Weather Protection

49
Front Hydraulic Brake

81
- Master Cylinder Replacement
  81
- System Description
  81
  - Remove Master Cylinder
    81
- Master Cylinder Fluid
  82
  - Brake Pad Replacement
    82
  - Check Brake Fluid
    82
  - Install Master Cylinder
    82
  - Flush Hydraulic Brake System
    82
- Routine Maintenance
  82
- Replacement of Wear Items
  82
- Bleeding Brakes
  83
  - Rotor Replacement
    83
  - Actuator Linkage Bushings
    83
  - Actuator Pivot Bushings
    83
  - Spindle Replacement
    83
  - General Information about Bleeding Brakes
    83
    
    Rear Hydraulic Brakes
    87
    
    Wheel Brake Components
    88
    
    Wheel Brake Cleaning and Inspection
    89
    
    Rear Hydraulic Brakes Reassembly
    90
    
    Park Brake
    93
    
    Park Brake Cable Replacement
    94
    
    Front Suspension and Steering
    97
    
    Axle Mounted Steering and Front Suspension View
    97
    
    Wheel Bearing and King Pin Bushing Inspection
    98
    
    Wheel Bearing Packing
    98
    
    Wheel Bearing Adjustment
    99
    
    Wheel Alignment
    99
    
    Front Suspension
    101
    
    Front Shock Absorber Replacement
    101
    
    Front Axle Replacement
    102
    
    Axle Linkage Rod Replacement
    102
    
    Front Spring Replacement
    103
    
    Hub Replacement
    104
    
    Wheel Bearing and Race Replacement
    105
    
    Steering
    106
    
    Rack Ball Joint Replacement
    106
    
    Tie Rod Inspection/Replacement
    107
    
    Bellows Replacement
    108
    
    Pinion Seal Replacement
    108
    
    Spindle Replacement
    109
    
    Rack and Pinion Unit Disassembly and Inspection
    110
    
    Rack and Pinion Unit Replacement
    111
    
    Checking/Adjusting Rack Extension-To-Rack and Pinion Unit Clearance
    111
    
    Steering Wheel Replacement
    112
    
    Steering Shaft and Column Replacement
    113
    
    Rear Axle
    117
    
    Checking the Lubricant Level (Rear Axle)
    117
    
    Rear Axle Disassembly
    118
    
    Axle Shaft Removal and Disassembly
    118
    
    Axle Shaft Seal Removal and Replacement
    118
    
    Axle Shaft Replacement
    119
    
    Rear Suspension
    121
    
    Shock Absorber Removal
    121
    
    Rear Leaf Spring Removal
    121
    
    Rear Suspension Exploded View
    122
    
    Continuously Variable Transmission (CVT)
    125
    
    Primary Clutch
    125
    
    Secondary Clutch
    126
    
    Increased Load
    126
    
    Removing the Transmission Belt
    126
    
    Primary Clutch Removal
    126
    
    CVT Components View
    127
    
    Primary Clutch Installation
    128
    
    Secondary Clutch Removal
    128
    
    Secondary Clutch Assembly
    128
    
    Secondary Clutch Installation
    128
    
    Engine
    131
    
    Four Cycle Engine Specifications
    131
    
    Oil Dipstick
    131
    
    Changing the Oil
    132
    
    Remove Oil Filter
    133
    
    Inspect Oil Filter
    133
    
    Add Engine Oil
    133
    
    Air Filter Inspection/Replacement
    134
    
    Starter/Generator Belt Tension
    134
    
    Clean the Air Filter Element
    134
    
    Adjusting the Belt
    135
    
    Starter/Generator Replacement
    136
    
    Cooling System Cleaning
    136
    
    Starter/Generator Wire Connections
    136
    
    Spark Plug
    137
    
    Cylinder Head
    137
    
    Compression Leak down Test
    137
    
    Rocker Cover Removal
    138
    
    Valve Clearance Inspection
    138
    
    Valve Clearance Adjustment
    138
    
    Engine Removal
    139
    
    Drive Clutch Removal
    140
    
    Engine Installation
    140
    
    Fuel System Diagram
    143
    
    Carburetor Operation
    144
    
    Float System
    144
    
    Main Jet System
    144
    
    Choke System
    144
    
    Choke Cable and Housing Removal
    145
    
    Choke Cable Attachment
    145
    
    Choke Cable and Housing Installation
    146
    
    Carburetor Removal
    146
    
    Carburetor Disassembly
    146
    
    Float Level Alignment
    147
    
    Carburetor Installation
    147
    
    Fuel Pump Replacement
    148
    
    Fuel Lines and Filter
    148
    
    Fuel Tank Removal
    148
    
    Carbon Canister
    149
    
    CARB Hoses View
    149
    
    Electrical
    151
    
    Starter
    151
    
    Generator
    151
    
    Testing the Ignition Circuit
    151
    
    Main Harness Wiring Diagram
    152
    
    Testing the Magneto
    153
    
    Testing the Starting Circuit
    154
    
    Testing the Charging Circuit
    154
    
    Starter/Generator View
    155
    
    Voltage Test for Battery
    156
    
    Starter/Generator Disassembly
    156
    
    Starter/Generator Repair and Replacement
    156
    
    Starter/Generator Brush Removal
    156
    
    Storage of Battery
    157
    
    DVOM (Digital Volt Ohm Meter)
    157
    
    Fault Testing
    157
    
    Power Supply
    158
    
    Accessory Wiring
    158
    
    Headlight Bulb Replacement
    158
    
    Taillight Replacement
    159
    
    Continuity Check
    161
    
    Testing a Switch for Continuity
    161
    
    Testing the Ignition System
    161
    
    Testing Fuses
    161
    
    Powertrain Performance
    162
    
    Starter Fault Testing
    164
    
    Suspension and Steering Fault Testing
    164
    
    Specifications
    167
    
    Scheduled Maintenance
    171
    
    Initial Service Requirements
    171
    
    Severe Use Conditions
    171
    
    Recommended Lubricants and Fluids
    173
    
    Replacement of Maintenance Items
    174

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