Cushman HAULER 1200X Utility Vehicle Manuals

Cushman HAULER 1200X Utility Vehicle Manuals

Manuals and User Guides for Cushman HAULER 1200X Utility Vehicle. We have 2 Cushman HAULER 1200X Utility Vehicle manuals available for free PDF download: Technician's Repair And Service Manual, Owner's Manual

Cushman HAULER 1200X Technician's Repair And Service Manual

Cushman HAULER 1200X Technician's Repair And Service Manual (214 pages)

GASOLINE POWERED UTILITY VEHICLE

Brand: Cushman | Category: Utility Vehicle | Size: 18 MB

Table of Contents

Table of Contents

5
- Safety
  2
- General Information
  4
  - Table of Contents
    5
- Safety Information
  7
General Information & Routine Maintenance

11
- General Information & Routine Maintenance
  13
  - Serial Number Location
    13
  - Starting the Vehicle with Adischarged Battery
    13
  - Servicing the Vehicle
    13
  - Fuel
    14
  - Towing
    14
  - Routine Maintenance
    15
  - Powertrain Maintenance
    15
  - Brakes
    16
  - Tires
    16
  - Trailering
    16
  - Top and Windshield
    16
  - Winter or Prolonged Storage
    16
  - Care and Cleaning of the Vehicle
    17
  - Vehicle Care Products
    17
  - Hardware
    17
  - Torque Specifications
    18
  - Periodic Service Schedule
    19
- Safety
  25
- Body
  32
Wheels and Tires

45
- Wheel and Tire Service
  47
  - Tire Repair
    47
  - Wheel Installation
    48
- Fig. 1 Wheel and Tire Installation
  48
- Front Suspension and Steering
  53
Speed Control

83
- Section Title
  
  85
- System Operation
  
  85
  - Pedal Box Operation
    85
  - Governor Operation
    86
- Troubleshooting
  
  86
- Speed Control
  
  86
- Pedal Box Adjustments
  
  88
  - Accelerator Pedal Arm Adjustment
    88
  - Micro Switch Adjustment
    88
  - Road Test
    89
Engine

91
- Section Title
  
  93
- Powertrain Maintenance
  
  93
  - Changing the Oil
    93
  - Checking the Oil Level
    93
- Air Filter Inspection/Replacement
  
  95
  - Cleaning the Air Filter Element
    96
- Starter/Generator Belt Tension
  
  96
  - Adjusting the Belt
    96
- Starter/Generator Replacement
  
  97
- Spark Plug
  
  98
- Cooling System Cleaning
  
  98
- Four Cycle Engine
  
  99
  - Engine Specifications
    99
  - Engine Description
    99
- Cylinder Head
  
  99
  - Compression Measurement
    99
  - Rocker Cover Removal
    100
  - Valve Clearance Inspection
    100
  - Valve Clearance Adjustment
    100
- Engine Removal
  
  101
  - Controls and Wiring
    102
  - Removing the Engine from the Vehicle
    102
  - Engine Installation
    102
- Drive Clutch Removal
  
  102
Fuel System

105
- Fuel System
  106
  - General
    107
  - Carburetor Operation
    108
    
    Float System
    108
    
    Pilot Jet System
    108
    
    Main Jet System
    108
    
    Carburetor Service
    108
    
    Choke System
    108
    
    Choke Operation
    108
  - Fuel System Component Service and Replacement
    109
    
    Choke Cable and Housing Removal
    109
    
    Choke Cable and Housing Installation
    109
    
    Carburetor Removal
    110
    
    Carburetor Disassembly
    110
    
    Float Level Alignment
    111
    
    Carburetor Installation
    111
  - Fuel Pump
    111
    
    Fuel Pump Replacement
    112
  - Fuel Lines and Filter
    112
  - Fuel Tank Removal
    113
- Continuously Variable Transmission (Cvt)
  117
- Direction Selector
  125
Electrical

131
- Section Title
  
  133
  - Circuits and Controls
    133
  - Generator
    133
  - Starter
    133
  - Testing Ignition Circuit
    133
    
    Testing the Magneto
    136
  - Wiring
    133
  - Testing Charging Circuit
    137
  - Testing Starting Circuit
    137
- Inspection
  
  138
  - Starter/Generator
    138
    
    Disassembly
    139
  - Battery Voltage Test
    139
- Troubleshooting
  
  140
  - Dvom (Digital Volt Ohm Meter)
    140
  - Power Supply
    140
  - Storage of Battery
    140
Mechanical Brakes

143
- Section Title
  143
  - Page no
    143
- Mechanical Brakes
  145
  - Brake System Overview
    145
    
    General Description
    145
    
    How the Service Brake Works
    145
    
    Equalizer Link
    145
    
    Automatic Adjuster Mechanism
    146
    
    How the Parking Brake Works
    146
    
    Compensator Assembly
    147
    
    Kick-Off Actuating Linkage
    147
  - Troubleshooting Table
    148
  - Troubleshooting and Inspection
    150
    
