Cushman HAULER 800 - User Manual

T ABLE OF C ONTENTS iii INTRODUCTION MANUFACTURER’S INTENDED USE ..................................................................................................................... 1WARRANTY AND REGISTRATION .............................................................................................

iv T ABLE OF C ONTENTS KEY SWITCH ........................................................................................................................................................ 13HEADLIGHT SWITCH .................................................................................................

T ABLE OF C ONTENTS v BATTERY ................................................................................................................................................................ 23HAULING CARGO ................................................................................................

vi T ABLE OF C ONTENTS LUBRICATION ........................................................................................................................................................ 40SPARK PLUG ......................................................................................................

S AFETY 1 INTRODUCTION The following symbols appear throughout this manual and on vehicle labels. Your safety is involved when these sym - bols are used. Become familiar with their meanings before reading the manual. DANGER indicates a hazardous situation that, if not avoided, will result in death o...

2 I NTRODUCTION BATTERY PROLONGED STORAGE Batteries discharge over time. The rate of discharge changes according to the ambient temperature, the age and con - dition of the batteries.Completely charged batteries will not freeze in winter temperatures unless the temperature is less than -75°F (- 60°C...

S AFETY 3 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.If...

4 S AFETY Negative Ground Label (P/N 28203G01) Located on the seat frame. (For CE vehicles only) Engine Warning CE (P/N 74093G01) Located on the truck bed closeout. Governor Warning (P/N 608527) Located on the governor bracket. Bed Latch Warning CE (P/N 74099G01) Located on the side panel near rear ...

S AFETY 5 Load Bed (P/N 74821G06) Located on the truck bed. Pinch Warning (P/N 651671) Located on the rear facing seat weldment for vehicles with a rear facing seat option. Patent Label (P/N 10005569) Located in the glove box (driver side) DO NOT FILL GAS CAN IN LOAD BED MAX SIDE SLOPE 14° HIGH CENT...

S AFETY 7 SAFETY For questions about the vehicle or the material in this manual, see the contact information on page i 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 ...

8 S AFETY • Operate your vehicle responsibly to prevent dangerous conditions for the operator, passengers and other people in the area of operation • Operate the vehicle responsibly and keep the vehicle in safe condition of operation. • A damaged vehicle or a vehicle that is not functioning properly...

10 S 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 22 for operational information. Driving ...

S AFETY 11 HOT EXHAUST SYSTEMS Exhaust system components are very hot during and after use. To avoid burn injuries, do not touch hot exhaust sys - tem components. Hot components can also cause a fire. Keep combustible materials away from the exhaust system. Check for buildup around the exhaust syste...

F EATURES AND C ONTROLS 13 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 The key switch is a two-position switch. • OFF; vehicle is...

14 F EATURES AND C ONTROLS STEERING WHEEL The steering wheel allows the driver to control the direction of travel. TURN SIGNAL (If Equipped) The turn signal switch is located on the steering column and is used to activate the turn signals. BRAKE PEDALS The brake pedal on vehicles with mechanical bra...

F EATURES AND C ONTROLS 15 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 The direction selector i...

16 F EATURES AND C ONTROLS CANOPY TOP AND WINDSHIELD The canopy top does not provide protection from rollover or falling objects.The windshield does not provide protection from tree branches or moving objects. To prevent damage to the vehicle, do not hold on to the canopy top struts. The canopy top ...

O PERATION 17 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 o...

18 O 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 complet...

O PERATION 19 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 ...

20 O 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 pe...

O PERATION 21 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 operatin...

22 O 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:1. Apply the brakes. 2. Verify that the area behind you is clear. 3. Put the transmission in R (rev...

O PERATION 23 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 i...

24 O 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 p...

O PERATION 25 3. Put the direction selector in forward (F). 4. Exit the vehicle. 5. Make sure the cargo is positioned evenly or located at the front of the truck bed. 6. Release the tailgate latches. 7. Manual bed lift vehicles: a. Stand clear and pull the release handle. Lift up on the truck bed to...

M AINTENANCE 27 VEHICLE 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 pe...

