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haulster - Jacobsen

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1. N Z Wi B B B Light r gt aca ais Bk NN Bk i Bk gt Bk Brake Y N Rd s Bu Bk Bu Bk Bu Bk Light A Ro Bk 33 Rd Bk Tail serge Jee Bn Tail Light Horn Horn Light Harness Button oo BES Bik 894314 Brake C Rd BEE ePk a Bk Ad Light 7 N Right Tail Light Cab Stop Og Bk Light Bk Accessory gt Brake P Wh Rd Accessory Bk Connector 1 gt Brake x OgBk e Accessory Bn Connector 2 Ld DCH Brake 15A Pedal Wh Rd Switch Jumper Wh Og c Og Bk e Bat Bu Bk Og Ye Bk gt Wh Bu Flasher Ye Rd Bk gt Og c e 15A Turn Signal vu Ye Rd Accessory L Og Bk Og E Gn Bk L gt L Main Harness to au SUP En Engine Harness Left Headlight 5 Connector 4 N Gas Units Low Beam y Pu Wh Bu Gn Bk d e PK Left Turn amp Bk A le E High B Signal Light 7 o en Accessory gt lt Low Beam Bk m e Right Turn gt Ye Bk pues Light gt Bk High Beam ccessory velgi A Right Headlight Wh Og 145 HAULSTER KIS duing Juge xa jan usum BEI g uM apoig u Pi er T PH UM plouajos
2. gt Change from previous revision 107 HAUL STER Serial No 84065 All 37 1 Diesel Electrical Components tem 8 Routing s s 2 ZA amp e 7 CE E ETTC 2 Engine Harne Ground Wires 108 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 450452 3 Nut M6 1 Hex Flange 2 452378 2 Screw M6 1 x 20 mm Hex Flange 3 2701465 1 Solenoid Starter 120052 2 s Lockwasher 10 132520 2 e Nut 10 32 Hex 306325 2 s Lockwasher 5 16 306932 2 e Nut 5 16 18 Hex 4 844167 1 Bracket Horn Brake Fluid Reservior 5 800943 15 Screw 10 16 x 3 4 in Thread Cutting 6 886425 1 Horn 7 800934 3 Screw M6 1 x 16 mm Hex Flange 8 894266 1 Harness Main See 48 1 9 843942 1 Socket 12V Accessory Plug 10 4152157 1 Panel Instrument with Tachometer 11 890000 1 Buzzer High Temperature Los Pa inside EES dash panel 12 831225 3 Clamp Wire Harness 13 306419 2 Screw 1 4 20 x 1 2 in Hex Head 14 306488 1 Lockwasher 1 4 External Tooth 15 828231 1 Insulator 16 548175 1 Flat Washer 1 4 17 4183304 1 Positive RED Battery Cable 18 4183301 1 Negative BLACK Battery Cable Battery to Transmission 19 306325 1 Lockwasher 5 16 20 450324 1 Nut M8 1 25 Hex 21 894602 1 Cable Ground Transmission to Right Frame Rail 22 450453 1 Nut M8 1 25 Hex Flange 23 452388 1 Screw M8 1 25 x 20 mm F
3. Change from previous revision 121 HAULSTER Serial No 84065 All 44 1 Transmission Clutch Release Shift Selector Diesel Engine Only 122 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 2701430 1 Transmission 4 Speed Diesel 2 09205 03019 1 Roll Pin 3 845223 1 Gasket Shift Case 4 2702659 3 s Screw M8 1 25 x 40 mm 5 01550 08553 1 Screw M8 1 25 x 55 mm 6 844228 1 Stop 5th Gear Lockout 7 548222 2 e Set Screw 8 32 8 2702684 Ile Plug Drain 9 11741 85200 1 s Support Transmission 10 2702475 4 Screw 11 37610 80023 Ile Switch Backup Light 12 09280 11002 Ile O Ring 13 23260 85203 1 Shaft Clutch Release 14 09300 14017 2 s Bushing Clutch Release 15 09448 20007 1 s Spring Clutch Release 16 23265 85200 1 s Bearing Clutch Release 17 REF Ile Shift Assembly See 47 1 REF 1 s Transmission Case See 45 1 gt Change from previous revision 123 HAUL STER 45 1 Transmission Case Diesel Engine Only Serial No 84065 All 124 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 24700 85200 1 Case Transmission Upper and Lower Half 2 2702690 2 Pin Alignment 3 09103 08131 4 Screw M8 1 25 x 120 mm Flange 4 2702470 3 s Screw M8 1 25 x 30 mm Flange 5 2702659 1 Screw M8 1 25 x 40 mm Flange 6 2702471 2 Screw M8 1 25 Flange 7 24741 83001
4. Engine Harness Connector Gas Only 2 Z Tal F Engine Harness Connector 3 4 Cab Stop Light E 6 5 Option BH E Flasher Jumper Plug Option Tail Light Harness Connector 1 Brake Accessor 4 y Turn Signal Option 2 Option 7 Brake Pedal ES euch em f Ignition Switch 7 E 11 Option e 4 Horn Button o Light Switch Clutch Pedal Switch Right Headlight Right Turn Signal Left Headlight Left Turn Signal Option 4 Brake Accessory Option 2 L Optional Accessories 130 Brake Fluid e a Reservoir 12 V Accessory Plug e Buzzer Dash Panel Ground 9 Wires O O Heater Option E Automatic Transmission Not Used Fuse Block 1 Fuse Block 2 von 282819 D JEREC HAULSTER Item Part No Qty Description Serial Number Notes 1 825973 3 Connecter Six Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge Single Wire 825961 AR Te
5. 242 6146 Weights Lbs 84005 trei tei ated debe ed ss 1690 84058 is ciae tue e rei 1561 84059 ride da eee te s 1503 84060 conia ue a e HERES 1661 SPECIFICATIONS 3 3 6 ACCESSORIES amp SUPPORT LITERATURE Contact your area Cushman Dealer for a complete listing of accessories and attachments Use of other than Cushman authorized parts excluding emission related components defined in the Emission Warranty and accessories may cause personal injury or damage to the equipment Flatbeds and Boxes Full Ton Sides and Tailgate 4111182G01 Tool BOX EE 887810 Hitches Pintle Hitch Requires 894779 2703513 Rear Tow Hitch Requires 894779 894780 ROPS Attachments Upper ROPS Roll Over Protective Structure 894761G01 Doors Left 8 Right Side Requires ROPS 36110G01 Outside Mirrors Left and Right 894768 Rear WIndOW sss sese seene 894758G01 Windshield with Wuer 894757G01 Roof Light Mounting Bracket 894777 Replacement Four Post ROPS 4205580 NOTE The four post ROPS equipped as standard equipment on this vehicle cannot be used with cab attachments If an enclosed cab is desired the four post ROPS must be replaced with Upper ROPS 894761 Truck Attachments Front Bumper cette tact itr tas 894778 Rear BUMPO wonne
6. 67 893544 41 43 893571 77 893581 117 893582 117 893583 58 113 893585 75 893586 75 893613 69 893632 43 45 47 893862 69 894066 83 894159 49 894167 55 894179 59 894201 103 894232 65 894266 109 8943068 55 57 894314 65 894348 79 894456 55 894471 99 894508 62 894573 71 894574 71 894581 67 894582 67 894584 62 894602 109 111 894635 73 894638 105 894922 103 894922G 103 894930 75 117 894931 75 117 894932 75 117 894933 75 117 894934 75 117 894935 75 117 894936 75 117 894998 7 67 85 87 895113 55 INDEX 151 World Class Quality Performance And Support Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations A worldwide dealer network and factory trained technicians backed by Genuine Jacobsen Parts provide reliable high quality product support gege A Textron Company When Performance Matters CUSHIVIAN JACOBSEN RANSOM ZS Jacobsen A Textron Company 11108 Quality Drive Charlotte NC 28273 www Ja
7. 131 135 889050 79 81 836426 117 840754 79 81 843561 49 889681 73 836428 121 841167 71 843562 49 889682 73 836431 119 841255 73 77 843563 49 889870 115 836440 121 841336 73 8435668 67 890000 109 111 836441 121 841404 73 843581 49 891829 113 115 836443 115 841428 39 843598 131 135 892164 62 836536 133 841429 71 843614 59 61 892228 77 836665 115 841430 75 117 843679 59 61 892676 65 836671 115 841477G01 39 843685 59 61 892921 55 836675 115 841630 71 843724 59 61 892933 57 836676 115 841637 39 843726 103 893145 67 836677 115 841663 49 843727 103 893145 7 67 836678 115 841715 39 843754 125 893233 71 836680 115 841737 71 843767 77 893234 71 836681 115 841738 71 843768 77 893266 71 836682 115 841753 39 843778 59 893322 41 43 150 893344 71 893375 14 41 43 893404 7 65 893404G 7 65 893519 117 893525
8. 121 111 825894 131 135 452389 67 83 85 550489 105 800944 117 825899 131 135 87 89 95 553020 95 800945 71 825961 133 452390 83 93 554663 69 8009468 83 825973 131 135 452391 53 558019 133 800949 83 825996 131 135 452392 81 83 600992 79 81 800973 115 825997 133 452394 105 600993 89 805837 117 825999 131 135 452395 79 81 89 601585 67 79 8067083 57 97 826000 131 135 452398 39 41 53 601591 79 81 806714 49 55 826005 133 55 67 75 601592 79 81 808060 77 826006 55 133 79 81 103 601596 79 808088 75 826190 135 452399 65 601596 81 809092 77 826191 135 452401 59 61 601937 41 43 809137 55 75 826584 133 149 INDEX 826590 63 105 836683 115 841799 45 47 843792 59 61 826726 131 135 836684 115 841839 75 843857 81 89 827182 53 836685 115 841841 75 843876 69 828231 109 111 836686 115 841842 55 75 843942 109 111 828382 39 8366
9. Inspect and adjust new belt after first 24 48 hours of operation Adjust every 200 hours thereafter Adjust alternator pulley so belt deflects 1 4 to 1 2 in 6 to 12 mm with a 20 Ib push at midpoint between water pump and alternator pulleys If tension is incorrect loosen alternator mounting bolts D and adjust alternator until proper belt tension is achieved 4 6 GAS ENGINE POWER STEERING ALTERNATOR BELT Inspect and adjust new belt after first 24 48 hours of operation Adjust every 200 hours thereafter Adjust power steering pump so belt deflects 1 4 to 1 2 in 6 to 12 mm with a 20 Ib push at midpoint between pulleys If tension is incorrect loosen power steering pump mounting bolts F and carefully pry pump away from the engine until proper belt tension is achieved 4 7 GAS ENGINE GOVERNOR BELT Inspect new belt after first 24 48 hours of operation Inspect every 200 hours thereafter Belt is dynamically adjusted with a spring loaded tensioner to 12 ft lbs No adjustment is required To remove belt rotate tensioner towards radiator to release tension and remove belt from pulleys 12 Figure 4H 4 8 PARKING BRAKE CABLE 1 ADJUSTMENTS 4 Remove the engine cover Put chocks in front of and behind at least two wheels at opposite corners of vehicle Engage parking brake If handle is at an angle greater than 45 to the panel adjustment is required D
10. 5 2 pints 2 5 Fluid Type SAE EP 80 90 gear lube To check differential fluid level remove the filler plug from the front of the differential Fluid should be level with the bottom of filler hole If fluid is low add gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug To change differential fluid remove drain plug from rear of differential Allow fluid to drain into a suitable container Dispose of used fluid properly according to federal state and local regulations Apply pipe thread sealer to drain plug and install Fill differential with gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug 5 21 DIESEL ENGINE MANUAL TRANSMISSION The transmission fluid should be checked every 100 hours or 3 months Fluid should be changed every 600 hours or yearly Differential Fluid Capacity 1 35 qts 1 3 I Fluid Type SAE EP 80 90 gear lube To check transmission fluid level remove the filler plug from the front of the transmission Fluid should be level with the bottom of filler hole If fluid is low add gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug To change fluid remove drain plug from rear of transmission Allow fluid to drain into a suitable container Dispose of used fluid properly according to federal state
11. 81 450455 45 65 67 523085 41 43 800695 121 820899 79 89 73 524358 137 800711 100 821071 49 450457 77 524633 49 800717 115 821164 59 93 97 450510 57 5246493 49 800737 121 821893 63 450541 89 41 43 548041 100 800743 117 822049 65 79 81 548061 69 800789 63 822819 51 450544 51 548079 71 800861 71 823549 39 77 450739 77 548155 91 800875 107 825204 105 452004 83 548159 39 8009068 75 117 825624 63 81 107 452006 107 548175 39 59 61 800909 67 69 825748 65 131 452378 49 51 79 65 109 800927 97 138 135 81 103 111 800930 39 45 47 825866 131 133 107 109 548222 123 55 103 825877 1338 111 548224 71 107 825878 65 131 452379 89 548325 99 800934 39 55 133 135 452388 41 43 53 548804 100 109 111 825884 79 83 55 57 79 548849 83 800937 65 825886 55 65 81 83 89 548910 51 95 800943 39 49 55 131 135 93 109 548911 49 77 109 825889 135 111 548952
12. Bk Gn Timing 207 gt ER Plug Gn Wh Gn Wh 208 5 SH 209 gt RN Di i iagnostic 210 Bk Rd Wh Plug 211 Bu Wh 212 213 Bk Wh 26 Pin 214 ECU gt Bk Wh Connector 215 Og Og 216 217 Shifter Switch 21g D Automatic Og Bu Transmission 219 Og Gn Og G 22029 g Gn P 221 Ad 8 Pk Bn Og Bu N 222 O C Bn Ye Wh Bk Gn D 223 EE O Bk Gn 224 Bu Gn Pk 26 Bk Rd 225 Gn Gn Bu 1 o Bn Ye Rd Rd 226 P y m Wh Bu Wh Pk O Pk ES Rd i gt Wh Ye 2 e 3 gt Bu Bk Wh Bk Wh Bu Rd 5 gt Bu Rd Engine 6 gt Harness 7 gt Bu Wh Bu Wh L 77 Connector 1 Bulk 8 I S Bu Bk Shift Solenoid 9 L 4 Automatic vin A e 10 gt Transmission 11 gt Bk Rd Bu 42 Ch Gn wh 138 HAULSTER Gn Bk Bk Wh B Rave Shifter Bk Wh e D Light U N 7 25A Bk Wh Bk Wh Wh Rd LG o Rd Bk E A 15 A Rd O Bn Ye Bn Ye g 10A Gn Wh Gn Wh b d Pr 10A Bk Rd Fan Wh Rd Motor Bu oT Ye Ye Bk Fan Me Rd Gn Relay Ra Gn d Bk Rd 7 Bk Gn Bk Gn OT PiBu pwBu Fuel Bk Fuel Pump pee Relay Bkwh L Pk Rd Wh Pk Wh Rd 7 BwRd Pk Main i Relay Wh Rd Bk Gn Wh Bk Wh Og Og Speedometer Wh Rd Signal Bk Rd Og c Bk Speed 7 Pk Sensor Wh Bk Gn
13. 4175883 Rev A ER By Jacobsen Parts amp Maintenance Manual Cushman Haulster With Four Post Roll Over Protective Structure CUSHMAN 84065 Kubota D1105 Diesel Engine Manual Transmission 84058 Suzuki K6 Gas Engine 5 Speed Manual Transmission 84059 Suzuki K6 Gas Engine Automatic Transmission 84060 Suzuki K6 Gas Engine RV and Utility JACOBSEN A Textron Company If incorrectly used this machine can cause severe injury Those who use and maintain this machine should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine When Performance Matters FOREWORD This manual contains adjustment maintenance troubleshooting instructions and parts list for your new Cushman vehicle This manual should be stored with the equipment for reference during operation Before you operate your machine you and each operator you employ should read the manual carefully in its entirety By following the safety operating and maintenance instructions you will prolong the life of your equipment and maintain its maximum efficiency If additional information is needed contact your Cushman Dealer Suggested Stocking Guide The serial plate is located on the frame rail under the steering wheel Cushman recommends you record these numbers below for easy reference JACOBSEN CHARLOTTE NC USA 1 800 848 1
14. adjust worn or damaged 3 Long hair jewelry or loose fitting clothing may get tangled in moving parts Be careful to prevent entrapment of the hands and fingers between moving and fixed components of the machine 4 Do not change governor settings or overspeed the engine 5 Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Never remove or install the engine cover while the engine is running The engine cover is a machinery guard and its removal exposes you to moving parts Keep hands hair and clothing away from flywheel radiator cooling fan alternator fan engine belts pulleys and air intake Keep clothing hands and hair away from moving parts These items could become entangled causing serious personal injury For servicing the engine and related components the engine cover can be tilted forward or removed To gain access to the engine unlock key lock if installed push the engine cover latch towards the rear of the unit and tilt cover forward When replacing the engine cover make sure the retaining tabs located at the front corners of the engine cover are inserted into the slots in the floorboard Tilt seat to the rear until the engine latch engages Lock key lock if equipped Failure to latch the seat properly can result in the engine cover tipping forward causing loss of control of the vehicle and possible personal injury 1
15. 1 4 3 450452 2 Nut M6 1 Hex Flange 4 450453 2 Nut M8 1 25 Hex Flange 5 REF 1 Decal Emmissions Gas Vehicles 6 893541 1 Handhold Right Side 7 450541 10 Screw M6 1 x 16 mm Pan Head 8 452388 2 Screw M8 1 25 x 20 mm Hex Flange 9 302288 8 Screw 1 4 20 x 1 in 10 523085 1 Latch Engine Cover 11 816401 1 Spring Torsion 12 830784 1 Clevis Pin 1 4 x 1 7 8 in 13 2702199 1 Catch Engine Latch 14 4139939 1 Insulation Engine Cover 15 893632 4 Mount Backrest See 3 1 or See 4 1 16 601937 2 Seat Base 17 893322 2 Backrest 18 893375 14 1 Cover Engine 19 845038 11 s Decal Operation 20 840436 1 Lock Engine Cover Optional Required in Europe 21 309488 2 Washer Optional Required in Europe Change from previous revision 43 HAULSTER 3 1 Upper ROPS Serial No All Optional Kit Console 44 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4205580 1 Four Post ROPS 2 1 Decal ROPS Warning 3 800547 HA Screw M10 1 25 x 20 mm Hex Head 4 452411 6 Screw M12 1 75 x 40 mm Flange 5 450455 3 Nut M12 1 75 Hex Flange 6 4140269 2 Seat Belt Assembly 7 N S lT 4 Screw 7 16 20 x 1 in Hex Head 8 N S 2 e e Flat Washer 7 16 9 N S 2 e Nut 7 16 20 Hex 10 841799 1 s Guard Seat Belt 11 800930 4 Screw M8 1 25 x 16 mm Flange 12 450453 4 Nut M8 1 25 Hex Flange 13 450401 1 Flat Washer M10 14 450412 1 Lock
