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Cushman HAULER PRO 2014 User Manual

Cushman HAULER PRO 2014
140 pages
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TECHNICIAN’S REPAIR AND SERVICE MANUAL
72V Electric Powered Utility Vehicle
634756
ISSUED MAY 2014

Table of Contents

Questions and Answers:

Cushman HAULER PRO 2014 Specifications

General IconGeneral
BrandCushman
ModelHAULER PRO 2014
CategoryOffroad Vehicle
LanguageEnglish

Summary

SAFETY

NOTICES, CAUTIONS, WARNINGS AND DANGERS

Explains the meaning of safety symbols and warnings.

GENERAL INFORMATION

BATTERY PROLONGED STORAGE

Guidelines for storing batteries for extended periods.

BATTERY DISPOSAL

Proper procedures for disposing of lead-acid batteries.

SAFETY INFORMATION

GENERAL

General safety considerations for vehicle operation.

GENERAL OPERATION

Safe practices for operating the vehicle.

SAFETY INFORMATION

MAINTENANCE

Safety precautions related to vehicle maintenance.

VENTILATION

Safety guidelines for charging operations.

GENERAL INFORMATION AND ROUTINE MAINTENANCE

SERIAL NUMBER LABEL LOCATION

Locating serial number and date code labels.

TRANSPORTING VEHICLE

Instructions and warnings for transporting the vehicle.

SERVICING THE ELECTRIC VEHICLE

Warnings and advice for servicing the electric vehicle.

GENERAL INFORMATION AND ROUTINE MAINTENANCE

ROUTINE MAINTENANCE

General guidelines for regular vehicle upkeep.

REAR AXLE

Maintenance requirements for the rear axle assembly.

BRAKES

Recommendations for brake system checks and maintenance.

TIRES

Guidelines for tire inspection and inflation pressure.

LIGHT BULB REPLACEMENT

Reference for replacing vehicle light bulbs.

GENERAL INFORMATION AND ROUTINE MAINTENANCE

VEHICLE CLEANING AND CARE

Procedures for cleaning and caring for the vehicle.

VEHICLE CARE PRODUCTS

Recommended products for vehicle maintenance.

SUN TOP AND WINDSHIELD

Care and cleaning instructions for sun top and windshield.

GENERAL INFORMATION AND ROUTINE MAINTENANCE

HARDWARE

Information on torque specifications and bolt grades.

SAFETY

NOTICES, CAUTIONS, WARNINGS AND DANGERS

Explanation of safety symbols and their meanings.

IMPORTANT SAFETY WARNING

Critical safety warnings regarding component failure and hazards.

MODIFICATIONS TO VEHICLE

Warnings against modifying vehicle weight distribution.

GENERAL MAINTENANCE

General safety precautions before maintenance.

SAFETY

BEFORE SERVICING THE VEHICLE

Essential warnings before vehicle inspection or service.

Additional Warnings Specific to Electrical System

Specific safety warnings for electrical system work.

SAFETY

BATTERY REMOVAL AND INSTALLATION

Safety precautions for battery removal and installation.

SAFETY

LIFTING THE VEHICLE

Safety procedures and precautions for lifting the vehicle.

BODY

GENERAL

General information and safety warnings for the vehicle body.

BODY COMPONENT REPLACEMENT

General procedures for replacing body components.

BODY

Instrument Panel Replacement

Instructions for replacing the instrument panel.

BODY

Center Compartment Replacement

Instructions for replacing the center compartment.

Cowl Replacement

Procedures for removing and replacing the vehicle cowl.

Brush Guard Replacement

Instructions for replacing the brush guard.

BODY

Rocker Panel Replacement

Steps for removing and installing rocker panels.

Side Panel Replacement

Instructions for replacing the side panels.

Rear Fender Replacement

Procedures for replacing the rear fenders.

BODY

Rear Body Panel Replacement

Steps for removing and installing the rear body panel.

BODY

PAINTING

Guidelines for painting minor and major scratches.

WHEELS AND TIRES

WHEEL AND TIRE SERVICE

Tools and procedures for wheel and tire service.

Tire Repair

Method for repairing flat tires using a tire plug.

WHEELS AND TIRES

Wheel Installation

Proper procedure for installing vehicle wheels.

FRONT SUSPENSION AND STEERING

MAINTENANCE

Routine maintenance procedures for front suspension and steering.

Lubrication

Lubrication points and procedures for front suspension components.

Wheel Bearing and King Pin Bushing Inspection

Inspecting wheel bearings and king pin bushings for wear.

Wheel Bearing Packing

Procedure for packing wheel bearings with grease.

FRONT SUSPENSION AND STEERING

Wheel Bearing Adjustment

Steps for adjusting front wheel bearings.

Wheel Alignment

Procedure for checking and adjusting front wheel alignment.

FRONT SUSPENSION AND STEERING

FRONT SUSPENSION

Components and procedures related to the front suspension system.

FRONT SUSPENSION AND STEERING

Front Shock Absorber Replacement

Steps for removing and installing front shock absorbers.