28 M 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 warr...

30 M AINTENANCE RECOMMENDED LUBRICANTS AND FLUIDS Check and lubricate all components at the intervals shown in the SCHEDULED MAINTENANCE CHART beginning on page 28. REPLACEMENT OF MAINTENANCE ITEMS These items or their equivalents can be purchased through an authorized dealer, directly from CUSHMAN ...

M AINTENANCE 31 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 warning...

32 M 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 pro...

M AINTENANCE 33 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 Repair NOTICE: Tire plug tools and plugs are available at automotive outlets...

34 M AINTENANCE Wheel Installation NOTICE: To decrease the risk of component damage, do not tighten the lug nuts 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. 1. Install the wheel on the hub with lug ...

M AINTENANCE 35 Taillight 1. Roll the rubber bezel from around the edge of the taillight and remove the lens. 2. Install the new bulb. 3. Replace the lens. FUSE REPLACEMENT The fuse block is under the driver seat. NOTICE: Have the vehicle inspected by an authorized dealer if fuses continue to blow a...

36 M 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...

M AINTENANCE 37 CHANGE THE ENGINE OIL Change the engine oil at the initial service and then intervals indicated in the SCHEDULED MAINTENANCE CHART on page 28. NOTICE: See RECOMMENDED LUBRICANTS AND FLUIDS on page 30 for oil capacity and grade. The use of an incorrect grade of engine oil can damage t...

38 M AINTENANCE 5. Inspect the new oil filter for any defects. 6. Apply engine oil to the oil filter o-ring (5). 7. 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). Refill Oil NOTICE: See RECOMME...

M AINTENANCE 39 Adjusting the Belt 1. Loosen the starter/generator pivot bolt. 2. 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. 3. Hold the lower nut in ...

40 M AINTENANCE 4. 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. 5. Reinstall or replace the filter, making sure it is fully seated in the housing. 6. Replace the housing and secure with the ...

M AINTENANCE 41 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 po...

42 M 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, ...

M AINTENANCE 43 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.Inspect the...

44 M 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 ...

M AINTENANCE 45 Towing the Vehicle Only tow the vehicle for recovery purposes. Ensure brakes and steering are operable. Always have a person driving the vehicle to steer and operate brakes when it is being towed. Do not tow the vehicle above 5 mph (8 kph).Failure to abide by these instructions could...

46 M AINTENANCE 1. Clean the vehicle. See VEHICLE CLEANING AND CARE on page 32. 2. Turn the key switch to the OFF position and put the direction selector in the NEUTRAL position. 3. Chock the wheels to prevent the vehicle from rolling. Do not engage the parking brake. 4. Perform all required routine...

S PECIFICATIONS 47 SPECIFICATIONS HAULER 800 - VEHICLE SPECIFICATIONS Item Specification Overall Length 110.0 in (279 cm) Overall Width 49.0 in (124cm) Overall Height (No Canopy) 47.0 in (119 cm)(Top of steering wheel) Overall Height (With Canopy) 69.5 in (177 cm) Wheel Base 65.5 in (166 cm) Front W...

M AINTENANCE L OG 49 MAINTENANCE LOG Record periodic maintenance in the following maintenance log. DATE MILES (KM) AND HOURS TECHNICIAN SERVICE PERFORMED COMMENTS

I NDEX 53 INDEX A accelerator pedal 21auxiliary outlet, 12V 19 B battery disposal 8battery maintenance 49bed lift switch, electric 19brakes 48 pedal, mechanical 20 break-in CVT belt 24engine 24 C capacity cargo load 13, 29fluids 36, 53hitch 31, 53load 53towing 31, 53 carbon monoxide 15cargo dumping ...

54 I NDEX P PIN plate 8pre-ride inspection 23 R registration information, vehicle 7 S safety carbon monoxide 15cargo 13, 29driving downhill 16driving in reverse 16driving uphill 16driving with passenger 15engine exhaust 15fuel 15hot exhaust 17labels 9lifting, vehicle 17, 37operation 23operator 13pre...