16. 5 8 in Power Steering 9 452395 2 Screw M8 1 25 x 80 mm Flange 10 452388 5 Screw M8 1 25 x 20 mm Flange 11 450453 2 Nut M8 1 25 Flange 12 4173262 1 Ring Pressure Plate 13 4175560 1 Belt Alternator Power Steering 46 6 in 14 4174282 1 Bracket Alternator Adjusting 15 452402 1 Screw M10 1 5 x 50mm Flange 16 450454 1 Nut M10 1 5 Flange 17 361005 1 Screw M8 1 25 x 25 mm Hex Head 18 306325 3 Lockwasher 5 16 19 452379 3 Screw M6 1 x 25 mm Flange 20 09111 08035 2 Bolt M8 Special Included with Transmission 21 22100 85200 1 Cover Clutch Included with Transmission 22 22400 85141 1 Disc Clutch Included with Transmission 23 4174260 1 Reducer 3 8 NPSF to 1 8 BPT 24 843857 1 Temperature Sender 25 820899 2 Clamp Hose Used to protect hose from belt 26 4186780 1 Plate Spacer Located behind water pump pulley Change from previous revision 89 HAUL STER Serial No 84058 All Serial No 84059 All Serial No 84060 All 27 1 Suzuki Gas Engine 90 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 N S 1 Suzuki K6 Engine See Engine Parts Manual 2701908 1 Oil Filter 4140919 1 Belt Water Pump and Alternator 2 4120017 1 Right Side Engine Mount 3 4140905 3 Bolt Right Side Engine Mount 4 4120018 1 Left Side Engine Mount 5 2701827 4 Bolt Left Side Engine Mount 6 2702469 4 Bolt 7 830425 AR Fuel Hose 1 4
17. Bk Rd Bn Ye Wh Pk Pk Rd Bk Wh Reverse Switch Manual Transmission Bn Ye Rd Rd D dq bd Backup Alarm Bk 4 Wh Ye Wh Ye Bu Bu Gn Wh Gn Wh 139 HAULSTER Gn Bk Bk Wh Bk Wh Bk Wh Bk Wh Bk Wh Gn Bk Wh 20A Ye 10A Ye Rd Clutch Switch Manual Transmission Ye Rd 10A uaria on Pk Bu WO Rd Wh Gn o n 0199 e E Bk Bk Bk Bk Bk 10A us g a o D g a a 77 E S e S z I S Accessory Accessory Accessory Accessory Accessory Ignition EC Connector 1 Connector 2 Connector 3 Connector 4 Connector5 Switch ON B Br Start B l S oB oO c Rd Bn Wh Pk Pk Rd Wh Wh Engine Starter 1 Harness 4 9 Solenoid Tachometer lt Connector 2 Ra Wh Rd Gas Tach Input lt lt 2 Brake Fluid o o XX po po pog PO L Level Switch BK OY Wh Og L xx Brake Fluid Level lt lt 4 Rd Bk Rd Bk q Bk LI APA Voltmeter lt 77 4 bed Pre Heat lt U Gn Wh Xx Temp Gauge lt 8 Wh Ye Starter i 9 4 xx High Beam lt lt Wh Og i 10 4 xx Oil Pressure lt Bu 5 k Hre Fuel Sonder ent Og Og A M H3 Fuel Guage 4 xx Parking Brake gi Pk Bu P ibis XX
18. Fuel Pick Up Gas Vehicles Only 3 4166841 1 Elbow 90 1 4 Gas Vehicles Only 4 361117 2 Bushing Gas Vehicles Only 5 4170840 1 Rollover Valve Gas Vehicles Only 6 4168131 1 s Grommet Fuel Tank Gas Vehicles Only 7 4166840 1 Cap Unvented Fuel Ratchet Gas Vehicles Only 8 843298 1 Sender Fuel Level 9 829954 1 Gasket Fuel Tank 10 833953 1 Cover Fuel Sender 11 800021 5 Screw 10 32 x 1 2 in Pan Head 12 120052 5 Lockwasher 10 13 829787 2 Terminal 1 4 in Male 14 894201 1 Harness Fuel Sender 15 843078 1 Support Fuel Tank 16 452398 5 Screw M10 1 5 x 20 mm Flange 17 450454 1 Nut M10 1 5 Hex Flange 18 894922 1 Panel Fuel Tank 18 894922G 1 Panel Galvanized Fuel Tank Optional Galvanized Panel 19 800930 4 Screw M8 1 25 x 16 mm Flange 20 829997 2 Grommet 21 4174289 1 Bracket Fuel Filter Diesel Vehicles Only 22 452378 2 Screw M6 1 x 20 mm Flange Head Diesel Vehicles Only 23 450452 2 Nut M6 1 Hex Flange Diesel Vehicles Only 24 841969 1 Fuel Tank Diesel Vehicles Only 25 843726 1 Tube Fuel Pick Up Diesel Vehicles Only 26 843727 1 Elbow 90 Fuel Diesel Vehicles Only 27 84310 2 s Grommet Fuel Tank Diesel Vehicles Only 28 836852 1 Breather Diesel Vehicles Only 29 4179802 1 Cap Diesel Fuel Diesel Vehicles Only gt Change from previous revision 103 HAULSTER 35 1 Diesel Fuel System Serial No 84065 All Opie A XG LA I Q C Vor
19. Gas Fuel System 106 37 4 Diesel Electrical Components 108 38 1 Gas Electrical Components 110 39 1 Differential Assembly 112 40 1 Differential Housing 114 41 1 Axle Tubes and Shafts 116 42 1 Front Cover seet 118 43 1 Input Shaft sissi II ea 120 44 1 Transmission Clutch Release Shift Selector 122 45 1 Transmission Cases 124 46 1 Input and Main Shalt 126 47 1 Gear Shift Fork Linkage 128 48 1 Diesel Engine Main Harness 130 49 1 Diesel Engine and Fan Harness 132 50 1 Gas Main Harness 134 50 1 Gas Main Harness Continued 136 51 1 Gas Engine Electrical Schematic 138 52 1 Gas Engine Schematic 142 53 1 Diesel Engine Electrical Schematic 144 37 HAUL STER 1 1 Front Body Serial No All CUSHMAN 29 1 e em maa R D p 30 31 S 12 g j 8 s 38 HAULSTER Item Part No Qty
20. Horn amp Plug an Relay 18 Main QB Relay Relay Brake Fluid Reservoir Fue 134 Fuse Block 2 Fuse Block 3 A e e HAULSTER Item Part No Qty Description Serial Number Notes 1 825973 1 Connecter Six Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge Single Wire 825961 AR Terminal 1 4 in Male 10 Gauge Two Wire 2 829631 1 Connector Four Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 3 826726 2 Connector One Female Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 4 826005 12 Connector Two Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 5 825894 1 Connector Flasher 825889 AR Terminal 5 16 in Female 14 16 Gauge 6 2700913 1 Jumper Plug Taillight 827877 1 Connector Six Female Terminal 825748 AR Terminal 1 4 in Female 14 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 7 826006 3 Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 8 837296 1 Connector Ignition Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 857878 AR Terminal 1 4 in Female 10 Gauge Two Wire 9 843598 1 Connector Rocker Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wi
21. Item Part No Qty Description Serial Numbers Notes 1 2701210 1 Console 2 822819 1 Decal Parking Brake 3 2701817 7 1 Cover Upper ECU Gas Units Only 4 4147117 1 Controller EFI Engine Gas Units Manual Transmission 4 4147118 1 Controller EFI Engine Gas Units Automatic Transmission 5 2701105 7 1 Cover Lower ECU Gas Units Only 6 800026 4 Screw 1 4 20 x 3 4 in Pan Head Gas Units Only 7 548910 2 Nut 1 4 20 Serrated Flange Gas Units Only 8 450544 2 Screw M6 1 00 30 YS Gas Units Only 9 450452 2 Nut M6 1 00 Verbus Ripp G10 Gas Units Only 10 4149981 1 Bracket ECU MTG Gas Units Only 11 452378 2 Bolt M6 1 00 20 YS Gas Units Only gt Change from previous revision 51 HAULSTER 7 1 Parking Brake Serial No All ARIES us st 2 ees ka KS i S T d i i 1 s f er _ ee 52 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4202860 1 Lever Parking Brake 2 845134 1 Bracket Parking Brake Lever 3 452388 5 Screw M8 1 25 x 20 mm Flange 4 452391 1 Screw M8 1 25 x 40 mm Flange 5 450453 6 Nut M8 1 25 Flange 6 845133 1 Cable Parking Brake 7 450377 1 Nut M6 1 Staytite 8 827182 1 Pulley 3 in Cable 9 843359 1 Bushing Pulley 10 809152 2 Flat Washer 5 16 x 1 3 16 in 11 843356 1 Equalizer Parking Brake 12 800446 1 Locknut 5 16 24 13 843158 1 Bracket Parking Brake Cables 14 452398 2 Screw
22. Nut Isolation 17 833440 1 Cap Overflow Bottle 18 833512 2 Seal Radiator Foam 19 889050 1 Overflow Bottle 20 4175402 1 Screen Right Side 21 450453 3 Nut M8 1 25 Hex Flange 22 450454 2 Nut M10 1 5 Hex Flange 23 452388 2 Screw M8 1 25 x 20 mm Hex Flange 24 452395 1 Screw M8 1 25 x 80 mm Hex Flange 25 452398 2 Screw M10 1 5 x 20 mm Hex Flange 26 452405 2 Screw M10 1 5 x 80 mm Hex Flange 27 601585 1 Box Air See 15 1 for Mounting Hardware 28 800146 1 Screw 10 x 3 4 Thread Cutting 29 2700867 1 Relay 12V 70A 30 820889 6 Clamp Hose 31 11391G7 2 Clamp Hose 32 36092 G01 1 Hose 2 in x 16 in High Temp Air 33 4174820 1 Hose Upper Radiator 34 4174660 1 Hose Upper 35 4174563 1 Hose Lower Radiator 36 894348 1 Tube Fan Switch 37 17680 50F70 1 Switch Fan 38 825884 2 Clamp Hose 39 840754 1 Decal Radiator Pressure Warning 40 009034880 1 Decal Fan Warning 41 4179801 1 Harness Radiator Fan Wiring Not Shown See 49 1 42 4174321 1 Harness Kubota Engine Wiring Not Shown See 49 1 43 4140090 1 Foam 1 25 x 1 00 x 13 50 44 4179800 1 Harness Oil Cooler Fan Wiring Not Shown See 49 1 gt Change from previous revision 79 HAUL STER 22 1 Gas Radiator Serial No 84059 All Serial No 84060 All 80 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 7033 AR Tube 1 4 in LD Clear Vinyl
23. and add a SAE 20W motor oil until the oil begins to leak from the rear port Replace both plugs When replacing the plugs use Teflon tape or a Permatex 20 sealant or equivalent pipe thread sealant on the threads of the plug Torque the plugs to 95 10 in Ib 10 7x1Nm g E WM e Governor Oil Fill Plug K Governor Oil Level Check Plug Figure 5G 23 5 MAINTENANCE 5 19 HYDRAULIC BRAKES N WARNING Improper maintenance of the brake system may result in loss of vehicle control by the operator Losing control of the vehicle due to brake loss may cause injury to the operator or bystanders and vehicle damage This vehicle is equipped with four wheel hydraulic brakes controlled by the brake pedal and a hand operated parking brake lever Keep your brake system clean and properly maintained Do not operate the truck if the brakes do not stop vehicle properly The brake fluid master cylinder reservoir is located under the front cowl The fluid level in the master cylinder reservoir must be kept between the MIN minimum and MAX maximum marks Add DOT 3 type brake fluid as required If the brake fluid indicator light comes on and remains on check the fluid level in the reservoir Bleeding Hydraulic Brakes If the brakes do not hold properly if they feel spongy or if the brake fluid reservoir is allowed to run dry it may be required to bleed the system in order to remove air from
24. and local regulations Apply pipe thread sealer to drain plug and install Fill transmission with gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug Level Check And Fill Plug Figure 5L Drain Plug Figure 5M Transmission Drain Plug Figure 5N 25 5 MAINTENANCE 5 22 GAS ENGINE MANUAL TRANSMISSION The transmission fluid should be checked every 100 hours or 3 months Fluid should be changed every 600 hours or yearly Differential Fluid Capacity 1 3 qts 1 2 I Fluid Type SAE EP 80 90 gear lube To check transmission fluid level remove the filler plug from the front of the transmission Fluid should be level with the bottom of filler hole If fluid is low add gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug To change fluid rear of transmission remove drain plug from Allow fluid to drain into a suitable container Dispose of used fluid properly according to federal state and local regulations Apply pipe thread sealer to drain plug and install Fill transmission with gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug CHE Fill Plug Fii piug Figure 50 5 23 GAS ENGINE AUTOMATIC TRANSMISSION The transmission fluid should
25. gt P High B Signal Light Z a Ben Accessor y an Low Beam YY Bu AA Bk Right Turn gt Ye Bk 7 MSS Wh Signal Light Bk High Beam Accessory RA 77 Right Headlight O Wh Og ee 141 HAULSTER 52 1 Gas Engine Schematic Serial No 84058 All Serial No 84059 All Serial No 84060 All ECU Br Bk Br Bk 1 Bn Wh 2 gt Bn Wh 32 Gy DK 5 gt Ye Wh 6 gt Ye Bu 72 8 gt 9 BklBu 10 gt Bn Rd Bk 11 gt Rd Bk Rd 12 Rd Rd Ye 13 gt Rd Ye Rd Bu 14 gt Rd Bu Wh 15 Wh Bn Rd 16 gt Bn Rd r gt 23 18 gt Pk Wh Wh Rd 19 gt Wh Rd Wh Wh 20 Wh Bk 21 gt Wh Bk Gn W Bu Ye Bu Ye 22 gt Gn 23 LG Ye 24 gt Rd Bu Wire Shield Ignition Resistor Rd Bu 25 gt LG Rd U 26 gt LG Rd LG Ye 27 gt Bu Bk 28 gt Bu Wh 29 gt 30 gt LG Bk Gn Bk Gy Ye Intake Air Temperature Bu Ye LG Rd AW LG Rd ANY Pressure Sensor Bu Ye Gy Ye 31 32 gt LG Wh 33 gt 34 gt Bu Ye Throttle Sensor Bu Ye A Bu Ye Engine Harness Connector 1 Engine Harness Connector 2 1 Ye Wh pk YXY ay Temperature Sender Ye Bk eT 77 Oil Press
26. 1 Retainer Input Shaft Bearing 8 09103 08152 8 Screw M8 1 25 x 25 mm Flange 9 09380 28007 1 Cir CLip 10 09262 28019 1 Bearing Front 11 24131 83002 1 Counter Shaft 12 09262 28020 1 Bearing Center 13 24671 83000 1 Gear Countershaft Reverse 14 REF 1 Input and Main Shaft See 46 1 15 09283 25088 1 Seal Oil 16 09390 68002 1 C Ring 17 09390 62010 1 C Ring 18 24560 83001 1 Gear Reverse Idle 19 24551 83010 1 Shaft Reverse Idle Gear 20 09261 06003 1 Pin 21 2702586 1 Cir Clip 22 09103 08132 3 Screw M8 1 25 x 100 mm Flange 23 01550 08353 5 Screw M8 1 25 Flange 24 2702659 4 Screw M8 1 25 x 40 mm Flange 25 01421 08303 1 Stud M8 1 25 26 2703002 1 Nut M8 1 25 Hex Flange 27 2702690 2 Pin Alignment 28 24770 85252 1 Case Extension 29 26131 85201 1 Gear Speedometer Driven 30 29431 85400 1 Case Seepometer Gear 31 09282 08001 1 Seal Oil 32 09280 19001 1 O Ring 33 09280 21014 1 O Ring 34 843754 1 Plug 35 09128 06032 1 Bolt Retaining 36 09166 16014 1 Washer 37 28391 85202 1 Bracket Shift Cables 38 2702662 1 Plug Inspection Timing 39 24780 83010 1 Seal Extension Case gt Change from previous revision 125 HAULSTER 46 1 Input and Main Shaft Serial No 84065 All 126 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 24110 80410 1 Shaft
27. 1 Tube Front Brake 24 4194421 1 Tube Rear Brake 25 842103 1 Union M10 1 26 4194420 1 Tube Rear Brake Line 27 809137 1 Clip Brake Line 28 832587 1 Rear Brake Hose See 39 1 29 810435 2 Clamp Brake Tube 30 450454 1 Nut M10 1 5 Flange 31 844167 1 Bracket Reservoir Horn See 37 1 32 841842 1 Tee M10 1 0 Flare Union See 19 1 33 812445 1 Clamp Tube 34 800943 1 Screw 10 14 x 5 8 in Self Tapping gt Change from previous revision 55 HAUL STER Serial No 84065 All Serial No 84058 All Serial No 84060 All 9 1 Clutch Pedal Linkage View Rotated 90 Degrees for Clarity Cable View Rotated 90 Degrees for Clarity Diesel Units Gas Units 56 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 892933 1 Pedal Clutch 2 840726 1 Bearing Brake Pivot 3 844611 1 Spring Torsion 4 840725 1 Tube Pedal Pivot 5 842935 1 Tab Locking 6 452388 1 Screw M8 1 25 x 20 mm Flange 7 450453 1 Nut M8 1 25 Flange 8 894308 1 Switch Clutch Micro 9 450510 2 Screw M3 0 5 x 20 mm Pan Head 10 452424 2 Nut M3 0 5 Flange 11 4192281 1 Cable Clutch Diesel Units 11 4154481 1 Cable Clutch Gas Units 12 844202 2 Washer Slotted 13 806703 1 Clevis Pin 5 16 x 31 32 14 306328 1 Cotter Pin 3 32 x 3 4 15 810152 1 Pad Pedal 16 842010 1 Bushing Clutch Release Arm Diesel Units Only 17 833273 1 B
28. 10 Foot Length Cut to 12 in 2 7162 AR Hose Radiator Overflow 3 300646 2 Screw 1 4 20 x 3 4 in Hex Head 4 306396 2 Lockwasher 1 4 5 308090 2 Flat Washer 1 4 6 450452 4 Nut M6 1 Hex Flange 7 450541 4 Screw M6 1 x 16 mm Hex Flange 8 452378 4 Screw M6 1 x 20 mm Hex Flange 9 4115033 1 Fan 13 in Radiator 10 600992 1 Panel Shroud 11 601591 1 Frame Radiator 12 601592 1 Radiator 13 888549 1 Connector Hose 14 845224 1 Cap 1 4 x 1 in 15 800177 4 Screw 5 16 18 x 3 4 in 16 831846 4 Nut Isolation 17 833440 1 Cap Overflow Bottle 18 833512 2 Seal Radiator Foam 19 889050 1 Overflow Bottle 20 4175402 1 Screen Right Side 21 450453 3 Nut M8 1 25 Hex Flange 22 843857 1 Sender Temperature 23 452388 2 Screw M8 1 25 x 20 mm Hex Flange 24 452395 1 Screw M8 1 25 x 80 mm Hex Flange 25 452398 2 Screw M10 1 5 x 20 mm Hex Flange 26 548827 2 Screw 1 4 20 x 1 2 in Hex Flange 27 548910 2 Nut 1 4 20 Hex Flange 28 2701442 1 Housing Temperature Sender 29 2701513 1 Gasket Thermostat 30 820889 4 Clamp Hose 31 2701108 2 Clamp Hose 32 36092G01 1 Hose 2 in x 16 in High Temp Air 33 825624 1 Clamp 1 4 to 5 8 in Worm Drive 34 4139442 1 Hose Upper 35 4115400 1 Hose Lower Radiator 36 833715 1 Plug Tube 37 452392 2 Screw M8 1 25 x 50 mm Flange 38 009034880 1 Decal Fan Warning 39 840754 1 Decal Radiator Pressure Warning 40 11391G7 3 Clamp
29. 129 25415 83000 129 25420 85201 129 25451 85261 129 25520 85203 129 25530 79501 129 25535 85412 129 25536 84200 129 25541 85201 129 25545 85055 129 25546 60C01 129 25547 70D00 129 25576 70D00 129 26121 85202 127 26131 85201 125 2700166 107 2700174 107 2700176 107 2700177 107 2700275 49 2700334 97 2700335 97 2700380 137 2700381 137 2700384 137 2700385 137 2700386 137 2700387 137 2700470 137 2700496 49 59 61 2701693 7 67 2701697 7 67 85 87 2701737 7 55 2701817 7 51 2701850 7 49 2701953 129 2702012 49 2702014 49 2702198 39 2702199 41 43 2702215 55 2702217 75 2702244 97 99 2702247 75 2702249 97 2702471 125 2702475 123 2702484 85 87 2702494 129 2702501 101 2702502 101 2702559 127 2702561 127 2702586 125 2702659 128 125 2702662 125 2702684 123 2702686 85 87 2703506 7 117 2703507 7 117 2703931 7 59 61 2703951 59 61 2703956 7 59 147 2703964 7 59 61 28391 85202 125 29165G01 49 29431 85400 125 300646 79 81 300977 59 61 302030 62 302288 41 43 97 99 302944 73 303269 73 83
30. 217 0 210 284 8 5 16 24 in Ibs Nm 240 27 1 300 33 9 3 4 10 ft lbs Nm 170 230 5 220 298 3 3 8 16 ft lbs Nm 30 40 7 40 54 2 3 4 16 ft lbs Nm 175 237 3 225 305 1 3 8 24 ft lbs Nm 35 47 5 45 61 0 7 8 14 ftlbs Nm 300 406 8 400 542 4 SIZE UNITS gt Non Critical e c Aluminum M4 m in Ibs 2 11 1 7 15 9 26 1 36 5 0 44 2 0 18 M5 m in Ibs 5 22 3 2 28 8 51 8 1 72 9 7 86 4 0 35 M6 m in Ibs 4 3 38 5 7 50 9 9 88 14 0 124 16 5 146 6 8 60 M8 m in Ibs 10 5 93 13 6 120 24 4 216 33 9 300 40 7 360 17 0 150 M10 m ft lbs 21 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 M12 m ft lbs 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 m ft lbs 58 3 43 76 4 55 131 5 97 184 4 136 219 7 162 94 9 70 14 5 1 GENERAL MAINTENANCE 5 Before you clean adjust or repair this equipment depress clutch pedal and shift transmission to Neutral engage parking brake stop engine and remove key from ignition switch to prevent injuries Make sure the vehicle is parked on a solid and level surface Never work on a vehicle that is supported only by a jack Always use jack stands 1 Adjustment and maintenance should always be performed by a qualified technician If proper adjustments cannot be made contact an Authorized Cushman Dealer 2 Ins