Front Axle Replacement

Procedure for replacing the front axle assembly.

Axle Linkage Rod Replacement

Instructions for replacing axle linkage rods.

Wheel Alignment Adjustment

Adjusting the front wheel alignment.

FRONT SUSPENSION AND STEERING

Front Spring Replacement

Procedure for replacing front suspension springs.

FRONT SUSPENSION AND STEERING

Hub Replacement

Steps for replacing the wheel hub assembly.

Wheel Bearing and Race Replacement

Procedures for replacing wheel bearings and races.

FRONT SUSPENSION AND STEERING

STEERING

Components and procedures related to the steering system.

Rack Ball Joint Replacement

Steps for replacing the rack ball joint.

FRONT SUSPENSION AND STEERING

Tie Rod Inspection/Replacement

Procedures for inspecting and replacing tie rods.

FRONT SUSPENSION AND STEERING

Bellows Replacement

Instructions for replacing steering bellows.

Pinion Seal Replacement

Procedure for replacing the pinion seal.

FRONT SUSPENSION AND STEERING

Spindle Replacement

Steps for replacing the steering spindle.

FRONT SUSPENSION AND STEERING

Rack and Pinion Unit Disassembly and Inspection

Procedures for disassembling and inspecting the rack and pinion unit.

FRONT SUSPENSION AND STEERING

Rack and Pinion Unit Replacement

Steps for replacing the rack and pinion unit.

Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance

How to check and adjust rack extension clearance.

FRONT SUSPENSION AND STEERING

Steering Wheel Replacement

Procedure for replacing the vehicle's steering wheel.

FRONT SUSPENSION AND STEERING

Steering Shaft and Column Replacement

Steps for replacing the steering shaft and column.

ELECTRONIC SPEED CONTROL

SPEED SENSOR

Information about the speed sensor's function.

CONTROLLER

Description of the electronic speed controller.

CONTROLLER REPLACEMENT

Procedure for replacing the electronic speed controller.

ELECTRONIC SPEED CONTROL

SOLENOID REPLACEMENT

Steps for replacing the solenoid.

ELECTRICAL SYSTEM

AWG TO METRIC CONVERSIONS

Table for converting wire gauges to metric sizes.

VOLTAGE TEST FOR BATTERIES

Procedure for testing battery voltage.

MAIN HARNESS

Information regarding the main wire harness and power supply.

MOTOR

GENERAL

General information and warnings about the motor.

Motor Replacement

Steps for replacing the vehicle's motor.

MOTOR

Motor Tests

Information on motor testing procedures.

BATTERIES AND CHARGING

SAFETY

Important safety instructions for batteries and chargers.

BATTERY

Basic definition and characteristics of lead-acid batteries.

BATTERIES AND CHARGING

BATTERY MAINTENANCE

Detailed procedures for maintaining battery health and levels.

BATTERIES AND CHARGING

Cleaning Batteries

Proper methods for cleaning battery terminals and surfaces.

BATTERIES AND CHARGING

Battery Replacement

Step-by-step guide for replacing vehicle batteries.

Prolonged Storage

Guidelines for maintaining batteries during long storage periods.

BATTERIES AND CHARGING

Battery Charging

Instructions and precautions for charging the vehicle batteries.

FAULT DIAGNOSIS

Methods for diagnosing battery and charging system faults.

BATTERIES AND CHARGING

Hydrometer

Information on using a hydrometer to test battery state of charge.

BRAKES

BRAKE SYSTEM OVERVIEW

Description of the vehicle's rear drum brake system.

BRAKES

Automatic Adjuster Mechanism

How the automatic brake adjuster compensates for wear.

How the Park Brake Works

Explanation of the park brake's operation and release methods.

BRAKES

FAULT DIAGNOSIS FLOWCHART

Visual guide to diagnosing brake system problems.

BRAKES

FAULT DIAGNOSIS TABLE

Table correlating brake symptoms with causes and corrections.

BRAKES

FAULT DIAGNOSIS AND INSPECTION

Procedures for initial inspection and diagnosis of brake issues.

BRAKES

OPTIONAL FRONT HYDRAULIC BRAKES

Information on the optional front hydraulic brake system.

MASTER CYLINDER REPLACEMENT

Steps for replacing the master cylinder.

BRAKE MASTER CYLINDER FLUID

Procedures for checking and flushing brake fluid.

ROUTINE MAINTENANCE

Routine maintenance tasks for the brake system.

BLEEDING BRAKES

Procedure for bleeding air from the hydraulic brake system.

BRAKES

REPLACEMENT OF WEAR ITEMS

Guidelines for replacing brake system wear components.

Brake Pad Replacement

Steps for replacing worn brake pads.

BRAKES

Rotor Replacement

Procedure for replacing brake rotors.

Spindle Replacement

Steps for replacing the wheel spindle.

Actuator Linkage Bushings

Information on replacing actuator linkage bushings.

Actuator Pivot Bushings

Information on replacing actuator pivot bushings.