    New Vehicles
    150
    
    Troubleshooting and Inspection Procedures
    150
    
    Brake Pedal and Linkage Inspection
    150
    
    Periodic Brake Performance Test (PBPT)
    152
    
    Aggressive Stop Test
    153
    
    Wheel Brake Inspection
    154
  - Maintenance and Repairs
    156
- Rear Suspension
  165
- Rear Axle
  171
Weather Protection

177
- Sun Top
  179
  - Rear Support Installation
    179
  - Front Strut
    179
- Sun Top and Windshield
  179
- Split Windshield
  181
- Full Windshield
  182
- Split Windshield (Clip-On Type)
  183
- Full Windshield (Clip-On Type)
  184
Troubleshooting

187
- Engine Overheating
  191
- Poor Low Speed Performance
  191
- Poor Midrange or High Speed Performance
  191
- Backfiring
  192
- Excessive Smoking
  192
- Repeated Spark Plug Fouling
  192
- Carburetor
  193
  - Overflow Leak
    194
  - Poor Acceleration
    194
  - Hard Starting
    194
  - Abnormal Combustion (Fuel Mixture)
    195
  - Loss of Power (Insufficient Fuel)
    195
  - Loss of Power (Insufficient Air)
    195
  - Stiff Steering
    196
- Erratic, Surging, or Sudden Change in Governed Speed
  193
- Fuel Accumulation in the Crankcase
  193
  - Fuel Distribution
    193
  - Mechanical
    193
- Brake System
  197
  - Neither Wheel Locks When Park Brake Is Latched
    198
  - Grabbing Brakes (over Sensitive)
    198
- General Specifications
  202

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Cushman HAULER 1200X Owner's Manual

Cushman HAULER 1200X Owner's Manual (78 pages)

Brand: Cushman | Category: Utility Vehicle | Size: 4 MB

Table of Contents

Table of Contents

5
- Safety
  7
  - Safety
    8
  - Notices, Cautions, Warnings, and Dangers
    9
  - General
    11
  - General Operation
    11
  - Maintenance
    12
  - Ventilation
    12
  - Labels and Pictograms
    13
- General Specifications
  19
Introduction

25
- Features
  27
- General Information
  27
- Key Switch / Headlight Switch
  27
- Low Oil Pressure Indicator Light
  27
- Accelerator Pedal
  28
- Brake and Park Brake
  28
- Direction Selector
  28
- Front Lights
  28
- Front Seats
  28
- Fuel Gauge
  28
- Hip Restraint - Front
  28
- Horn
  28
- Brake Light/Turn Signal
  29
- Choke
  29
- Cup Holder
  29
- Glove Box
  29
- Steering Wheel
  29
- Volt Power Outlet
  29
- Electric Lift Bed
  30
- Manual Lift Bed Operation
  30
- Utility Bed
  30
Operating Procedures

33
- Serial Number Location
  
  35
- Before Initial Use
  
  36
- Operating the Vehicle
  
  36
  - Run-In
    37
  - Cold Starting
    38
- Starting and Driving
  
  38
  - Starting the Vehicle
    38
  - Coasting
    39
  - Fuel
    39
  - Battery
    40
  - Sun Top and Windshield (if Equipped)
    40
  - Volt Power Outlet
    41
  - Terrain
    41
- Optional Winch
  
  41
  - Operation of the Winch
    41
  - Winch Applications
    42
- Modifications to Vehicle
  
  45
- Load Bed
  
  46
- Manual Lift Bed
  
  46
- Electric Lift Bed Operation
  
  47
- Tail Gate Operation
  
  47
Maintenance

49
- Vehicle Cleaning and Care
  53
  - Vehicle Cleaning
    53
- Common Sense Operation
  54
- Environmental Concerns
  54
- Repair
  55
  - Lifting the Vehicle
    55
- Wheels and Tires
  56
  - Tire Repair
    56
  - Wheel Installation
    57
- Fuse Replacement
  58
- Light Bulb Replacement
  58
- Transporting Vehicle
  59
  - Towing
    59
  - Neutral Lock
    59
  - Hauling
    59
- Service and Maintenance
  60
- Routine Maintenance
  61
  - Tire Inspection
    61
  - Rear Axle
    61
  - Four Cycle Engine
    61
  - Checking the Oil Level
    61
- Starter/Generator Belt Tension
  65
  - Adjusting the Belt
    65
- Battery Cleaning
  66
- Brakes
  67
- Air Intake and Cooling Fins
  68
- Periodic Brake Test for Mechanical Brakes
  68
- Rear Axle
  69
  - Checking the Lubricant Level
    69
- Air Cleaner Inspection and Replacement
  70
  - Cleaning the Air Filter Element
    70
- Lubrication
  71
- Prolonged Storage
  72
- Spark Plugs
  72
- Periodic Service Schedule
  73
  - General Operation
    73
- Capacities and Replacement Parts
  75
- Hardware
  75

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