31. 4118027 1 Air Filter 840352 1 Element Alr Filter 18 4139211 1 Hose Engine Air Intake 19 4140617 1 Grommet 20 4140618 1 Sensor Air Temp 21 11391G7 2 Clamp 2 3 4 in Worm Drive 22 4118423 1 Elbow 1 4 NPT Street 23 4118422 1 Hose Fitting 1 4 NPT Brass 24 2702484 1 Clamp 25 894998 7 1 Left Engine Mount See 15 1 26 2701697 7 1 Right Engine Mount See 15 1 27 4179803 1 Transmission Mount See 15 1 28 452405 3 Screw M10 1 5 x 80 mm Flange 29 450454 3 Nut M10 1 5 Hex Flange 30 4138391 1 Switch Reverse 31 4148082 1 O Ring 32 4142772 1 Bracket Cable Mount gt Change from previous revision 85 HAULSTER 25 1 Gas Engine and AT Mounting Serial No 84059 All 86 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Engine Assembly See 27 1 2 4148212 1 Automatic Transmission 3 4140900 1 Plate Transmission Housing 4 4148213 1 Torque Converter 5 4120097 1 Plate Drive 6 4148065 6 Screw M8 1 25 x 9 5 mm Flange 7 2702688 2 Stud M10 1 25 x 65 mm 8 2702686 1 Screw M10 1 25 x 55 mm Flange 9 2702756 1 Screw M10 1 25 x 50 mm Flange 10 2702690 2 Alignment Pins 11 4148361 1 Starter Automatic Transmission 12 2702470 2 Screw M8 1 25 x 30 mm Hex Flange 13 2702689 2 Nut M10 1 25 Hex Flange 14 842915 1 Bracket Air Filter 15 452389 2 Screw M8 1 25 x 25 mm Hex Flange 16 450453 2 Nut M8 1 25 Hex Flange 17 4
32. 8 16 Hex Jam 14 548804 2 Nut 3 8 16 Whizlock 15 548041 2 e Screw 3 8 16 x 1 Flat Socket Head 16 306981 1 Flat Washer 3 8 17 800711 1 Screw 3 8 16 x 1 3 4 Hex Flange 18 N S 1 Plate Tensioner 100 gt Change from previous revision 33 1 Gas Engine Exhaust HAULSTER Serial No 84058 All Serial No 84059 All Serial No 84060 All Item Part No Qty Description Serial Numbers Notes 1 4142914 1 Muffler 2 4144338 1 Catalytic Converter 3 2702502 2 Bolt Muffler Flange 4 2702501 2 Spring Muffler Flange 5 838295 8 1 Strap Muffler Hanger 6 450193 2 Screw M8 1 25 x 30 mm Hex Head 7 450378 2 Locknut M8 1 25 8 4150237 1 Bracket Muffler Attaches to Transmission Case 9 841982 1 Clamp 1 1 2 in Exhaust 10 306419 4 Screw 1 4 20 x 1 2 in Hex Head 11 306396 4 Lockwasher 1 4 12 4148153 1 Ring Muffler Flange 13 4121517 8 1 Shield Muffler 14 306450 4 Screw 5 16 18 x 3 4 in Hex Head 15 306325 6 Lockwasher 5 16 16 103867 4 Flat Washer 5 16 17 4144336 2 Shield Catalytic Converter gt Change from previous revision 101 HAUL STER 34 1 Fuel Tank Serial No All 102 2 lt 9 LS E Diesel Vehicles Right Frame Rail HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4166842 1 Fuel Tank Gas Vehicles Only 2 843726 1 Tube
33. 89 95 303952 39 304632 100 304636 73 75 117 305134 73 306320 97 306322 115 119 306325 89 95 97 101 109 111 306328 41 43 49 55 57 306372 97 306375 62 97 306396 59 61 79 81 97 99 101 306397 59 61 306405 117 306419 39 101 109 111 306450 101 306468 39 306488 39 109 111 306506 99 306562 83 306799 77 306825 73 306829 115 306836 83 306839 71 306915 99 306932 109 111 306981 83 97 100 119 306982 115 307776 119 308008 73 308089 97 308090 41 43 59 61 79 81 97 148 INDEX 4140072 4140075 4140090 4140269 4140431 4140617 4140618 4140899 4141031 4141037 4141425 4142186 4142627 4142630 4142772 4166084 4166085 4166086 4166840 4166841 4166842 4168131 4168143 4170802 4170840 4172648 INDEX 450391 65 452409 65 89 603102 99 809152 53 450393 71 4524096 67 79 85 604174 59 61 809156 65 450398 65 87 7033 79 81 809174 83 450400 39 452406 67 tel sess sa 79 81 809180 67 69 121 450401 45 4524068 73 17
34. 9 303269 3 Lockwasher 7 16 10 889681 2 End Left Hand Thread Tie Rod 11 816586 1 Retainer Grease 12 306825 1 Nut 7 16 20 Castle 13 889682 2 End Right Hand Thread Tie Rod 14 816586 1 s Retainer Grease 15 306825 1 Nut 7 16 20 Castle 16 304636 4 Cotter Pin 1 8 x 1 1 8 in 17 831405 4 Grease Fitting 18 841404 2 Tie Rod 19 800485 2 Nut 9 16 18 Left Hand Thread Jam 20 302944 2 Nut 9 16 18 Right Hand Thread Jam 21 813850 2 Bumper Travel Limiting 22 842033 1 Plate Skid 23 452408 6 Screw M10 1 75 x 20 mm Grade 10 9 gt Change from previous revision 73 HAUL STER Serial No All 19 1 Front Brakes Hose Clamp Location MTN E u ah N ALI 7 LEE a SN MER N 1 pods x N 74 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 2702257 7 2 Front Hub 2 808088 1 s Outer Bearing Cup 3 814474 1 Inner Bearing Cup 4 800908 4 Bolt M12 1 5 x 42 mm Wheel 5 385174 2 Outer Bearing Cone 6 815403 2 Inner Bearing Cone 7 817928 2 Seal Grease 8 2702247 2 Nut 3 4 16 Castle 9 304636 2 Cotter Pin 1 8 x 1 1 8 in 10 817250 2 Cap Grease 11 841430 2 Brake Drum 12 893585 1 Front Left Side Brake Assembly 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 Ile Kit Brake Cylinder Repair Repair of Cylinder 894932 Ile Kit Brake Shoe Includes Left and Right sides 894933 Ile Kit Left Si
35. Description Serial Numbers Notes 1 2700792 1 Front Clip Includes decals 821071 amp 840901 2 800930 2 Screw M8 1 25 x 16 mm Hex Flange 3 548159 4 Flat Washer 5 16 x 1 1 4 in 4 450400 2 Washer M8 5 4207160 1 Hood Orange 6 4208620 1 s Weather Seal 7 841477G01 1 Hinge Hood 8 841637 1 Angle Front Clip Mounting 9 450541 7 Screw M6 1 x 16 mm Round Head 10 452695 6 M6 1 00 20 HW Taptite 11 841913 2 Plate Access 12 800934 20 Screw M6 1 x 16 mm Hex Flange 13 4139691 2 Flap Mud 14 548175 8 Flat Washer 1 4 x 1 1 4 in 15 800943 8 Screw 10 14 Self Tapping 16 837303 2 Headlight Rectangular 17 841428 2 Bezel Headlight 18 828382 AR Seal Foam 19 452398 4 Screw M8 1 25 x 25 mm Hex Head 20 2702198 1 Latch Hood 21 841715 1 Rod Hood Release 22 303952 1 Flat Washer 10 23 306463 1 Cotter Pin 1 16 x 1 2 in 24 841753 1 Bracket Hood Latch 25 306419 2 Screw 1 4 20 x 1 2 in Hex Head 26 306488 2 Lockwasher 1 4 in Shakeproof 27 2703158 1 Decal Fuses Diesel Engine 27 4117221 1 Decal Fuses Gas Engine 28 844293 3 Plug Panel Not Used on 84060 29 844430 1 Decal Cushman 30 844428 1 Decal Left Side Turf Haulster 31 844429 1 Decal Right Side Turf Haulster 32 38541 1 Tube Clear Document 33 38061A 2 Cap Vinyl 34 840508 2 Mount Cable Tie 35 800344 2 Screw 10 Type AB Self Tapping 36 823549 2 Cable Tie 15 1 2 in Change from previous revisio
36. Hose 41 4140090 2 Foam 42 601596 1 Fan Shroud Included with engine See engine parts catalog for service gt Change from previous revision 81 Serial No 84065 All 23 1 Diesel Engine and Transmission Mounting HAULSTER Q7 N gt DIAS la X Ce 82 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Engine and Clutch See 26 1 2 4192125 1 Frame Engine Mount 3 REF 1 Mount Engine See 14 1 Left shown right similar 4 306836 2 Screw 3 8 16 x 2 1 4 in Hex Head 5 306981 6 Flat Washer 3 8 6 841885 2 Mount Engine Isolation 7 809174 2 Washer Isolator 8 120177 4 Lockwasher 3 8 9 306562 2 Nut 3 8 16 Hex 10 452388 6 Screw M8 1 25 x 20 mm Flange 11 450453 14 Nut M8 1 25 Flange 12 452389 13 Screw M8 1 25 x 25 mm Flange 13 4174620 1 Hose Intake 14 3001965 1 Air Filter 5000919 1 Element Air Filter 5000920 1 Cover 5000921 1 Valve 15 3001388 1 Bracket Air Filter 16 4174285 1 Bracket Air Filter Mount 17 452390 3 Screw M8 1 25 x 30 mm Flange 18 450412 2 Lockwasher M10 19 800571 1 Nut M10 1 25 Hex 20 4191140 1 Bracket Muffler 21 11391G7 2 Clamp Hose 22 894066 1 Transmission Assembly MT5 Includes Clutch Disc and Cover 23 11741 85200 1 e Support Transmission 24 08310 00103 1 Nut 25 11710 77100 Ile Bracket Rear Mount 26 800547 4 Bolt M10 1 25 x 20mm Hex Head 27 4523
37. M10 1 5 x 20 mm Flange 15 450454 2 Nut M10 1 5 Flange 16 893583 2 Parking Brake Cables See 39 1 gt Change from previous revision 53 HAULSTER OO O 8 1 Brake Pedal Serial No All Route both hoses through opening in front clip Pedal Mounting View Rotated 90 Degrees for Clarity Route front brake w tube through opening in front clip 28 32 Route rear brake tube under floor 30 access panel 22 Left Frame Rail Tube Routing 54 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 2701737 7 1 Bracket Master Cylinder 2 892921 1 Pedal Brake 3 840726 1 Bearing Brake Pivot 4 840725 1 Tube Brake Pivot 5 842935 1 Tab Locking 6 452388 2 Screw M8 1 25 x 20 mm Flange 7 450453 2 Nut M8 1 25 Flange 8 895113 1 Master Cylinder 9 800930 2 Screw M8 1 25 x 16 mm Flange 10 894167 1 Rod Brake 11 806714 1 Clevis Pin 5 16 x 15 16 in 12 103867 1 Flat Washer 5 16 13 306328 1 Cotter Pin 3 32 x 3 4 in 14 894456 1 Reservoir Brake Fluid 2702215 1 Reservior 826006 1 s Electrical Connector 2 Wire 825886 2 e Terminal 1 4 L Male 15 800934 2 Screw M6 1 x 16 mm Flange 16 830930 4 Clamp Hose 17 4194500 2 Hose 5 16 x 18 in Brake 18 810152 1 Pad Pedal 19 894308 1 Switch Brake Micro 20 450410 2 Screw M3 0 5 x 20 mm Pan Head 21 452424 2 Nut M3 0 5 Hex 22 452398 7 Screw M10 1 5 x 20 mm Flange 23 843021
38. Shaft High Speed Fork 3rd and 4th Gear 3 25451 85261 1 Shaft Reverse Fork Reverse 4 06111 12004 5 Ball 5 25415 83000 3 Spring Detent 6 09261 03017 1 Roller 7 25211 85201 1 Fork Low Gear Shift 1st and 2nd Gear 8 25221 85202 1 Fork High Gear Shift 3rd and 4th Gear 9 25221 83002 1 Fork Reverse Gear Shift Reverse 10 09205 05012 3 Pin 4x 25 mm Spring 11 09250 10006 1 Plug Locating 12 25121 85051 1 Case Gear Shift Lever 13 25520 85203 1 Shaft Grear Shift Lever 14 09284 17004 1 Seal Oil 15 25576 70D00 1 Spring 16 09160 17035 1 Washer 17 x 32 x 1 2 mm 17 25541 85201 1 Lever Gear Select 18 25545 85055 1 Dog Reverse Shift Limit 19 25546 60C01 1 Spring 20 09128 10002 1 Bolt M10 x 9 mm Retaining 21 09168 10007 1 Gasket 22 25547 70D00 1 Spring 23 09135 08005 1 Ball 24 2701953 1 Pin 25 25530 79501 1 Shaft Gear Select 26 09286 09001 1 Seal Oil 27 25535 85412 1 Arm Gear Select 28 09162 08008 1 Washer 29 2702883 1 Washer 30 2702494 1 Nut M8 1 25 Hex 31 25536 84200 1 Boot Gear Select 32 09135 08005 1 Bolt Retaining 33 24821 09001 1 Plug Breather gt Change from previous revision 129 HAULSTER 48 1 Diesel Engine Main Harness Part Number 894266 B Engine Harness Connector 2 g Engine Harness Connector 1 Serial No 84065 All fral
39. for any reason the vehicle needs to be towed follow the procedures below 1 If towing the vehicle with a tow rope or chain an operator is required to steer the vehicle and to control the brakes 2 Attach a tow rope only to the front vertical frame member on either side of the vehicle 3 Shift transmission into Neutral and release parking brake 5 18 GOVERNOR OIL LEVEL 4 Slowly drive towing vehicle forward until tow line is pulled tight 5 While towing try to keep the tow line taut at all times Be careful going down inclines and turning corners Tow Line Attachment A Front Bumper Accessory Part No 894778 is available for use with this vehicle If a Front Bumper is mounted to your vehicle make sure to follow the instructions included with the bumper for proper connection of the chain or tow rope Figure 5F Suzuki Gas Engine only Check the oil level in the governor every 100 hours of use To check the level remove the plug from the back side of the governor Oil level should be up to the level of the plug opening Governor Oil Capacity 1 5 oz 44 ml OilType SAE 20W engine oil If oil level is low add the recommended oil type Remove the plug from the rear of the governor remove the plug from the top of the governor
40. fuel system Keep tires properly inflated to prolong tire life Check inflation pressure while the tires are cool Inspect tread wear Lower pressure will help avoid leaving tire marks in soft turf Higher pressures may be required for heavier loads Rear tire pressure must be set at 28 psi 1 93 BAR when operating with a full load Never exceed the maximum pressure indicated on the tire Check the pressure with an accurate low pressure tire gauge Due to the low volume of air needed over inflation may be reached in a matter of two to three seconds Keep tires inflated to Front 50 psi 3 44 BAR Rear 50 psi 3 44 BAR 21 5 MAINTENANCE 5 15 TIRE REMOVAL AND INSTALLATION Removal 1 Park the vehicle on a flat and level surface Apply parking brake turn the ignition switch to the OFF position and shift transmission to 1st gear or Park 2 Refer to Section 5 16 for proper lifting procedures Always use jack stands Never rely only on a jack for support Raise the vehicle only enough to remove the tire Never place feet hands or any part of your body under the vehicle when raising it 3 Remove the wheel retaining nuts and remove wheel and tire assembly from the hub 4 Perform required service on tire 5 16 RAISING THE VEHICLE Unless you have the proper training tools and experience DO NOT attempt to mount a tire on a rim Improper mounting can produce an explosion which may result in ser
41. in 102 mm Add a 50 50 antifreeze water mixture if required 18 Drain and refill cooling system every 400 hours or 9 months whichever comes first Allow system to cool before draining a Remove the cooling fan fuse b Remove the radiator cap c Open the engine block drain and the radiator drain Remove lower radiator hose Close both drains and install lower radiator hose once system has completely drained Empty and clean the recovery bottle Fill radiator to the bottom of the filler neck with 50 50 antifreeze water mixture f Fill recovery bottle to full mark with 50 50 antifreeze water mixture Keep radiator air passages clean Use compressed air 30 psi maximum to clean the fins Water left between the fins will collect dirt and reduce the amount of air flow to properly cool the engine To provide proper air flow do not obstruct the air intake screen on the right side of the vehicle Keep screen clean Replace clamps and hoses every two years If you have to add coolant more than once a month or add more than one quart at a time have a authorized Cushman Dealer check the cooling system 5 8 AIR FILTER MAINTENANCE 5 Do not remove the element for inspection or cleaning Unnecessary removal of the filter increases the risk of injecting dust or other impurities into the engine When service is required first clean the outside of the filter housing Remove the old element as gently as possible a
42. terminals and cable ends to prevent corrosion Keep vent caps and terminal covers in place Keep the top of the battery clean and free of corrosion by washing battery with a solution of baking soda and water Rinse with clean water Verify battery polarity before connecting or disconnecting the battery cables 5 11 CHARGING BATTERY When installing the battery always assemble the Positive RED battery cable first and the Negative BLACK battery cable last When removing the battery always remove the Negative BLACK battery cable first and Positive RED battery cable last Make sure battery is properly installed and secured to the battery tray Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash your hands after handling Charge battery in a well ventilated area Batteries generate explosive gases To prevent an explosion keep any device that may create sparks or flames away from the battery To prevent injury stand away from battery when the charger is turned on A damaged battery could explode 1 Refer to Section 5 10 Read the battery s and charger s manuals for specific instructions 2 Whenever possible remove the battery from the vehicle before charging If battery is not sealed check that the electrolyte covers the plates in all the cells Battery cabl
43. the brake lines 1 Bleed the brakes in the following order Left Rear Right Rear Right Front and Left Front 2 Attach a hose to the bleeder screw and place the other end of the hose in a container to catch fluid from brake when bleeding the system 3 Bleed brake a Have an assistant push down on the brake pedal and hold the pedal down b Loosen the bleeder screw allowing fluid to flow c Tighten the bleeder screw d Have assistant release pedal NOTE Do Not release brake pedal until the bleeder screw is tightened or air will be sucked back into the brake lines e Repeat Steps a through d as required until all air bubbles are purged from the system and a steady flow of fluid comes from the brake line f Periodically check fluid level in reservoir Do not allow the reservoir to fully empty or bleeding procedure will need to be repeated 24 4 Repeat Step 3 for each brake 5 Most communities have a disposal system for DOT 3 brake fluid Please dispose of fluids properly ME Brake Fluid EE Reservoir KS Li Brake Fluid Lever Indic ator Light U 7 m 099008 Figure 5J Ib Bleeder er Screw s Figure 5K 5 20 DIFFERENTIAL FLUID MAINTENANCE 5 The differential fluid should be checked every 100 hours or 3 months Fluid should be changed after the first 100 hours and every 600 hours or yearly thereafter Differential Fluid Capacity