BRAKES

Brake Bleeding Procedure

Detailed instructions for bleeding the hydraulic brake system.

BRAKES

Adjusting Brake Pedal Free Travel

Procedure for adjusting brake pedal free travel.

BRAKES

Brake Drum Removal and Installation

Steps for removing and installing brake drums.

Wheel Brake Service

General procedures for servicing wheel brakes.

BRAKES

Backing Plate/Entire Wheel Brake Assembly Removal and Installation

Procedures for removing/installing backing plates or wheel brake assemblies.

BRAKES

Brake Shoe Removal

Steps for removing brake shoes.

BRAKES

Brake Shoe Installation

Steps for installing new brake shoes.

BRAKES

Brake Cable and Equalizer Assembly Removal and Installation

Procedures for replacing brake cables and equalizer.

Compensator Assembly, Removal and Installation

Steps for removing and installing the compensator assembly.

Brake Pedal Removal and Installation

Procedures for removing and installing the brake pedal.

BRAKES

Park Brake Catch Bracket Removal and Installation

Steps for replacing the park brake catch bracket.

Pedal Bumper Adjustment

Procedure for adjusting the brake pedal bumper.

BRAKES

Park Brake Release Linkage Removal and Replacement

Procedures for removing and replacing park brake release linkage.

Park Brake Kick-Off Cam Removal, Replacement and Installation

Steps for replacing the park brake kick-off cam.

BRAKES

OPTIONAL FRONT HYDRAULIC BRAKES

Information on the optional front hydraulic brake system.

BRAKES

BRAKE MASTER CYLINDER FLUID

Procedures for checking and flushing brake fluid.

REPLACEMENT OF WEAR ITEMS

Guidelines for replacing brake system wear components.

Brake Pad Replacement

Steps for replacing worn brake pads.

BRAKES

Rotor Replacement

Procedure for replacing brake rotors.

Spindle Replacement

Steps for replacing the wheel spindle.

Actuator Linkage Bushings

Information on replacing actuator linkage bushings.

Actuator Pivot Bushings

Information on replacing actuator pivot bushings.

BLEEDING BRAKES

Procedure for bleeding air from the hydraulic brake system.

BATTERY CHARGER

CHARGER DESCRIPTION

Description of the Delta Q automatic battery charger.

PORTABLE CHARGER OPTION

Information and safety for the portable charger option.

REAR SUSPENSION

REAR SUSPENSION

General overview of the rear suspension system.

Shock Absorber Removal

Steps for removing the rear shock absorbers.

Shock Absorber Installation

Procedures for installing rear shock absorbers.

Rear Spring Removal

Steps for removing the rear suspension springs.

REAR SUSPENSION

Rear Spring Installation

Procedures for installing rear suspension springs.

Rear Axle Assembly Removal

Steps for removing the rear axle assembly.

REAR SUSPENSION

Rear Axle Assembly Installation

Procedures for installing the rear axle assembly.

REAR AXLE

REAR AXLE MAINTENANCE

Maintenance requirements for the rear axle.

Checking the Lubricant Level

Procedure for checking and filling rear axle lubricant.

REAR AXLE DISASSEMBLY

General instructions and precautions for rear axle disassembly.

REAR AXLE

Axle Shaft Removal and Replacement

Steps for removing and replacing axle shafts.

REAR AXLE

Axle Shaft Replacement

Procedures for replacing the axle shaft.

GENERAL SPECIFICATIONS

PRODUCT OVERVIEW

Summary of key vehicle features and configurations.

PRODUCT SPECIFICATION

Detailed specifications of vehicle components.

Dimensions

Key physical dimensions of the vehicle.

GENERAL SPECIFICATIONS

VEHICLE DIMENSIONS

Visual representation of vehicle dimensions.

GENERAL SPECIFICATIONS

INCLINE AND TURNING CLEARANCE

Information on maximum allowable incline and turning radius.

HANDHELD DIAGNOSTICS

HOW TO USE THE HANDHELD PROGRAMMER

Guide on using the handheld programmer for diagnostics and setup.

HANDHELD DIAGNOSTICS

Navigation

How to navigate the handheld programmer menus.

Changing Data Value

Procedure for modifying parameter values.

Bookmark

Functionality for setting and jumping to menu positions.

HANDHELD DIAGNOSTICS

Program

Accessing vehicle profile settings and adjustments.

Monitor

Viewing vehicle real-time diagnostics and data.

Fault Counters

Monitoring and analyzing fault counter data.

HANDHELD DIAGNOSTICS

Faults

Accessing active and historical fault codes.

Functions

Uploading and downloading parameter settings.

Information

Viewing controller and handheld information.

HANDHELD DIAGNOSTICS

Programmer Setup

Configuring handheld programmer settings and display.

TROUBLESHOOTING

ELECTRICAL SYSTEM

Diagnosing common electrical system issues and faults.

TROUBLESHOOTING

SUSPENSION AND STEERING

Diagnosing and resolving suspension and steering problems.

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