44. tighten hose clamps Figure 5D Before attempting to jump start the vehicle check the condition of the discharged battery Engage parking brake of both vehicles shift transmission to Neutral and turn off all electrical loads Batteries generate explosive hydrogen gas To reduce the chance of an explosion avoid creating sparks near battery Always connect the Negative BLACK jumper cable to the frame of the vehicle with the discharged battery away from the battery When connecting jumper cables 1 Stop the engine on the vehicle with the good battery 2 Connect RED jumper cable to the Positive terminal on the good battery and to the Positive terminal on the discharged battery 3 Connect the BLACK jumper cable from the Negative terminal on the good battery and to the frame of the vehicle with the discharged battery After cables have been connected start the engine on the vehicle with the good battery and then start the vehicle with the discharged battery 19 5 MAINTENANCE 5 10 BATTERY Make absolutely certain the ignition switch is OFF and the key has been removed before servicing the battery Always use insulated tools wear protective glasses or goggles and protective clothing when working with batteries You must read and obey all battery manufacturer s instructions Tighten cables securely to battery terminals and apply a light coat of silicone dielectric grease to
45. 0 iz x x P Ra Figure 4A Kee Si Retaining Tab LIN x In Slot On Floor board Figure 4B 4 3 FRONT COWL ACCESS ADJUSTMENTS The front cowl opens to gain access to two access panels fuse panel horn and master cylinder reservoir To open the front cowl locate the release lever at the upper left corner of front clip near the left side headlight Pull the lever toward the headlight to release the front cowl latch and at the same time pull up on the front cowl Fully open the cowl and allow it to rest on the steering wheel or upper ROPS structure if installed The front cowl will not spring up when the release lever is pulled and so must be lifted manually 4 4 ACCESS PANELS Pull Lever To Release Cowl Latch There are two access panels located under the front cowl and one located in the middle of the floorboard Remove panel A under cowl to access the shifter linkage and wiring for the instrument panel Remove panel B under cowl to access the front suspension Remove the center panel C in the middle of floorboard to access the throttle cable accelerator pedal linkage wire harness and rear hydraulic brake line NOTE It will be necessary to remove the accelerator pedal in order to completely remove the center floorboard panel Figure 4D Figure 4E 11 4 ADJUSTMENTS 4 5 DIESEL ENGINE ALTERNATOR BELT
46. 0 32 Special 20 2702244 2 Nut 4410 32 Hex 21 800024 1 Screw 1 4 20 x 1 1 2 in Truss Head 22 306375 3 Nut 1 4 20 Hex 23 2703684 1 Throttle Cable See 4 1 24 308089 1 Flat Washer M6 25 821164 2 Hair Pin 1 4 x 1 1 8 in 26 818395 1 Clevis Pin 1 4 x 1 2 in 27 302288 1 Screw 1 4 20 x 1 in 28 306372 1 Cotter Pin 3 32 x 1 2 in 29 4139209 1 Cable Throttle 30 2701510 1 Bracket Throttle Cable 31 843013 1 Pulley Governor 32 800927 1 Shoulder Bolt 1 4 20 x 5 8 in 33 REF 2 Bolt Part of Engine 34 831586 1 Ball Joint 35 306320 3 Nut 5 16 24 Hex 36 4139210 1 Rod Governor 37 810722 1 Yoke 38 806703 1 Clevis Pin 5 16 x 31 32 in 39 103867 1 Flat Washer 5 16 40 306325 1 Lockwasher 5 16 Special 41 2702249 1 Woodruff Key 12 x 50 PS gt Change from previous revision 97 HAULSTER 31 1 Governor Serial No 84059 All Serial No 84060 All 98 HAULSTER Item Part No Qty Description Serial Numbers Notes 4141425 1 Governor 1 111812 1 s Yoke Spool 2 111814 1 Washer Thrust 3 111816 1 s Washer Thrust A 111817 1 s Spool Governor 5 112840 1 Bearing Thrust 6 130728 1 e Nut 1 4 20 Hex Jam 7 111813 1 Seal Shaft 8 160410 1 Carrier 8 Weights 9 302288 2 Screw 1 4 20 x 1 in Hex Head 10 306396 2 s Lockwasher 1 4 11 306506 2 s Lockwasher 6 12 306915 2 Screw 6 32 x 5 16 in Machine 13 603102 1 Roll Pin 1
47. 022 10 Clamp Hose 3 4166086 1 Hose Adapter to Pump 7 16 in Cut to 3 in 4 4166085 1 Hose Pump to Fuel Filter 5 16 in 10 Foot Roll Cut to 9 in 5 4166085 1 Hose Fuel Filter to Tee 1 4 in 10 Foot Roll Cut to 4 1 4 in 6 4166085 1 Hose Tee to Engine 1 4 in 10 Foot Roll Cut to 29 in 7 4113019 1 Adapter 5 16 to 7 16 in Hose 8 4113022 4 Clamp Hose 9 2700174 1 Pump Electric Fuel 10 2700176 1 Fuel Filter 11 2700177 1 Regulator Fuel 12 452378 2 Screw M6 1 x 20 mm Hex Flange 13 450452 2 Nut M6 1 Hex Flange 14 800930 2 Screw M8 1 25 x 16 mm Hex Flange 15 450453 2 Nut M8 1 25 Hex Flange 16 800875 1 Nut M12 1 25 Hex 17 309067 1 Lockwasher 1 2 in External Tooth 18 REF 1 Bracket Fuel System See 15 1 19 REF 1 Grommet See 34 1 20 21 4166084 1 Hose Rollover Valve to Canister 10 Foot Roll Cut to 27 in 22 4166084 1 Hose Tank Return to Regulator 10 Foot Roll Cut to 20 in 23 825624 6 Clamp Hose 24 7326 1 Hose Regulator to Tee 6Foot Roll Cut to 2 in 25 2700166 1 Clamp Filter 26 4113020 1 Adapter 5 16 in Tee 27 7301 1 Flex Guard Cut to 5 in 28 830930 2 Hose Clamp 29 4168143 1 Adapter 5 32 in Tee 30 7326 Hose Tee to Engine Cut to 20 in 31 4170802 1 Canister Carbon 32 4172648 1 Bracket Canister Mtg 33 452006 2 Washer Flat 5 16 in 34 400108 2 Screw 5 16 18 x 1 35 7326 1 Hose Tee to Canister Cut to 14 in 36 18292 G1 1 Clamp
48. 1 300977 1 Screw 1 4 28 x 5 8 in Hex Head 22 306396 1 Lockwasher 1 4 23 2702996 1 Boot Control Lever 24 2702695 1 Knob Shifter 25 548175 3 Flat Washer 1 4 x 1 1 4 in 26 308090 1 Flat Washer 1 4 27 843778 1 Connector Shift Cable 28 2703707 1 Connector Shift Cable 29 103867 2 Flat Washer 5 16 30 821164 2 Hair Pin 31 2703964 7 1 Panel Right Side Dash 32 843792 1 Plate Shifter Boot 33 452692 2 Screw M6 1 x 12 mm Self Tap 34 2700496 4 Insert 1 4 20 Threaded 35 2703931 7 1 Ring Boot Hold Down 36 452695 4 Screw M6 1 x 20 mm Self Tap gt Change from previous revision 59 HAUL STER Serial No 84058 All Serial No 84060 All 11 1 Manual Transmission Shifter Linkage Gas Units Gas Unit Cable Attachment Shifter Mounting and Cable Routing View Rotated 90 Degrees for Clarity 60 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4146819 1 Retaining Ring M6 2 4142630 1 Mount Shifter 3 4142627 1 Selector Gear 4 842773 1 Rod End 1 2 20 5 308091 1 Flat Washer 1 2 6 311763 1 Screw 1 2 20 x 2 1 4 in Hex Head 7 843679 1 Plate Wear 8 452692 2 Screw M6 1 x 12 mm Self Tap 9 604174 1 Flat Washer 3 8 in 10 843614 1 Spring Torsion 11 843685 1 Bushing Spring 12 2703951 1 Tab Locating 13 452401 1 Screw M10 1 5 x 40 mm Flange 14 450454 1 Nut M10 1 5 Flange 15 2701273
49. 118027 1 Air Filter 840352 1 Element Alr Filter 18 4139210 1 Hose Engine Air Intake 19 4140617 1 Grommet 20 4140618 1 Sensor Air Temp 21 11391G7 2 Clamp 2 3 4 in Worm Drive 22 4118423 1 Elbow 1 4 NPT Street 23 4118422 1 Hose Fitting 1 4 NPT Brass 24 2702484 1 Clamp 25 894998 7 1 Left Engine Mount See 15 1 26 2701697 7 1 Right Engine Mount See 15 1 27 4179803 1 Transmission Mount See 15 1 28 452405 3 Screw M10 1 5 x 80 mm Flange 29 450454 3 Nut M10 1 5 Hex Flange 30 4120098 1 Plate Rear Drive 31 4120096 1 Flange Drive Plate 32 4119955 6 Screw M10 1 25 x 18 5 mm gt Change from previous revision 87 HAUL STER 26 1 Diesel Engine and Clutch a yes VAD N Ds T N du zs A E Sg Za EOL N W A lt EU br 1 W OAL We Vue ee eet A CR p A lt IS SS DA Le SC IRRE j VAN SY J SE ASS E A CAD AN ES ZNA N Zt d II s d 88 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4173201 1 Engine Kubota D1105 E3B 4113986 1 s Engine Oil Filter 4183623 1 Alternator 2 4174440 1 Mount Right Side Engine 3 800547 8 Screw M10 1 25 x 20 mm Flange 4 303269 8 Lockwasher 7 16 5 103867 1 Flat Washer 5 16 6 452389 9 Screw M8 1 25 x 25 mm Flange 7 REF 1 Pump Power Steering See 19 1 8 600993 1 Pulley
50. 16 836892 5 Fuse 10 Amp 16 842983 2 Fuse 15 Amp 16 826000 1 Fuse 20 Amp Change from previous revision 131 HAULSTER 49 1 Diesel Engine and Fan Harness erial No 84065 Part Numbers 4174321 4179800 and 4179801 Starter OO N UTP Oil Pressure Switch amp AD Ground Wires 2 Parking Brake e Glow Plug Starter Solenoid Fuel Solenoid 2 Fuel Shutoff a Relay 6 Engine Harness Connector 1 RH Engine Harness Connector 2 Diod Engine Harness iode H Connectors Connector 3 E 2 1 e je 2 3 15 Fuel Fuel Level Pump Sender 10 Diodes 4 4 D E E Fan Relay E Fuse 15 2 Ground Pre Heat 19 7 LZ Relay 16 E Fan U 0 e Relay 17 11 16 EZ Glow Plug e Fuse Fan Motor EM L Starter 9 Fan Radiator Fan Switch Motor Fuse 18 ke Oil Cooler Fan Motor Fuse Temperature v Sender 4 d E 7 Ground Starter Oil Cooler Alternator Solenoid Fan Motor 19 Radiator Fan Oil Cooler Fan Harness Harness 132 HAULSTER Item Part No Qty Description Serial Numbers Notes 4174321 1 Engine Harne
51. 1846 79 81 838295 8 95 101 842966 138 135 844988 47 832584 113 838340 63 842983 131 133 845038 41 43 832587 55 113 838427 65 135 845133 53 833056 99 838463 133 137 843013 97 845134 53 833101 99 838539 117 843021 55 845223 123 833103 99 838602 83 843078 103 845224 81 833104 99 838768 137 84310 103 845327 137 833257 133 137 838769 137 843158 53 845328 137 833273 57 838770 137 843167 111 133 845329 137 833345 99 839917 137 843168 133 135 845330 137 833366 99 839921 137 843238 69 845345 7 62 833440 79 81 840017 77 8432968 103 845356 117 833512 79 81 840222 77 843356 53 884398 133 833715 81 840352 85 87 843359 538 884513 111 833953 103 840436 41 43 843418 75 886425 109 111 835271 97 99 840508 39 843537 99 887259 77 836420 121 840725 55 57 843550 131 135 888549 81 836423 121 840726 55 57 843551
52. 2 Cable Shifter 16 842774 2 Ball Joint 1 4 28 17 816307 1 Flat Washer 1 4 18 306397 1 Nut 1 4 28 Hex 19 843724 2 Clamp Cable 20 452695 4 Screw M6 1 x 20 mm Self Tap 21 300977 1 Screw 1 4 28 x 5 8 in Hex Head 22 306396 1 Lockwasher 1 4 23 308090 1 Flat Washer 1 4 24 4146818 1 Retaining Ring M5 25 2702696 1 Boot Control Lever 26 4140431 1 Knob Shifter 27 548175 3 Flat Washer 1 4 x 1 1 4 in 28 308090 1 Flat Washer 1 4 29 4142796 1 Connector Shift Cable 30 2703964 7 1 Panel Right Side Dash 31 843792 1 Plate Shifter Boot 32 452692 2 Screw M6 1 x 12 mm Self Tap 33 2700496 4 Insert 1 4 20 Threaded 34 2703931 7 1 Ring Boot Hold Down 35 452695 4 Screw M6 1 x 20 mm Self Tap 36 2701371 1 Connector Shift Cable 37 800582 4 Screw 1 4 20 x 3 4 in Truss Head Change from previous revision 61 HAULSTER 12 1 Automatic Transmission Shifter en Item Part No Qty Description Serial Numbers Notes 1 103867 2 Flat Washer 5 16 2 302030 1 Screw 1 4 20 x 1 1 4 in 3 306375 1 Nut 1 4 20 Hex 4 306396 1 Lockwasher 1 4 5 800582 4 Screw 1 4 20 x 3 4 in 6 821164 2 Hair Pin 1 4 x 1 1 8 in 7 842740 1 Lever Shifter 8 845345 7 1 Bracket Shifter Cable Mount 9 894584 1 Shifter with Cable 10 894508 1 s Cable Shifter 11 892164 1 s Kit Cable Mounting Hardware 12 2700496 4 Insert 1 4 20 gt Change from previo
53. 2 28019 125 09262 28020 125 09262 30086 127 09263 30031 127 09263 35015 127 09280 11002 123 09280 19001 125 09280 21014 125 09282 08001 125 09283 25088 125 09284 17004 129 09286 09001 129 09300 14017 123 09300 30003 127 09380 28007 125 127 09390 62010 125 09390 68002 125 09448 20007 123 103867 55 57 59 89 93 95 97 101 111074 115 119 111758 115 111812 99 111813 99 111814 99 111816 99 111817 99 111838 77 111893 97 99 INDEX 112050 113 112840 99 11391G7 79 81 83 85 11657G3 67 69 11710 77100 83 11741 85200 83 123 120052 103 109 111 120177 83 95 130728 97 99 132520 109 111 160410 99 17680 50F70 79 18292 G1 107 22100 85200 89 22400 85141 89 23260 85203 123 23265 85200 123 23266 85002 57 24110 80410 127 24121 85252 127 24131 83002 125 24211 83011 127 24220 60A01 127 24230 83001 127 24400 83000 127 24410 83000 127 24420 83000 127 24431 83001 127 24432 83001 127 24436 83000 127 24441 85F41 127 24442 81A20 127 24471 60A00 127 24473 70D10 127 24551 83010 125 24560 83001 125 24671 83000 125 24681 83000 127 24700 85200 125 24741 83001 125 24770 85252 125 24780 83010 125 24821 09001 129 25121 85051 129 25211 85201 129 25221 83002 129 25221 85202 129 25411 85201
54. 20 443102 4 Nut 1 4 20 Hex 21 4179161 1 Muffler 22 4174560 1 Tube Exhaust Inlet 23 4190700 1 Fitting Straight 24 452389 4 Screw M8 1 25 x 25 mm Flange 25 838295 8 1 Strap Muffler Hanger 26 450193 2 Screw M8 1 25 x 30 mm Hex Head 27 450378 2 Locknut M8 1 25 28 REF 1 Bracket Muffler See 23 1 841982 2 Clamp 1 1 2 in Exhaust 29 N S 1 U Bolt 30 N S 1 s Bracket 31 N S 2 e Nut 5 16 18 Hex 32 103867 2 Flat Washer 5 16 33 REF 1 Cover Starter Hole See 23 1 34 REF 1 Left Side Screen See 14 1 gt Change from previous revision 95 HAUL STER Serial No 84058 All Serial No 84059 All Serial No 84060 All 30 1 Governor Linkage 96 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4139208 1 Plate Governor 2 4141031 2 Bolt Intake Manifold Included with Engine 3 306396 1 Lockwasher 1 4 4 308090 1 Flat Washer 1 4 5 845224 2 Plug Tube 6 825624 2 Clamp 1 4 in to 5 8 in Worm Drive 7 4144145 1 Plug 3 8 x 1 in Tube 8 2700540 1 Lever Governor 9 2700859 1 Lever Governor Arm 10 01116G01 1 Screw M10 1 5 x 40 mm Hex Flange 11 830140 2 Ball Bearing 12 306981 5 Flat Washer 3 8 13 450454 1 Nut M10 1 5 Hex Flange 14 2701129 1 Arm Throttle 15 835271 1 Nut Governor 16 130728 3 Nut 1 4 20 Hex Jam 17 2700335 1 Spring Governor 18 2700334 1 Spring Governor 19 111893 1 Screw 1
55. 23 32 7 306322 1 Screw 5 16 18 x 7 8 in Hex Head 8 306982 Ale Flat Washer 7 16 9 517226 2 Bushing 10 800973 1 Nut 3 4 16 Hex Lock 11 836443 1 Rear Cover 12 836665 Ile Top Cover 13 814476 1 s Cup Bearing 2 17 32 in O D 14 836680 1 Cone Bearing 1 1 8 in I D 15 836688 AR gt Shim 003 Thick 16 836689 AR Shim 005 Thick Add or remove shims as required to 17 836690 AR Shim 010 Thick adjust gear backlash 18 836691 AR gt Shim 030 Thick 19 836692 1 s Baffle Oil 20 836685 AR gt Shim 003 Thick i 21 836686 AR Shim 005 Thick Add or remove shims as required to i adjust gear backlash 22 836687 AR Shim 010 Thick 23 836677 1 Cup Bearing 2 84 in O D 24 836678 1 Cone Bearing 1 3 8 in I D 889870 1 Gear Set 25 N S Ile Pinion Gear and Shaft 26 N S 1 Ring Gear 27 N S 1 Differential Carrier 28 800717 10 Screw 3 8 24 x 13 16 Hex Head 29 836675 2 Cup Bearing 2 89 in O D 30 836676 2 Cone Bearing 1 5 8 in I D 31 836681 AR gt Shim 003 Thick 32 836682 AR Shim 005 Thick Add or remove shims as required to 33 836683 AR Shim 010 Thick adjust gear backlash 34 836684 AR gt Shim 030 Thick 35 836671 1 Gasket Top Cover 36 306322 14 Screw 5 16 18 x 7 8 in Hex Head 37 306325 6 Lockwasher 5 16 gt Change from previous revision 115 HAULSTER 41 1 Axle Tubes and Shafts Serial N
56. 301 s 107 809231 63 450410 55 452410 67 tr saa 107 810152 55 57 450412 45 83 452411 45 47 800017 95 810435 55 119 450452 41 43 49 452413 73 800021 103 810437 67 75 119 51 65 79 452444 65 800024 97 810722 97 81 93 452415 67 800026 51 65 812335 121 108 107 452424 55 57 800146 79 812445 55 109 111 452692 59 61 75 800177 79 81 813850 69 73 450453 41 43 45 452695 39 49 57 800198 69 814474 75 53 55 57 59 61 800227 99 119 814476 115 67 77 79 452738 93 800344 39 815403 75 81 83 85 4600930 71 800446 53 816307 59 61 87 89 93 471221 71 800485 73 816401 41 43 105 107 48540 01 95 800547 45 83 89 816586 73 109 111 5000919 83 93 95 817250 75 450454 41 53 55 5000920 83 800558 99 817928 75 59 61 65 5000921 83 800559 121 818395 97 67 79 85 5001947 105 800571 83 819923 77 87 89 97 515268 49 800582 49 59 61 820008 113 103 517226 115 800602 69 820889
57. 4 843767 1 Hose Power Steering Pressure 15 111838 2 e O Ring 16 843768 1 Hose Power Steering Return 17 111838 1 O Ring 18 840222 1 Hose Formed 19 830930 2 Clamp Hose 20 450739 1 Screw M10 1 5 x 30 mm Socket 21 800943 1 Screw 10 14 x 5 8 in Self Tapping 22 809092 2 Clamp Tube 23 320107 3 Cable Tie 7 1 2 in Secure hoses together 24 823549 4 Cable Tie 15 1 2 in Secure hoses to frame See 26 1 or 27 1 for mounting Ser vice parts for pump are available at 25 892534 1 Power Steering Pump with Reservior ee Pai with a 3 8 liter V6 Engine Saginaw Pump 26025515 26 2700573 1 Cap Steering Reservior gt Change from previous revision 77 HAUL STER 21 1 Diesel Radiator Serial No 84065 All 78 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 843862 AR Tube 1 4 in LD Clear Vinyl 10 Foot Length Cut to 12 in 2 835805 AR Hose Radiator Overflow 3 300646 2 Screw 1 4 20 x 3 4 in Hex Head 4 306396 2 Lockwasher 1 4 5 308090 2 Flat Washer 1 4 6 450452 6 Nut M6 1 Hex Flange 7 450541 4 Screw M6 1 x 16 mm Hex Flange 8 452378 6 Screw M6 1 x 20 mm Hex Flange 9 4176887 1 Fan 12 in Hi Perf Puller 10 600992 1 Panel Shroud 11 601591 1 Frame Radiator 12 601592 1 Radiator 13 601595 1 Plate Blockoff 14 4177253 1 Shroud 12 in Fan 15 800177 4 Screw 5 16 18 x 3 4 in 16 831846 4
58. 4139793 1 Rim 10 00 x 7 in Five Bolt 3 94 in Bolt Circle N S 1 Tire 20 5 x 8 00 10 USA Trail Obtain Locally 11657G3 1 s Valve Stem 12 311398 6 Screw 1 2 13 x 3 1 2 in Hex Head 13 800602 6 Nut 1 2 13 Nylon Insert 14 843876 4 Shackle Rear Spring 15 843238 2 Bushing Nylatron 16 829045 2 U Bolt 2 1 2 in 17 4174288 1 Driveshaft Complete Diesel Engine 17 4144334 1 Driveshaft Complete Gas Engine MT 17 4140071 1 Driveshaft Complete Gas Engine AT 18 4174287 1 s Shaft Drive Diesel Engine 18 4144345 1 s Shaft Drive Gas Engine MT 18 4140067 1 s Shaft Drive Gas Engine AT 19 554663 2 e Cross and Bearing Kit Includes Grease Fitting 20 4140069 1 s Yoke Differential 21 4140075 1 Yoke Transmission Diesel Engine 21 4140072 Ile Yoke Transmission Gas Engine Change from previous revision 69 HAUL STER 17 1 Front Control Arms Serial No All G E q N CR 23 EN GX 2 70 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4120138 1 Frame 4 Wheel Steering 2 893266 2 Upper Control Arm 3 893233 1 Left Side Lower Control Arm 4 893234 1 Right Side Lower Control Arm 5 844148 2 Upper Ball Joint 6 N S 1 s Boot 7 N S 1 s Boot Retainer 8 N S 4 Screw 5 16 24 x 1 in Hex Head Black Oxide Finish Grade 8 9 N S 4 e Lockwasher 5 16 Black Oxide Finish 10 548079 4 Nut 5 16 24 Hex Black Oxid
59. 636 Jacobsen com MODEL 84043 DATE CODE M1903 LABEL A 75984655 Lb kg W Batt SERIAL 2128855 Nom Power Hp kw CE To Keep your equipment fully operational and productive Cushman suggests you maintain a stock of the more commonly used maintenance items We have also included part numbers for additional support materials and training aids To order any of the following material 1 Write your full name and complete address on your order form 2 Explain where and how to make shipment C Overnight Q 2nd Day 3 Order by the quantity desired the part number and the description of the part 4 Send or bring the order to your authorized Cushman Q UPS Q Regular Mail Dealer Service Parts Qty Part No Description Qty Part No Description 4113986 Diesel Engine Oil Filter 550489 Diesel Engine Fuel Filter Element 4175560 Diesel Alternator Power Steering Belt 2701908 Gas Engine Oil Filter 2701898 Gas Engine Fuel Filter 4139265 Gas Alternator Power Steering Belt 5000919 Diesel Engine Air Filter Element 840352 Gas Engine Air Filter Element Service Support Material Aty Part No Description Qty Part No Description 4175882 Safety 8 Operation Manual 4171642 MT Truck Service Manual 4175883 Parts 8 Maintenance 4171675 AT Truck Service Manual 4160162 Kubota D1105 Engine Parts Manual 4171985 Suzuki KGA Service Manual 4140632 Suzuki K6A Engine Parts M
60. 8 x 3 4 in 14 548325 1 s Ring Retaining 15 800227 2 Plug 1 8 NPT 16 800558 1 Set Screw 3 8 16 x 5 16 in 17 833056 1 Gasket Governor 18 4189960 1 Seal Oil 19 835271 1 e Nut Governor Arm 20 843537 1 s Bracket Governor Knee 21 4114867 1 s Head Governor 22 894471 1 e Reservior Governor 23 833103 1 s Bearing Needle 24 4119678 1 Shaft Governor Complete 25 833104 1 s Ring Retaining 26 833345 Ile Bearing Ball 27 4115584 1 Ring Support 28 2700525 1 Lever Governor Control 29 306396 2 Lockwasher 1 4 30 833101 1 Spring Extension 31 833366 1 Bracket Governor Spring 32 111893 1 Screw 10 32 Special 33 2702244 2 Nut 10 32 Hex 34 00414G5 2 Screw Hex Head gt Change from previous revision 99 HAULSTER 32 1 Gas Engine Remote Oil Fill Serial No 84058 All Serial No 84059 All Serial No 84060 All Item Part No Qty Description Serial Numbers Notes 1 4188041 1 Bracket Valve Cover 2 548971 2 Screw 5 16 18 x 5 8 Hex Flange 3 4148202 1 Cap Oil FIII Included with Engine 4 843420 1 O Ring 5 843399 1 Adapter Valve Cover 6 836206 2 Clamp 1 7 8 Worm Drive 7 4139271 1 Hose Remote Oil Fill 8 2701640 1 Adapter Oil Cap 9 4117892 4 Screw M6 1 x 16 mm Hex Flange 10 800425 2 Screw M6 1 x 12 mm Hex Head 11 306396 2 Lockwasher 1 4 12 4188387 1 Bracket Governor See 27 1 13 304632 2 Nut 3
61. 87 115 8418696 49 843997 49 828590 77 836688 115 841885 83 844148 71 828629 131 135 836689 115 841913 39 844156 65 829044 69 836690 115 841969 103 844167 55 109 829045 69 836691 115 841982 95 101 111 829630 65 133 836692 115 842010 57 844202 57 829631 65 135 83669 121 842030 41 844223 49 829787 103 836694 117 842033 73 844224 49 829954 103 836695 117 842103 55 844228 123 829997 103 836852 103 119 842104 75 844298 39 830140 97 836892 131 135 842740 62 844428 39 830366 49 836959 119 842773 59 61 844429 39 830784 41 43 49 837295 49 842774 59 61 844430 39 830930 55 77 107 837296 131 135 842870 67 844601 67 831039 105 837298 49 842915 85 87 844611 57 831225 109 111 837301 131 135 842935 55 57 844647G01 67 831405 73 837303 39 842959 133 844813 117 831586 97 838154 105 842961 83 844847 65 83
62. 88 4 Screw M8 1 25 x 20mm Hex Flange 28 4173062 1 Adapter Transmission 29 838602 2 Screw M10 1 25 x 50 mm Flange 30 452392 2 Screw M8 1 25 x 60 mm Flange 31 303269 6 Lockwasher 5 16 32 800949 1 Screw M10 1 25 x 50 mm Flange 33 800948 1 Screw M10 1 25 x 35 mm Flange 34 842961 2 Sleeve Alignment 35 4174286 1 Cover Starter Hole 36 548849 2 Screw 3 8 16 x 4 3 4 in Hex Head 37 4174281 1 Mount Transmission See 14 1 38 400184 2 Screw 5 16 18 x 3 4 in Hex Head 39 4174200 1 Mount Hydraulic Pump 40 825884 1 Clamp 41 400108 1 Screw 1 4 20 x 3 4 Hex Head 41 452004 1 Flat Washer 1 4 Change from previous revision 83 HAULSTER 24 1 Gas Engine and MT Mounting Serial No 84060 All 84 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Engine Assembly See 27 1 2 N S 1 Manual Transmission Order with engine 3 4140899 1 Plate Clutch Housing 4 2702548 1 Clutch Disc 5 4117900 1 Pressure Plate 6 2702547 6 Screw M8 1 25 x 16 mm Lockwasher 7 2702688 2 Stud M10 1 25 x 65 mm 8 2702687 1 Screw M10 1 25 x 75 mm Flange 9 2702686 1 Screw M10 1 25 x 55 mm Flange 10 2702690 2 Alignment Pins 11 4148360 1 Starter Manual Transmission 12 2702470 2 Screw M8 1 25 x 30 mm Hex Flange 13 2702689 2 Nut M10 1 25 Hex Flange 14 842915 1 Bracket Air Filter 15 452389 2 Screw M8 1 25 x 25 mm Hex Flange 16 450453 2 Nut M8 1 25 Hex Flange 17
63. A s6nid apoig apoid e jan P woe ml Den tom te T O 39 A d uy Z 1 pu s Rejoy nd 1e H 1d PH plouajos Aejay jeune Pu 4oinus n4 Ny sg uo Bo SES youms 1 1 og ueJ L ss na vzg d Enid 1olsis u _ youms RF LU ES Og eJnssaJd IO yapua ngid o E A ve T dual YOUMS ZN a um g ayeig Bum ed PH pu A 1oleui 1lV od S PH sed g sl gl 2 k SI ss z s z e p N VV NZ SseuJeu UEL JojeipeJ y Jo ped 218 ui pexeui SAM 107994409 SseuJeH UIN Z 101994409 ssouJleH VIEW L 1ol5 uuoo SseuJeH UN sseuJeu UEL 191009 Io eui Jo Wed 218 YIM pey ew SEIM pR ae A Oo o 94g uM V SL A A Ve aj AA UM ASUM lt oIg uM V Or Wh Bk S Wh Bk Aa ps Agiau UB JOJBIPEH ug 1O1O N uey JOJBIPEH PH DVG Ald O Aejay UB 13 009 110 x J010lN ueJ 191009 IIO PH 146 00414 G5 99 009034880 79 81 01116 G01 97 01421 08303 125 01550 08353 57 125 01550 08553 123 06111 06003 127 06111 12004 129 08310 00103 83 09103 08131 125 09103 08132 125 09103 08152 125 09111 08035 89 09128 06032 125 09128 10002 129 09135 08005 129 09160 17035 129 09162 08008 129 09166 16014 125 09166 30007 127 09168 10007 129 09205 03019 123 09205 05012 129 09250 10006 129 09261 03017 129 09261 06003 125 0926
64. Causes Action Engine will not start 1 Clutch pedal not depressed 1 Check startup procedure 2 Battery low on charge or 2 Inspect condition of battery and battery defective connections 3 Fuel tank empty or dirty Fuel 3 Fill with fresh fuel Change fuel filter Bleed fuel shut off valve closed lines Open fuel shut off valve 4 Fuse blown 4 Replace fuse Engine hard to start or 1 Fuel level low Fuel or fuel filter 1 Fill with fresh fuel Change fuel filter Bleed fuel runs poorly dirty lines 2 Air cleaner dirty 2 Inspect and replace air filter 3 Injectors fuel pump 3 Consult engine manual 4 Engine problem 4 Consult engine manual Engine stops 1 Fuel tank empty 1 Fill with fresh fuel and bleed fuel lines Engine overheating 1 Coolant level low 1 Inspect and add coolant 2 Airintake restricted 2 Clean cooling air intake 3 Water pump belt broken or 3 Replace or Tighten belt loose 4 Engine overload 4 Reduce forward speed Vehicle does not react 1 Parking brake engaged Disengage parking brake to throttle pedal 2 Transmission in Neutral Depress brake and clutch pedals Shift to proper gear for desired ground speed Release brake pedal Slowly let out clutch while pressing the throttle pedal 3 Clutch Pedal Depressed Slowly let out clutch pedal 31 7 MAINTENANCE amp LUBRICATION CHARTS 7 1 GENERAL Before you clean adjust or repair this equipment disengage all dri
65. ERING RESERVOIR MAINTENANCE 5 Before servicing or doing any maintenance work around the engine area make sure the engine has had time to cool Serious burns can result if the engine or surrounding surfaces are hot The power steering reservoir is located on the right side of the engine below the alternator The level in the reservoir should be checked after the first 35 and 70 hours After that the level should be checked every 100 hours 5 5 MUFFLER AND EXHAUST When checking the fluid level before the engine has been warmed up the level should be at the COLD mark on the dipstick After the engine has been warmed up and the fluid is warm the level should be between the COLD and HOT marks Use General Motors Power Steering Fluid as necessary to bring fluid up to proper level Power Steering Dipstick 4109 TINA I o E Figure 5C Exhaust fumes contain carbon monoxide that is toxic and can be fatal when inhaled NEVER operate an engine without proper ventilation 5 6 ENGINE OVERHEAT PROCEDURE To protect against carbon monoxide poisoning inspect the complete exhaust system regularly and always replace a defective muffler If you notice a change in the color or sound of the exhaust stop the engine immediately Identify the problem and have the system repaired Torque all exhaust manifold hardware evenly Tighten or replace exhaust clamps During vehicle operation if the water t
66. Gas Engine Gas Units 14 842870 1 Angle Support 15 844647G01 1 Angle Hold Down 16 4185841 1 Battery Tray 17 N S 1 Battery 18 844601 1 Battery Clamp 19 452389 1 Screw M8 1 25 x 25 mm Flange 20 4174281 1 Transmission Mount Diesel Units 20 4179803 1 Transmission Mount Gas Units 21 452405 2 Screw M10 1 5 x 80 mm Flange 22 809180 8 Flat Washer 23 2701693 7 1 Bracket Fuel System Gas Units 24 601585 1 Box Air Diesel Units Only See 21 1 25 800909 10 Nut M12 1 5 Wheel Lug 26 4139806602 2 Wheel and Tire USA Trail 4139793 1 Rim 10 00 x 7 in Five Bolt 3 94 in Bolt Circle N S 1 Tire 20 5 x 8 00 10 USA Trail Obtain Locally 11657G3 1 s Valve Stem 27 452389 4 Screw M8 1 25 x 25 mm Flange 28 450453 4 Nut M8 1 25 Hex Flange 29 810437 1 Clamp Tube 30 4145325 1 Bracket Solenoid Gas Units Only gt Change from previous revision 67 HAUL STER 16 1 Rear Axle Serial No All Gas Units Diesel Units 68 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 2701165 1 11 16 1 Rear Differential Assembly See 39 1 2 800198 1 Locknut 1 2 20 3 809180 1 Flat Washer 1 2 4 893862 2 Spring Leaf 5 843238 2 Bushing Nylatron 6 893613 2 Upstop 7 813850 2 Bumper Travel Limiting 8 829044 4 U Bolt 2 x 5 1 4 in 9 548061 8 Nut 7 16 14 10 800909 10 Nut M12 1 5 Wheel Lug 11 4139806G02 2 Wheel and Tire USA Trail
67. Input 4th Gear 2 2702561 1 Bearing Needle 3 4141037 1 Bearing Input Shaft Ball 4 09380 28007 3 Cir Clip 5 24410 83000 1 High Speed Syncroniser Includes Hub and Sleeve 6 24471 60A00 6 Key Syncronizer 7 24442 81420 2 Spring High Speed Syncronizer 8 24432 83001 3 Ring Syncronizer 9 24230 83001 1 Gear Main Shaft 3rd 3rd Gear 10 09263 30031 1 Bearing Needle 11 24121 85252 1 Shaft Main 12 06111 06003 2 Ball 13 24400 83000 1 Low Speed Syncronizer Includes Hub and Sleeve 14 24436 83000 2 Spring Low Speed Syncronizer 15 24441 85F41 2 Spring Low Speed 16 24431 83001 2 Ring Low Speed Syncronizer 17 24220 60A01 1 Gear Main Shaft 2nd 2nd Gear 18 09263 35015 3 Bearing Needle 19 09300 30003 2 Bushing 20 24211 83011 1 Gear Main Shaft Low 1st Gear 21 09166 30007 2 Washer 22 09262 30086 1 Bearing Ball 23 24420 83000 1 Syncronizer Reverse Drive Includes Hub and Sleeve 24 24473 70D10 3 Key Syncronizer 25 2703581 1 Spring Reverse Syncronizer 26 24681 83000 1 Gear Main Shaft Reverse Reverse Gear 27 26121 85202 1 Gear Speedometer Drive 28 2702559 2 Cir Clip gt Change from previous revision 127 HAULSTER Serial No 84065 All 47 1 Gear Shift Fork Linkage 128 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 25411 85201 1 Shaft Low Speed Fork 1st and 2nd Gear 2 25420 85201 1
68. SINE Z eee MIR CN A MISSA AND AR NAGU 7 SA BW 31522 5 QU OR 1j L ys Su NS b S 104 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 826590 1 Hose Fuel Tank to Fuel Pump 5 16 in 25 Foot Roll Cut to 13 in 2 4113022 8 Clamp Hose 3 826590 1 Hose Fuel Return 25 Foot Roll Cut to 21 1 2 in 4 826590 1 Hose Pump to Fuel Filter 5 16 in 25 Foot Roll Cut to 7 in 5 826590 1 Hose Fuel Filter to Engine 5 16 in 25 Foot Roll Cut to 19 1 2 in 6 831039 1 Hose Engine Fuel Return 3 16 in 25 Foot Roll Cut to 2 3 4 in 7 4139967 1 Connector 5 16 to 3 16 in Hose 8 825264 2 Clamp Hose 9 REF 1 Engine 10 5001947 1 Fuel Filter 550489 Ile Element Fuel Filter 11 894638 1 Pump Electric Fuel 12 452394 1 Screw M8 1 25 x 70 mm Flange 13 450453 1 Nut M8 1 25 Flange 14 838154 1 Bracket Fuel Pump Mounting 15 REF 1 Grommet See 34 1 16 REF 1 Bracket Fuel System See 34 1 17 REF 1 Bracket Air Filter Mount See 23 1 gt Change from previous revision 105 HAUL STER 36 1 Gas Fuel System Serial No 84059 All Serial No 84060 All Jee CONNECTTO FUEL INJECTOR RAIL PORT ON INTAKE MANIFOLD lt CONNECT TO REAR FACING 106 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4166085 1 Hose Fuel Tank to Adapter 5 16 in 10 Foot Roll Cut to 58 1 4 in 2 4113
69. UMBERS JACOBSZN CHARLOTTE NC USA 1 800 848 1636 Jacobsen com MODEL 84043 C DATE CODE M1903 LABEL 75984655 Lb kg W Batt SERIAL 2128855 Nom Power Hp kw I IIIAII III IIIII IIIIIIII Figure 2A Always provide the Vehicle Identification Number of the unit when ordering replacement parts or requesting service information Vehicle Identification Numbers must appear on all correspondence concerning this vehicle The Haulster is equipped with either a Kubota three cylinder diesel powered liquid cooled four cycle engine or a Suzuki three cylinder gas powered liquid cooled four cycle engine The Engine Serial Number for the Kubota engine is ona plate located on the valve cover The Engine Serial Number for the Suzuki engine is stamped onto the upper engine block on the right side of the engine under the engine mount and may be partially hidden by the electrical harness The serial number is also hand printed on the fuel rail Record the Engine Serial Number below for easy reference Engine Serial Number L Engine Serial No WG Kubota Diesel SS j d n Fy GK LAO Gr aQ Engine Serial No CA Figure 2B K6A Suzuki 3 1 PRODUCT IDENTIFICATION SPECIFICATIONS 3 84065 Haulster liquid cooled diesel engine 4 speed manual transmission single speed differential and four post ROPS 84058 ce
70. Y 1 1 2 IMPORTANT SAFETY NOTES A This safety alert symbol is used to alert you to potential hazards Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury and property damage It may also be used to alert against unsafe practices fey i 9 9 Indicates a potentially hazardous situation which if not avoided MAY result in property damage It may also be used to alert against unsafe practices For pictoral clarity some illustrations in this manual may show shields guards or plates open or removed Under no circumstances should this equipment be operated without these devices securely fastened in place The Interlock System on this vehicle prevents the vehicle from starting unless the clutch pedal is depressed Manual Transmission or gear selector is in Park P or Neutral N Automatic Transmission NEVER operate vehicle unless the Interlock system is working 1 Before leaving the operator s position for any reason a Remove foot from accelerator pedal b Slow vehicle using service brake c Depress clutch and shift transmission to 1st Gear Manual Transmission or Park Automatic Trnasmission d Engage parking brake e Stop engine and remove the ign
71. and Lower ROPS 66 16 1 Rear Axle uessanssononnunannonnunnnenennnensnnnnnnnannnennnn 68 17 1 Front Control Arms 70 18 1 Steering Linkages 72 19 1 Front Brakes 74 20 1 Steering Column 76 21 1 Diesel Radiator 78 22 1 Gas Radiator 80 23 1 Diesel Engine and Transmission Mounting 82 24 1 Gas Engine and MT Mounting 84 25 1 Gas Engine and AT Mounting 86 26 1 Diesel Engine and Clutch 88 27 4 Suzuki Gas Engine 90 28 1 Diesel Engine Speed Control 92 29 1 Diesel Engine Exhaust and Remote Oil Filter 94 30 1 Governor Linkage 96 31 1 VE d TE 98 32 1 Gas Engine Remote Oil Fill 100 33 1 Gas Engine Exhaust esee 101 34 1 Fuel Tank eese 102 35 1 Diesel Fuel System 104 36 1
72. anual Copyright 2009 Jacobsen A Textron Company All rights reserved including the right to reproduce this material or portions thereof in any form Proposition 65 Warning This product contains or emits chemicals known to State of California to cause cancer and birth defects or other reproductive harm Litho in U S A 11 2009 Table of Contents Safety Operating Safety 4 Important Safety Notes ne 5 Vehicle Identification Numbers Vehicle Identification Number 6 Engine Identification Numbers 6 Specifications Product Identification 7 se T ub temen ubi 7 Vehicle near tete ee 8 Gear Ratios u ns unusual asya 8 Weights and Dimensions 8 Accessories amp Support Literature 9 Adjustments Gerieral ei eniin esie 10 Engine Access een 10 Front Cowl Access 11 Access Panels ENNEN 11 Diesel Engine Alternator Belt 12 Gas Engine Power Steering Alternator Belt 12 Gas Engine Governor Belt 12 Parking Brake Cable 13 Torque Specification 14 Maintenance ET TEE 15 Ge UE 15 Engine il 1 1 xr pr tetti 16 Power Steering Reservoir 17 Muffler and Exhaust nen 17 Engine Overheat Procedur
73. ary protective clothing and personal safety devices to protect your head eyes ears hands and feet Operate the machine only in daylight or in good artificial light Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Cushman Stay alert for holes in the terrain and other hidden hazards Inspect the area where the equipment will be used Pick up all the debris you can find before operating Beware of overhead obstructions low tree limbs electrical wires etc and also underground obstacles sprinklers pipes tree roots etc Enter a new area cautiously Stay alert for hidden hazards Never allow anyone near the machine while in operation The owner operator can prevent and is responsible for injuries inflicted to themselves to bystanders and damage to property Do not carry passengers Keep bystanders and pets a safe distance away Never operate equipment that is not in perfect working order or is without decals guards shields or other protective devices securely fastened in place 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Never disconnect or bypass any switch Do not change the engine governor overspeed the engine setting or Carbon monoxide in the exhaust fumes can be fatal when inhaled Never operate the engine without proper ventilation or in a
74. be checked every 100 hours or 3 months Fluid should be changed every 600 hours or yearly Differential Fluid Capacity 3 7 qts 4 2 1 Fluid Type Mercon Dexron II To check transmission fluid level the engine must be running Place the gear selector in Park apply the parking brake and start the engine With engine running remove the dipstick and wipe it with a clean rag Insert the dipstick into the extension tube until it contacts the tube Remove the dipstick and read the fluid level Fluid must be kept between the two marks on the dipstick If fluid is low add fluid to obtain the proper level Do Not Overfill Add fluid using the extension tube as a fill tube To change fluid remove drain plug from bottom of transmission Allow fluid to drain into a suitable container Dispose of used fluid properly according to federal state and local regulations Apply pipe thread sealer to drain plug and install Fill transmission until fluid reaches proper mark on dipstick 26 ransmission Fluid Dipstick and Fill Tube Drain Plug Automatic Transmission L er a Figure 5P 5 24 ELECTRICAL SYSTEM MAINTENANCE 5 Always turn the ignition switch OFF and remove the Negative BLACK battery cable before inspecting or working on the electrical system General precautions that can be taken to reduce electrical problems are 1 Make certain all term
75. ble See 5 1 for other end of cable 2 REF 1 Kubota Diesel Engine See 26 1 3 4174720 1 Bracket Throttle 4 452390 1 Screw M8 1 25 x 30 mm Flange 5 450453 2 Nut M8 1 25 Flange 6 800547 1 Screw M8 1 25 x 16 mm Hex Head 7 452388 1 Screw M8 1 25 x 20 mm Flange 8 4175021 1 Lever Throttle 9 103867 1 Flat Washer 5 16 10 821164 1 Hair Pin 11 450452 1 Nut M6 1 Flange 12 452738 1 Screw M6 1 x 20 mm Flange Change from previous revision 93 HAUL STER 29 1 Diesel Engine Exhaust and Remote Oil Filter Serial No 84065 All Tailpipe Outlet to be parallel to ground View Rotated 180 94 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Kubota Engine See 26 1 2 553020 1 Gasket Exhaust 3 4183634 1 Head Remote Filter 4 4113986 1 Engine Oil Filter 5 4190701 1 Fitting 90 6 4174290 1 Bracket Remote Filter 7 800547 4 Screw M10 1 25 x 20 mm Hex Head 8 303269 2 Lockwasher 7 16 9 306325 4 Lockwasher 5 16 10 120177 2 Lockwasher 3 8 11 4175620 2 Fitting 90 12 4175561 1 Hose Remote Oil Filter 13 4175562 2 Hose Remote Oil Cooler 14 48540 01 2 Clamp Hose 15 4176960 1 Remote Oil Cooler 16 4177560 1 Fan 7 1 2 in Push 17 4185240 2 Bracket Fan Mount 18 548910 4 Nut 1 4 20 Hex Flange 19 800017 4 Screw 1 4 20 x 1 in Pan Head
76. cobsen com 800 848 1636
77. d Acid Group 24 Service Brake 4 wheel hydraulic drum brakes 3 4 GEAR RATIOS Brake Fluid DOT 3 Parking Brake aseenaan Integral to rear drum hand lever actuated Steering Front wheel power steering Vehicle Rated Capactiy 2400 Ib 1089 kg NOTE When calculating load weight include 118 Ib 53 5 kg for the standard four post ROPS Do not exceed Vehicle Rated Capacity Diesel Engine Manual Transmission Gear Ratios Ath Gear 1 000 1 Ird Gear 1 423 1 and Gear 1 947 1 1st Gear 3 652 1 Reverse 3 463 1 Hydpoid Differential 11 16 1 3 5 WEIGHTS AND DIMENSIONS Gas Engine 5 Speed Manual Transmission Gear Ratios 5th Gear 1 000 1 Ath Gear 1 264 1 3rd Gear 1 908 1 and Gear 3 017 1 1st Gear 5 106 1 Reverse 5 151 1 Hypoid Differential 11 16 1 Gas Engine Automatic Transmission Gear Ratios Ird Gear 1 000 1 2nd Gear 1 536 1 Tst Gear ues 2 727 1 Reverse 2 222 1 Hypoid Differential 11 16 1 Dimensions Inches mm Bu le DE 136 3454 Height 5i 22 eigen 74 5 1892 Wheel Base eese 88 2 2240 Turning Radius Outside
78. de Spring 894935 Ile Kit Left Side Adjuster Repair 13 893586 1 Front Right Side Brake Assembly 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 894932 Ile Kit Brake Shoe Includes Left and Right sides 894934 Ile Kit Right Side Spring 894936 1 s Kit Right Side Adjuster Repair 14 452398 10 Screw M10 1 5 x 20 mm Hex Flange Grade 8 8 15 841842 1 Tee M10 1 0 Flare Union 16 843418 1 Clamp Tee 17 452692 1 Screw M6 1 0 x 12 mm Taptite 18 841841 2 Hose Brake 19 2703081 2 Protector Brake Hose 20 842104 2 Bracket Brake Tube 21 810437 2 Clamp Hose 22 809137 2 Clip Brake Hose Retaining 23 2702217 1 Tube Left Front Brake 24 841839 1 Tube Right Front Brake Change from previous revision 75 HAULSTER 20 1 Steering Column Serial No All 76 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 893571 1 Tube Steering Mount 2 800930 4 Screw M8 1 25 x 16 mm Flange 3 306799 4 Lockwasher 5 16 External Tooth 4 450453 4 Nut M8 1 25 Flange 5 893344 1 Shaft Steering 887259 2 Bearing Assembly 6 828590 1 s Housing Bearing 7 808060 1 s Bearing Needle 8 819923 2 Collar Foam 9 2700453 1 Cover Steering Tube 10 892228 1 Steering Wheel 11 450457 1 Nut M16 2 Flange 12 840017 1 Cover Steering Wheel 13 841255 1 Gear Steering See 18 1 1
79. e 17 Cooling System 18 Le a ep 19 Jump Starting 19 Battery ut nu dek nete so itg 20 5 11 Charging Battery 20 5 12 EU6l cine iaaii ast d 21 5 13 Fuel System sss 21 5 14 Tite Pressure iarr h eniin edian eean 21 5 15 Tire Removal and Installation 22 5 16 Raising the vehicle 22 5 17 Towing the Vehicle 23 5 18 Governor Oil Level 23 5 19 Hydraulic Brakes AA 24 5 20 Differential Fluid 25 5 21 Diesel Engine Manual Transmission 25 5 22 Gas Engine Manual Transmission 26 5 23 Gas Engine Automatic Transmission 26 5 24 Electrical System 27 5 25 Dash Panel 2 icit cote 27 5 26 Headlight Replacement 28 5 27 Tail Light Replacement 28 5 28 EFI Diagnostic Check 29 5 29 Care and Cleaning 30 5 30 Storage au mu ae 30 6 Troubleshooting 6 1 General sn 31 7 Maintenance amp Lubrication Charts 7 1 EE EE 32 72 Lubrication Chart 32 7 3 Maintenance Charts 33 7 4 Com
80. e code is set correctly The Haulster with a Kubota Diesel engine uses the following sequence code for 10 5 pulses revolution Kubota Diesel Sequence Code 00010100 The Haulster with a Suzuki Gas engine uses the following sequence code for 1 5 pulses revolution Suzuki Gas Sequence Code 00000010 5 26 HEADLIGHT REPLACEMENT Using a small blade screwdriver or similar tool push the switch levers either up or down to match the sequence code for this unit Diesel Engine Setting Baa uda Gas Engine Setting BRT Figure 5R The headlight should be replaced as soon as it stops functioning or is damaged The headlight is a sealed unit and can only be replaced as a complete unit Description bulb type Cushman Part No Headlight H6545 837303 1 Disconnect the Negative BLACK battery cable 2 Remove the four screws securing the headlight bezel to the front cowl 3 Pull headlight and bezel forward out of the front clip opening 4 Disconnect the electrical connector from the rear of the headlight 5 27 TAIL LIGHT REPLACEMENT 5 Remove the headlight from the bezel Properly dispose of old bulb 6 Install new headlight in reverse order of removal Figure 5S The tail light should be repaired as soon as it stops functioning or is damaged The tail light bulb and lens are replaceable components Damage to the body of the tail light requires a comple
81. e Finish 11 306839 1 Nut 5 8 18 Slotted Hex 12 460030 1 s Cotter Pin 1 8 x 1 1 4 in 13 471221 1 Grease Fitting 1 4 28 90 14 841429 2 Lower Ball Joint 15 N S 1 e Boot 16 800861 1 Nut 9 16 18 Slotted Hex 17 460030 1 s Cotter Pin 1 8 x 1 1 4 in 18 548224 1 s Grease Fitting 1 4 28 Straight Special Drive Thread 19 841167 8 Bushing Silentbloc 20 450382 8 Nut M16 2 Locking Insert 21 450077 4 Bolt M16 2 x 90 mm Hex Head Grade 8 8 22 450393 8 Washer M16 23 894573 1 Knuckle Left Side Steering 24 894574 1 Knuckle Right Side Steering 25 841630 2 Trunnion Control Arm 26 800945 4 Bolt M12 1 75 x 60 mm Hex Head Grade 10 9 i Add or remove shims as reguired to 27 841738 AR Shim 024 in Thick adjust CASTER angle q i Add or remove shims as reguired to 28 841737 AR Shim 060 in Thick adjust CAMBER anole q 29 810437 2 Clamp Hose gt Change from previous revision 71 HAUL STER Serial No All 18 1 Steering Linkage KANDIS char d sesch m U U T m I NK We 72 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 841255 1 Steering Gear 2 305134 1 Nut 7 8 14 Hex Jam 3 308008 1 s Lockwasher 7 8 4 841336 1 Arm Pitman 5 894635 2 Strut Assembly 6 452413 4 Screw M12 1 75 x 60 mm Hex Head 7 450455 4 Nut M12 1 75 Hex Flange Grade 10 9 8 311392 3 Screw 7 16 14 x 2 in Hex Head
82. e done at Authorized Dealer Change oil and filter on Suzuki engines after first fifty hours 7 4 COMMON REPLACEMENT PARTS Lubricants and Fluids I Manual grease gun with NLGI Grade 2 Service Class LB H Engine Oil See Section 5 3 III SAE EP 80 90 gear lube IV Capacity 3qt 2 8 I 50 50 water ethylene glycol mix V GM Power Steering Fluid VI DOT 3 brake fluid VII Mercon Dextron Il automatic transmission fluid VIII SAE 20W engine oil Part Number Part Description 840352 Gas Air Filter Element 5000919 Diesel Air Filter Element 4113986 Diesel Oil Filter 2701809 Gas Oil Filter 4183591 Diesel Fuel Filter 2701898 Gas Fuel Filter Part Number Part Description 4175560 Diesel Alternator Belt 841966 Diesel Hydraulic Pump Belt 4139265 Gas Alternator Power Steer ing Belt 4139351 Gas Hydraulic Pump Belt 7 5 KUBOTA DIESEL ENGINE SERVICE PARTS The following common engine parts are provided for reference only Parts may be obtained from your nearest Kubota Engine Dealer Part Number Part Description 2811021 Fuel Solenoid 5000894 Injection Pump 5000901 Injection Pipe 1 5000902 Injection Pipe 2 5000903 Injection Pipe 3 4183586 Fuel Injector 5001265 Injector Return Pipe 4177227 Glow Plug 556412 Thermostat 4134370 Thermostat Gasket 4165525 Water Pump 557867 Water Pump Gasket 4177260 O
83. emperature gauge shows 230 F 110 C or above and or the overheat warning buzzer sounds follow this procedure 1 Stop the vehicle DO NOT shut the engine off Place vehicle in Neutral and engage the parking brake 2 Immediately disengage any accessories that are operating Slow the engine speed to a fast idle Remove any dirt chatt debris etc from the radiator intake screen located on the right side of the vehicle Be careful when opening the engine access cover or cleaning the intake screen Metal surfaces near the radiator and engine may be hot to the touch Use a brush or gloves to clean screen Temperature gauge needle should start to go down approximately 30 seconds after the screen is cleaned If temperature does not go down STOP the engine and check the following 1 Check to see if cooling fan is operating Fan should be turning with coolant above 180 F even with ignition switch in OFF position Check engine oil level Check for a leak in the cooling system Do not open radiator when hot Check coolant levels after system completely cools Failure to heed the overheat warning and properly maintain the cooling system will cause permanent engine damage 17 5 MAINTENANCE 5 7 COOLING SYSTEM This vehicle is eguipped with a radiator temperature controlled fan temperature gauge and an overheat buzzer To prevent serious bodily injury from hot coolant or steam blow out never attempt to
84. ender 13 i xx Left Turn lt lt Gn Bk Gn Bk Tach Input ga Wh Rd gt Right Turn g Ye Bk Ye Bk 12V 16 Bk Overheat S 7 o Alarm at Wh Bu Wh Bu Bk Pk Bu JE 12V 7 18 Bk Wh Coolant 7 Aa lt Overheat i Dash Parking Brake Alarm i Panel Switch Wh Ye Bu Wh Og Gn Wh 140 Left Tail Light HAULSTER Tail N di Wh B Bi Bi Light mee N Bk Bk e Bk Bk Brake Y v Rd y BuBk Bu Bk 3 Bu Bk 77 Light AAS Rd Bk Sy Rd Bk Tail Light Horn Tail yo Why Bn Harness Eas Light A Ze 894314 an 99 Brake Y Y Rd SS Rub Bk b g Bk e Eg Light A DET Right Tail Light Cab Stop Og Bk Light Bk Accessory gt L FTF Brake gt Wh Rd Accessory Bk Connector 1 L 77 Brake EN Og Bk e Accessory Bn Connector 2 Bn Rd wh Brake 15A GE pedal Switch Wh Rd e Jumper Turn Signal p Wh O Og Bk ug Zoo Accessory 2700913 Bu Bk O gt b g Ye Bk gt Wh Flasher Rd Bk gt gt 09 A 15A Turn Signal 7 vu Ye Rd Accessory Og Bk 2 P 9 gt Gn Bk gt Bu Bn Left Headlight 5 Low Beam Y V B C z Wh Bu Gn Bk Bk 9 77 VW T Wh Wh Bn Left Turn Gn Bk i T Ye Bk
85. es must be disconnected before using a fast charger or damage to the alternator may result 3 Make sure the charger is Off Then connect the charger to the battery terminals as specified in the charger s manual 4 Always turn the charger Off before disconnecting charger from the battery terminals 20 5 12 FUEL MAINTENANCE 5 Handle fuel with care it is flammable and highly explosive under certain conditions Use an approved container The spout must fit inside the fuel filler neck Do not use cans and funnels to transfer fuel Remove the fuel cap slowly Fuel may be under pressure Spray could cause serious injury Never remove the fuel cap from the fuel tank or add fuel when the engine is running or while the engine is hot Do not smoke when handling fuel Never fill or drain the fuel tank indoors Do not spill fuel immediately If spilled clean spilled fuel Never handle or store fuel containers near an open flame or any device that may create sparks and ignite the fuel or fuel vapors Be sure to reinstall and tighten fuel cap securely 1 Fill the fuel tank to within 1 in 25 mm of the bottom of the filler neck 2 Store fuel according to federal state and local ordinances and recommendations from your fuel supplier 3 Never overfill or allow the tank to become empty Check fuel level in the tank by turning the ignition switch to the ON position and reading the level indicated by the
86. fuel gauge 5 13 FUEL SYSTEM 4 Check fuel lines and clamps every 50 hours Replace fuel lines and clamps at the first sign of damage 5 The fuel tank capacity is 6 5 gal 24 5 Fill tank using the following fuel recommendations Diesel Engine a Use clean fresh 2 Diesel fuel when operating temperature is above 20 F 7 C Minimum Cetane rating 45 b Use clean fresh 1 Diesel fuel when operating temperature is below 20 F 7 C If 1D fuel is not available a winterized blend of 1D and 2D may be available This blended fuel is usually called 2D and may be used in colder climates Do not use 2D unless you are sure it has been winterized Cold temperatures may cause it to thicken which will keep your vehicle from running properly c DONOTuse Aviation Fuel JP4 Refer to Engine Manual for additional information Gas Engine Use clean fresh Unleaded Gasoline 87 octane or higher The use of any fuel containing greater than 10 ethanol may harm the engine s emission control system and therefore invalidate the emission related warranty through the improper action of the operator The Kubota diesel engine in the Haulster is self priming It is not required to purge air from the system Refer to Section 7 3 for specific maintenance intervals 5 14 TIRE PRESSURE Before replacing any filter thoroughly clean the filter housing and the area around the filter Dirt must not be allowed to enter into
87. gs with damaged gasket surfaces After oil has completely drained clean excess oil from oil pan and drain plugs Install drain plugs and tighten securely Refer to Engine Manual for proper torque Always replace the engine oil filter when changing the engine oil Apply a light coat of engine oil to the rubber gasket surface of new filter before installing Diesel Engine Fill Kubota engine with approximately 3 7 ats 3 5 I of clean engine oil Check oil level and add additional oil if required Gas Engine Fill Suzuki engine with approximately 3 3 ats 3 0 I of clean engine oil Check oil level and add additional oil if required 16 Oil Level Must Be Between Marks DO NOT OVERFILL Ct Diesel ADD Engine FULL o ADD FULL D Gas Engine Figure 5A Kubota Diesel SAE 20W 10W 30 SAE 30W 10W 30 10W 40 gt 20 32 40 60 7780 100 I 20 25 30 40 SAE 10W 10W 30 Suzuki Gas SAE 10W 30 for all temperature ranges 20 0 C 30 20 10 0 10 Figure 5B Diesel Engine Above 77 F 25 C SAE 30W or SAE10W30 32 to 77 F 0 to 25 C SAE 20W or SAE 10W30 Below 32 0 C SAE10W or SAE 10W30 Gas Engine All temperature ranges SAE 10W30 Above 85 F 29 C SAE 10W 40 Replacement Oil Filters Kubota Diesel 4113986 Suzuki Gas 2701908 5 4 POWER STE
88. il Pan Drain Plug 2500811 Oil Pan Drain Plug Gasket 4113986 Oil Filter 4145944 Oil Fill Cap 2809955 Oil Fill Cap Seal 2500856 Valve Cover Gasket 557888 Starter Motor 34 Part Number 4183623 Part Description Alternator NOTES 8 35 9 PARTS CATALOG 9 1 HOW TO USE THE PARTS CATALOG Abbreviations N S Not serviced seperately can only be obtained by ordering main component or kit AR Variable quantity or measurement is required to obtain correct adjustment Symbols such as next to the item number indicates that a note exists which contains additional information important in ordering that Indented Items Indented items indicate component parts that are included as part of an assembly or another component These parts can be ordered separetely or as part of the main component part Item PartNo Qty Description Serial Numbers Notes e 1 123456 1 Mount Valve Indicates a piece part 2 789012 1 Valve Lift Includes Items 3 and 4 3 345678 1 Handle Serviced part included with Item 2 4 N S 1 Seal Kit Non serviced part included with Item 2 5 901234 1 Screw 1 4 20 x 2 Hex Head 9 2 TO ORDER PARTS 1 Write your full name and complete address on the order 2 Explain where and how to make shipment 3 Give product number name and serial number that is stamped on the name plate or serial plate of your 36 product Order b
89. in 25 Foot Roll Cut to 24 Inches 8 4188387 1 Bracket Governor See 32 1 9 2702249 1 Key Woodruff 1 8 x 1 2 in 10 4141425 1 Governor See 31 1 11 306450 2 Screw 5 16 18 x 3 4 in Hex Head 12 306325 2 Lockwasher 5 16 13 548155 2 Flat Washer 5 16 14 4139288 1 Pulley 4 Groove Micro V 4 4 in Dia Includes two set screws 15 4146490 1 Plate Hose Clamp 16 831225 1 Clamp Hose 17 4150138 1 Screw 3 8 16 x 2 1 4 in Hex Flange 18 548971 2 Screw 5 16 18 x 5 8 in Hex Flange 19 4143072 1 Tensioner Rotary 20 4144332 1 Pulley 2 3 4 in Idler 21 4140241 1 Bracket Air Cleaner 22 4142186 1 Belt 45 3 in Micro V 23 312176 1 Screw 1 2 13 x 1 3 4 in Hex Head 24 800602 1 Nut 1 2 13 Nylon Insert 25 4139259 1 Bracket Power Steering Pump 26 450452 1 Mut M6 1 Hex Flange 27 4147588 1 Stand Off M6 1 28 452389 2 Screw M8 1 25 x 25 mm Hex Flange 29 4140264 1 Spacer 7 16 x 25 64 in 30 REF 1 Pump Power Steering See 20 1 31 452395 2 Screw M8 1 25 x 80 mm Hex Flange 32 450453 3 Nut M8 1 25 Hex Flange 33 600993 1 Pulley 5 80 in Diameter 34 4139265 1 Belt 7 16 x 26 1 2 in V Alternator and Power Steering Change from previous revision 91 HAUL STER Serial No 84065 All 28 1 Diesel Engine Speed Control T E IPAO VEN A SENNA i v N A Na N SA 92 Item Part No Qty Description Serial Numbers Notes 1 2703683 1 Throttle Ca
90. inal 825748 AR Terminal 1 4 in Fem 14 16 Gauge 20 842983 1 Fuse 40 Amp gt Change from previous revision 133 HAUL STER 50 1 Gas Main Harness Part Number 4115709 Serial No 84058 All Serial No 84059 All Serial No 84060 All Engine Harness Speed 24 Connector Sensor Shift 125 5 LET PackUp Solenoid ST Switch amp 2 Shift Switch 2 7 Back Up Alarm Starter Solenoid a Tail Light Harness Connector Fuel Sender Radiator Fan Wires Cab Stop Light Option 21 35 2 Brake Accessory amp p 1 6 4 Option 19 7 8 G Turn Signal 70 Brake Pedal lt 5 5 Option Jumper Plug Switch e e Flasher 12 V Accessory Option 11 Plug eo Left Turn 2 SE pedal itch Left Headlight we E Right Turn Signal Horn Button 4 Option Light Switch o e OE 3 Speedometer 2072 Signal Ee Signal 4 Tach Speedometer Signal Dash Panel Ground Heater s Option A Optional 2 Accessories 4 X Brake Accessory Positive 3 S Option 45 Standoff lt P m Timing Wires sninen Plug 31 32 e Light Diagnostic aj
91. inals and connections are clean and properly secured 2 Check the Interlock System and fuses regularly If the Interlock does not function properly and the problem cannot be corrected contact an authorized Cushman Dealer 3 Keep the wire harness and all individual wires away from moving parts to prevent damage 4 Check the battery and battery charging circuit 5 Do not wash or pressure spray around electrical connections and components 6 Circuits are protected by fuses located under the front cowl and a fuse located near the cooling fan 5 25 DASH PANEL Diesel Engine Power Port 15 A GL Brake Light 5th Wheel Brake 10 Al gem 10A Accessary Flashers 8 10 A 4Zd e 10 A Heater 20 A Dash Panel Fuel Pump amp Ignition Horn Accessary Headlights 15 A oom 10 A Wiper Dome Light amp Back Up Alarm Gas Engine Dash Panel ECU Fuel Accessary 10 A 20 A amp Engine Coils Power Port 15A 25 A Radiator N OW ono Fan 15 A ECU Main Relay Headlights 15 A s Injectors Brake Light SS 10 A Backup Alarm 5th Wheel Brake 10 A s Shift CEN Flashers 8 10 A 6 10A ECU 7 The dash panel contains gauges and instrument lights to display unit functions Maintenance of the panel is limited to replacing bulbs and setting the DIP switches Remove the four screws securing the instrument panel to the dash Pull panel out tilt panel forward and di
92. ious injury Installation 1 Remove dirt grease and oil from stud thread Do not lubricate threads 2 Position wheel on hub and inspect to ensure full contact between mounting surface of wheel and hub or brake drum Make sure valve stem is located towards the outside Finger tighten all hardware then torque hardware in criss cross order always tightening nuts in the top position 3 Check and retorque daily until 70 100 ft lbs 95 140 Nm torque is maintained Make sure the vehicle is parked on a solid and level surface Never work on a vehicle that is supported only by a jack Always use jack stands Whenever possible empty the truck platform before raising the vehicle Loads moving on truck platform can cause an unbalanced load that could tip the vehicle Never raise the vehicle with the engine running or with a person sitting in the operator s seat Always block the tire diagonally opposite the tire being raised Never place hands feet or any part of your body under the vehicle when raising it with a hoist or if vehicle is not properly supported by jack stands A scissors type jack or a floor jack with a 1 1 2 ton minimum capacity that can be lowered to a_height of 3 3 8 in 86 mm is required Refer to Figure 5E for jacking locations Shift the transmission into 1st gear or Park and apply the parking brake Chock or block the tire diagonally opposite the side being raised Raise the vehicle o
93. isengage parking brake Tighten adjustment nut E a couple of turns Engage parking brake Repeat steps 3 and 4 until handle is at an approximate 45 angle when parking brake is engaged Figure 41 13 4 ADJUSTMENTS 4 9 TORQUE SPECIFICATION All torque values included in these charts are approximate and are for reference only Use of these torque values is at your sole risk Jacobsen is not responsible for any loss claim or damage arising from the use of these charts Extreme caution should always be used when using any torque value Cushman uses Grade 5 Inch or Grade 8 8 Metric bolts as standard unless otherwise noted SIZE UNITS SIZE UNITS C C 9 GRADE 5 GRADE 8 GRADE 5 GRADE 8 6 32 in Ibs Nm 20 2 3 7 16 14 ft lbs Nm 50 67 8 65 88 1 8 32 in lbs Nm 24 2 7 0 3 4 7 16 20 ft lbs Nm 55 74 6 70 94 9 310 24 in Ibs Nm 35 4 0 45 5 1 1 2 13 ft lbs Nm 75 101 7 100 135 6 10 32 in lbs Nm 40 4 5 0 5 7 1 2 20 ft lbs Nm 85 115 3 110 149 2 312 24 in lbs Nm 50 5 7 65 7 3 9 16 12 ft lbs Nm 105 142 4 135 183 1 1 4 20 in Ibs Nm 95 10 7 125 14 1 9 16 18 ft lbs Nm 115 155 9 150 203 4 1 4 28 in Ibs Nm 95 10 7 150 17 0 5 8 11 ft lbs Nm 150 203 4 195 264 4 5 16 18 in lbs Nm 200 22 6 270 30 5 5 8 18 ft lbs Nm 160
94. ition key 2 Keep hands feet and clothing away from moving parts Wait for all movement to stop before you clean adjust or service the machine Keep the area of operation clear of all bystanders and pets Never carry passengers unless a seat is provided for them Never operate mowing equipment without the discharge deflector securely fastened in place By following all instructions in this manual you will prolong the life of your machine and maintain its maximum efficiency Adjustments and maintenance should always be performed by a qualified technician If additional information or service is needed contact your Authorized Cushman Dealer who is kept informed of the latest methods to service this equipment and can provide prompt and efficient service 2 VEHICLE IDENTIFICATION NUMBERS 2 1 VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number VIN consisting of the model number date code and serial number are all printed on the Nameplate Identification Decal attached to the cross member under the dash The serial number is also stamped on the cross member It is located to the left of the Nameplate Identification Decal NOTE Reference to the Front Rear Left and Right sides of the vehicle are always determined by the operator s seated position Record the Vehicle Identification information below for easy reference Model Number Date Code Serial Number 2 2 ENGINE IDENTIFICATION N
95. k Accessory gt Ye Rd Connector 1 8 Clutch Pen Switch Pk Pk Accessory Ye Rd Wh Gn Gd Connector 2 Bk gt S amp Accessory gt Rd A e s Connector 3 Bk 21 ACC B A gt o Ignition OFF None L Switch ON B A l Start B I S Accessory gt Rd oB Connector 4 Bk N 2 Bk w Overheat Alarm OO Wh Bu Bk e RaBk r Bk Brake Fluid Power Level Switch Point Tachometer lt Gas Tach Input lt 2 Wh Bn amp 5 i Pu Voltmeter lt 6 4 bd Pre Heat lt lt Sc 7 Wh Bk XX lt o 4 x 4 Temp Gauge e Wh Ye a m E 2 Es c S 9 ol x amp g Zi Si c QI a z 0 n High B n pee gt WhOg NJ jv vv V V V vl V Vv Oil P 10 wn P 2 XX E Main Harnessto Main Harness to Main Harness to A en Fuel Sender au Og Engine Harness Engine Harness Engine Harness Fuel Guage Connector 1 Connector 2 Connector 3 Parking Brake 7712 Pk Bu lt 18 4 ce Left Turn Gn Bk Diesel Tach Input lt Wh Rd i 15 xx Right Turn lt lt Ye Bk 12V L SH Dk Overheat Alarm a Wh Bu 12V Ai Gn Dash Panel 144 Left Tail Light Tail HAULSTER
96. l Numbers Notes 1 841663 1 Panel Floor Access 2 800943 10 Screw 10 14 x 5 8 in Self Tapping 3 894159 1 Pedal Throttle 4 524633 2 Bolt 5 16 18 x 1 in Shoulder 5 524643 2 Bearing Split 6 548911 2 Nut 5 16 18 Flange 7 2703257 7 1 Bracket Foot Throttle 8 452378 6 Screw M6 1 x 20 mm Flange 9 450452 6 Nut M6 1 Flange 10 843997 1 Bracket Pedal Stop 11 843562 1 Mount Channel 12 452695 1 Screw M6 1 x 20 mm Self Tapping 13 830784 1 Clevis Pin 1 4 x 1 7 8 in 14 306328 4 Cotter Pin 3 32 x 3 4 in 15 843563 2 Plate Pivot 16 843561 1 Link Throttle Pivot 17 806714 3 Clevis Pin 5 16 x 3 4 in 18 844224 2 Roll Pin 3 16 x 1 3 4 in 19 515268 2 Bushing 20 844223 2 Spring Torsion 21 2703683 1 Throttle Cable Diesel Vehicles See 28 1 21 2703684 1 Throttle Cable Gas Vehicles See 30 1 22 800582 6 Screw 1 4 10 x 3 4 in Truss Head 23 2700496 4 Insert 1 4 20 Threaded 24 2701850 7 1 Panel Ignition Switch 25 2702014 1 Decal Ignition Switch Panel 26 837295 1 Ignition Switch 27 837298 1 Spacer 28 29165601 1 Decal Off Road Use 29 2700275 1 Decal Control Panel 30 841866 1 Panel Control 31 830366 1 Switch Horn 32 843581 1 Switch Light 33 2702012 1 Strap Nut 1 4 20 x 2 in 34 821071 1 Decal Not Motor Vehicle Notice gt Change from previous revision 49 HAULSTER Serial No All 6 1 Control Console 50 HAULSTER
97. l Transmission 21 884513 1 Cable Frame Ground Automatic Transmission 22 450453 1 Nut M8 1 25 Hex Flange 23 452388 1 Screw M8 1 25 x 20 mm Flange 24 4154081 1 Cover Positive Battery Terminal 25 2700867 1 Relay EFl 12 V 70A SP 26 843167 2 Relay 12V 15A DPST 27 4116017 1 Harness Generator gt Change from previous revision 111 HAULSTER Serial No All 39 1 Differential Assembly Part Number 2701165 112 HAULSTER Item Part No Qty Description Serial Numbers Notes 2701165 1 Differential Assembly 11 16 1 Differential 1 891829 1 Differential Housing See 40 1 2 N S 1 Axle Tubes and Shafts See 41 1 3 N S 1 Input Shaft See 43 1 4 N S 1 s Front Cover See 42 1 5 112050 Ile Screw 1 4 20 x 5 8 in Self Tap 6 820008 1 Fitting Hydraulic Brake Tee 7 832584 1 s Clamp Tee Fitting 8 832587 1 s Hose Brake 9 2703170 1 Tube Left Side Brake 10 2703171 1 s Tube Right Side Brake 11 893583 2 s Cable Parking Brake gt Change from previous revision 113 HAUL STER 40 1 Differential Housing Part Number 891829 Serial No All 114 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 891829 1 Differential Housing 2 N S 2 Bearing Caps 3 306829 4 Screw 7 16 14 x 2 in Hex Head 4 103867 14 Flat Washer 5 16 5 111074 1 Plug Drain 6 111758 10 Stud 3 8 16 amp 3 8 24 x 1
98. lange gt Change from previous revision 109 HAUL STER 38 1 Gas Electrical Components Gini saani Serial No 84060 All Hem 8 Routing 5 12 x 3 Engine Harness 5 Ce Ground Wires A RUB N 110 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 450452 3 Nut M6 1 Hex Flange 2 452378 2 Screw M6 1 x 20 mm Hex Flange 3 2701465 1 Solenoid Starter 120052 2 s Lockwasher 10 132520 2 e Nut 10 32 Hex 306325 2 e Lockwasher 5 16 306932 2 e Nut 5 16 18 Hex 4 844167 1 Bracket Horn Brake Fluid Reservior 5 800943 15 Screw 10 16 x 3 4 in Thread Cutting 6 886425 1 Horn 7 800934 3 Screw M6 1 x 16 mm Hex Flange 8 4115709 1 Harness Main See 48 1 9 843942 1 Socket 12V Accessory Plug 10 4152157 1 Panel Instrument with Tachometer 11 890000 1 Buzzer High Temperature oa inside EES dash panel 12 831225 3 Clamp Wire Harness 13 306419 2 Screw 1 4 20 x 1 2 in Hex Head 14 306488 1 Lockwasher 1 4 External Tooth 15 828231 1 Insulator 16 548175 1 Flat Washer 1 4 17 4183304 1 Positive RED Battery Cable Manual Transmission 17 4183303 1 Positive RED Battery Cable Automatic Transmission 18 4183301 1 Negative BLACK Battery Cable Battery to Transmission 19 306325 1 Lockwasher 5 16 20 450324 1 Nut M8 1 25 Hex 21 894602 1 Cable Frame Ground Manua
99. light at the lower left corner of the dash panel will flash a diagnostic code The first digit of the code will be given by each 0 3 second flash followed by a one second pause followed by the second digit with no pause A code of 12 System Normal would turn the light on for 0 3 seconds a one second pause then two fast flashes Flash Pause Flash Flash A code of 46 Shift switch would turn the light on four times for 0 3 seconds and a one second pause then six fast flashes Flash Pause Flash Pause Flash Pause Flash Pause Flash Flash Flash Flash Flash Flash The following list shows which code number corresponds to which component and lists possible causes for each fault Code Engine Component Possible Causes Voltage at pin 25 Green Yellow wire of the 34 pin ECU connector is higher U Pressure Sender than 4 5 Volts or ower than 0 19 Volts 12 Normal System operating normally Voltage at pin 33 Gray Yellow wire ofthe 34 pin ECU connector is higher TS Throttle Sensor than 4 73 Volts or lower than 0 25 Volts 14 O Sensor one for a length of time at pin 24 Red Blue wire of the 34 pin ECU con 15 Crank Angle Sensor bin ECU a Meds no signal is seen at pin 16 Brown Red wire of the 34 16 Vehicle Speed Sensor na for a length of time at pin 16 Orange wire of the 26 pin ECU con Voltage at pin 32 Green White wire ofthe 34 pin ECU connector is higher TR Water Temperature Sensor than 4 85 Vol
100. mon Replacement Parts 34 7 5 Kubota Diesel Engine Service Parts 34 8 NOTES 9 PARTS CATALOG 9 1How To Use The Parts Catalog 36 9 2 To Order Parts 36 9 3 Table Of Contents 37 U 1 1 SAFETY OPERATING SAFETY EQUIPMENT OPERATED IMPROPERLY OR BY UNTRAINED PERSONNEL CAN BE DANGEROUS Familiarize yourself with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine 10 11 Safety is dependent upon the awareness concern and prudence of those who operate or service the equip ment Never allow minors to operate any equipment It is your responsibility to read this manual and all publications associated with this equipment Safety amp Operation Manual Engine Manual accessories and attachments If the operator cannot read English it is the owner s responsibility to explain the material contained in this manual to them Learn the proper use of the machine the location and purpose of all the controls and gauges before you operate the equipment Working with unfamiliar equipment can lead to accidents Never allow anyone to operate or service the machine or its attachments without proper training and instructions or while under the influence of alcohol or drugs Wear all the necess
101. n 39 HAULSTER 2 1 Engine Cover Vehicles without ROPS Serial No All L 1 READ AND UNDERSTAND ALL LABELS AND THE OPERATOR S MANUAL 8 SHIFT INTO NEUTRAL OR PARK BEFORE STARTING ENGINE 2 DO NOT ALLOW UNTRAINED PERSONNEL TO OPERATE THIS VEHICLE 9 ONLY CARRY PASSENGERS IN SEATS PROVIDED 3 DO NOT MODIFY THIS VEHICLE WITHOUT MANU FACTURER S AUTHORIZATION 10 WHEN PARKING LEAVING VEHILE FOLLOW ALL INSTRUCTIONS IN 4 PLACE LOADS FOWARD OF REAR AXLE OPERATOR S MANUAL 5 TOP HEAVY LOADS CAN CAUSE UPSETTING DO NOT EXCEED PAYLOAD FAILURE TO HEED THESE CAPACITY WARNINGS MAY RESULTIN 6 DO NOT OPERATE IF REPAIRS ARE REQUIRED 12 KEEP ALL LABELS AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT SERIOUS INJURY OR DEATH 7 KEEP ALL SHIELDS IN PLACE 13 KEEP ARMS AND LEGS WITHIN VEHICLE BO DY HAULSTER Item Part No Qty Description Serial Numbers Notes 1 306328 1 Cotter Pin 3 32 x 3 4 in 2 308090 9 Washer 1 4 3 450452 2 Nut M6 1 Hex Flange 4 450453 2 Nut M8 1 25 Hex Flange 5 450454 3 Nut M10 1 5 Hex Flange 6 893541 1 Handhold Right Side 7 450541 10 Screw M6 1 x 16 mm Pan Head 8 452388 2 Screw M8 1 25 x 20 mm Hex Flange 9 452398 3 Screw M10 1 5 x 20 mm Hex Flange 10 523085 1 Latch Engine Cover 11 816401 1 Spring Torsion 12 830784 1 Clevis Pin 1 4 x 1 7 8 in 13 2702199 1 Catch Engine Latch 14 4139939 1 Insulation Engi
102. n enclosed area Fuel is highly flammable handle with care Keep the engine clean Allow the engine to cool before storing and always remove the ignition key Place transmission in Neutral depress clutch and engage parking brake before starting the engine motor Start the engine only when sitting in operator s seat never while standing beside the unit Equipment must comply with the latest federal state and local requirements when driven or transported on public roads Watch out for traffic when crossing or operating on or near roads Local regulations may restrict the age of the operator Operate the machine up and down the face of the slopes vertically not across the face horizontally To prevent tipping or loss of control do not start or stop suddenly on slopes Reduce speed when making sharp turns Use caution when changing directions Always use the seat belt when operating vehicles equipped with a ROPS Never use a seat belt when operating vehicle without a ROPS Keep legs arms and body inside the seating compartment while the vehicle is in motion Always shift transmission to 1st Gear Manual Transmission or Park Automatic Transmission engage parking brake and stop engine before leaving the vehicle Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting and disconnecting from battery Wear protective clothing and use insulated tools SAFET
103. nd discard 1 Carefully clean the inside of the filter housing without allowing dust into the air intake 2 Inspect the new element Do not use a damaged element and never use an incorrect element 3 Assemble the new element and make sure it seats properly 4 Assemble cap making sure it seals completely around the filter housing Dust evacuator A must be facing down 5 Check all hoses and air ducts Tighten hose clamps Replacement Diesel Only 1 Clean the outside of the filter housing especially around hose connections and cover 2 Note location of hoses Loosen hose clamps and remove both hoses from air cleaner Use caution to prevent dust or other debris from entering engine intake hose 3 Remove air cleaner mounting hardware B Air filter is secured with a single screw and nut 4 Lift the air cleaner assembly out of the vehicle Unsnap retaining clamps and remove the old element as gently as possible and discard 5 9 JUMP STARTING 6 Carefully clean the inside of the filter housing without allowing dust into the air intake 7 Inspect the new element Do not use a damaged element and never use an incorrect element 8 Assemble the new element and make sure it seats properly 9 Assemble cap making sure it seals completely around the filter housing Dust evacuator A must be facing down 10 Install air cleaner assembly into the vehicle Secure with hardware B 11 Connect both hoses and
104. ne Cover 15 842030 1 Mount Backrest Not Used on 84060 16 601937 2 Seat Base 17 893322 2 Backrest 84060 See 4 1 for mounting 18 893375 14 1 Cover Yellow Engine 19 845038 1 s Decal Operation 20 840436 1 Lock Engine Cover Optional Required in Europe 21 309488 2 Washer Optional Required in Europe 22 REF 1 Decal Emmissions Gas Vehicles 23 302288 8 Screw 1 4 20 x 1 in gt Change from previous revision 41 HAULSTER 2 2 Engine Cover Vehicles with Four Post ROPS Serial No All L 8 SHIFT INTO NEUTRAL OR PARK BEFORE STARTING ENGINE 9 ONLY CARRY PASSENGERS IN SEATS PROVIDED 1 READ AND UNDERSTAND ALL LABELS AND THE OPERATOR S MANUAL 2 DO NOT ALLOW UNTRAINED PERSONNEL TO OPERATE THIS VEHICLE 3 DO NOT MODIFY THIS VEHICLE WITHOUT MANU FACTURER S AUTHORIZATION 10 WHEN PARKING LEAVING VEHILE FOLLOW ALL INSTRUCTIONS IN OPERATOR S MANUAL 4 PLACE LOADS FOWARD OF REAR AXLE 5 TOP HEAVY LOADS CAN CAUSE UPSETTING DO NOT EXCEED PAYLOAD FAILURE TO HEED THESE CAPACITY WARNINGS MAY RESULTIN 6 DO NOT OPERATE IF REPAIRS ARE REQUIRED 12 KEEP ALL LABELS AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT SERIOUS INJURY OR DEATH 7 KEEP ALL SHIELDS IN PLACE 13 KEEP ARMS AND LEGS WITHIN VEHICLE BO DY HAULSTER Item Part No Qty Description Serial Numbers Notes 1 306328 1 Cotter Pin 3 32 x 3 4 in 2 308090 9 Washer
105. nly enough to perform maintenance required 22 Jack the vehicle to an appropriate height and place jack stands or equivalent support beneath the frame near the jack Lower the jack and allow the vehicle to rest on jack stands Do not remove jack When using a hoist to raise the vehicle use the same procedure for supporting the frame and blocking the tires as you would when using a jack To prevent damage to the vehicle or attached accessory never use a hoist to raise only one corner of the vehicle Always raise BOTH front or rear corners equally Block Tire Here ug 358 LRT Nia ME Jacking Location S on Em dones If Using Jack Here Figure 5E 5 17 TOWING THE VEHICLE MAINTENANCE 5 To prevent injury or vehicle damage the following guidelines should always be followed Never accelerate or stop suddenly when towing a vehicle Never change the direction of the vehicle abruptly or make sharp turns on an incline when towing a vehicle Never tow the vehicle faster than 5 mph 8 km h Towing at excessive speed could cause either vehicle to lose proper steering control Adjust your speed for weather and surface conditions rain snow ice hills etc when towing Use care when loading or unloading machine onto a trailer or truck If
106. nnector Male 4 Terminal 825886 4 e Terminal 1 4 in Male 14 16 AWG 829631 1 e Connector Female 4 Terminal 825748 4 Terminal 1 4 in Female 16 AWG 825878 2 e Terminal 1 4 in Female 16 AWG 2 Wire Terminal 17 800934 12 Screw M6 1 x 16 mm Flange Head 18 548175 8 Flat Washer 1 4 19 450452 12 Nut M6 1 Hex Flange 20 REF 1 Frame Lower ROPS and Platform See 15 1 21 838427 2 Decal Cushman 22 844847 2 Decal Textron gt Change from previous revision 65 HAUL STER Serial No All 15 1 Frame and Lower ROPS Gas Engine and Transmission Mounts 66 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 N S 1 Frame Main 4 Wheel Standard Frame Painted Black 1 N S 1 Frame Galvanized Main 4 Wheel Optional Galvanized Frame 2 893145 7 1 ROPS Lower 3 REF 1 Front Suspension See 17 1 18 1 and 19 1 4 893525601 2 Support Platform 5 452406 4 Screw M10 1 5 x 90 mm Flange Grade 8 8 6 452398 6 Screw M10 1 5 x 20 mm Flange Grade 8 8 7 450454 8 Nut M10 1 5 Hex Flange 8 450455 16 Nut M12 1 75 Hex Flange 9 452410 12 Screw M12 1 75 x 30 mm Flange 10 309067 2 Lockwasher 1 2 Shakeproof 11 452415 8 Screw M12 1 75 x 80 mm Flange 12 894581 1 Mount Left Side Diesel Engine Diesel Units 12 894998 7 1 Mount Left Side Gas Engine Gas Units 13 894582 1 Mount Right Side Diesel Engine Diesel Units 13 2701697 7 1 Mount Right Side
107. ntil it contacts the oil tube remove the dipstick and read the oil level The oil level should always be between the ADD and FULL mark on the dipstick If oil level is below the ADD mark remove filler cap and add oil to bring the level up between marks Do Not Overfill NOTE Ifthe engine has recently been running allow time with engine turned OFF to let the oil settle to obtain an accurate oil level reading Diesel Engine Use only engine oils with API classification CH4 Gas Engine Use only engine oils with API classification SL Using oil other than the service class listed or oil change intervals longer than recommended could reduce engine life Damage to engine due to improper maintenance or use of incorrect oil quality and or viscosity is not covered by the engine warranty Diesel Engine Perform initial oil change after first 35 hours of operation and every 75 hours or two months thereafter See Engine Manual Gas Engine Perform initial oil change after first 50 hours of operation and every 100 hours or three months thereafter See Engine Manual Significant oil loss can damage the engine Considerable oil loss could be due to a loose or incorrectly installed drain plug cracked gaskets or a loose oil filter Drain plugs are located beneath the engine in the oil pan Remove both plugs when changing the oil Check drain plugs and oil for metal chips that could indicate engine damage Immediately replace drain plu
108. o All 116 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 2701165 1 Differential Assembly 11 16 1 Differential 2 2703507 7 1 Tube Right Side Axle 3 2703506 7 1 Tube Left Side Axle 4 2700528 1 Left Side Axle Assembly 2700510 1 Shaft Left Side Axle 5 845356 1 Washer 6 800743 1 e Nut 3 4 16 Slotted Hex 7 304636 1 e Cotter Pin 1 8 x 1 1 8 in 8 2700529 1 Right Side Axle Assembly 2700513 Ile Shaft Right Side Axle 9 845356 1 Washer 10 800743 1 e Nut 3 4 16 Slotted Hex 11 304636 1 e Cotter Pin 1 8 x 1 1 8 in 12 836694 2 Seal 1 3 4 in LD O Ring 13 2703481 2 Seal 2 in LD O Ring 14 836426 2 Collar Axle Bearing 15 838539 2 Seal Oil 16 836695 2 Bearing Tapered Roller 17 893581 1 Left Side Brake Assembly Includes Parking Brake Lever 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 Ile Kit Brake Cylinder Repair Repair of Cylinder 894932 Ile Kit Brake Shoe Includes Left and Right sides 894933 1 e Kit Left Side Spring 894935 1 Kit Left Side Adjuster Repair 18 893582 1 Right Side Brake Assembly Includes Parking Brake Lever 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 Ile Kit Brake Cylinder Repair Repair of Cylinder 894932 1 Kit Brake Shoe Includes Left and Right sides 894934 1 Kit Right Side Spring 894936 1 Kit Right Side Adjuster Repair 19 893519 2 s Retainer Comple
109. ould not rise above 80 F 27 C Room temperature should not fall below 20 F 7 C to prevent electrolyte from freezing Engine General 1 While the engine is warm remove the drain plug drain the oil from the crankcase and change oil filter Install drain plug and refill with fresh oil Let engine cool before storing 30 2 Clean exterior of engine Paint exposed metal or apply a light coat of rust preventative oil Add a fuel conditioner or biocide to prevent gelling or bacterial growth in fuel See your local fuel supplier If storing indoors drain fuel from tank Close fuel shut off valve After Storage 1 Check and reinstall battery 2 Check or service fuel filter and air cleaner 3 Check the radiator coolant level 4 Check oil level in the engine crankcase 5 Fill the fuel tank with fresh fuel Open fuel shut off valve and bleed the fuel system o Make certain that the tires are properly inflated 7 Start and operate the engine at 1 2 throttle Allow enough time for the engine to become properly warmed and lubricated Never operate the engine without proper ventilation Exhaust fumes can be fatal when inhaled 6 1 GENERAL TROUBLESHOOTING 6 The troubleshooting chart below lists basic problems that may occur during startup and operation For more detailed information regarding the electrical system contact your area Cushman Dealer Symptoms Possible
110. pect the equipment on a regular basis establish a maintenance schedule and keep detailed records a Keep the equipment clean b Keep all 5 2 ENGINE moving parts properly adjusted and lubricated c Replace worn or damaged parts before operating the machine d Keep all fluids at their proper levels e Keep shields in place and all hardware securely fas tened f Keep tires properly inflated 3 Long hair jewelry or loose fitting clothing may get tangled in moving parts 4 Use the illustrations in the Parts amp Maintenance Manual as reference for the disassembly and assembly of components 5 Recycle or dispose of all hazardous materials batteries fuel lubricants anti freeze etc according to federal state and local regulations 6 Keep hands and feet away from moving parts Whenever possible do not make adjustments with the engine running IMPORTANT A separate Engine Manual prepared by the engine manufacturer is supplied with this vehicle Read the Engine Manual carefully until you are familiar with the operation and maintenance of the engine Proper attention to the engine manufacturer s directions will assure maximum service life of the engine To order replacement Engine Manuals contact the engine manufacturer The proper break in of a new engine can make a considerable difference to the performance and life of the engine Note The vehicle is designed to operate most efficiently a
111. r 4 Contact Male 833257 4 Terminal Female 838463 4 Seal Wire 26 845327 1 Connector 3 Contact Female 2700380 3 Terminal 2700381 3 Seal Wire 27 845328 1 Connector 9 Contact Female 2700385 2 Terminal 2700387 2 Seal Wire 2700384 7 Terminal 2700386 7 Seal Wire 28 839917 1 Plug 2 Wire Deutsch 29 839921 1 Lock 2 Wire Deustch 30 524358 2 Terminal 18 20 AWG Male Pin 31 838768 2 Lock 4 Wire Deutsch 32 838769 4 Terminal 18 20 AWG Socket 33 838770 2 Plug 4 Wire Deutsch gt Change from previous revision 137 HAULSTER 51 1 Gas Engine Electrical Schematic Io 24058 Aii Serial No 84060 All ECU IT IT 201 206 205 od 208 201 amp cn c 4 Es 4 Er See page 142 for 34 pin connector 213 212 211 210 209 208 17 16 15 14 18 12 11 10 J t J J d J IL J I X J J 220 219 218 217 216 215 214 26 25 24 23 21 20 19 18 Jj EE EE EME EE LR OO E E E E E EI E E 226 225 224 223 222 221 34 33 32 31 30 29 28 27 Bn Ye J I J J J J J L J E T T E J t J J n rYT nT Tn SB H N T Gn wh Bk Rd Bk Rd 201 Wh Rd Wh Rd 202 203 gt Rd Gn Rd Gn 204 Pk 205 gt 206 yh Rd Wh
112. r failure Damage of this nature is not covered by the factory warranty 5 30 STORAGE 3 Do not spray water directly at the dash panel ignition switch controls or any other electrical components or at bearing housings and seals 4 Clean all plastic or rubber trim with a mild soap solution or use commercially available vinyl rubber cleaners Repair damaged metal surfaces and use touch up paint Wax the equipment for maximum paint protection Clean grass and debris from drives muffler and engine to prevent fires General 1 Wash the vehicle thoroughly and lubricate Repair and paint damaged or exposed metal 2 Inspect the vehicle tighten all hardware replace worn or damaged components Drain and refill radiator 4 Clean the tires thoroughly and store the vehicle so the load is off the tires If vehicle is not on jack stands check tires at regular intervals and reinflate as necessary 5 Keep the machine and all its accessories clean dry and protected from the elements during storage Never store equipment near an open flame or spark which could ignite fuel or fuel vapors Battery 1 Remove clean and store battery in upright position on a nonconductive surface wood in a cool dry place To prevent accelerated discharge do not store battery on concrete or steel surface 2 Check and recharge battery every 60 to 90 days while in storage 3 To reduce the self discharge rate room temperature sh
113. re 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 10 843550 1 Connector Eighteen Terminal 843551 AR Terminal 11 837301 2 Connector Headlight 825889 AR Terminal 5 16 in Female 14 16 Gauge One Wire 828629 AR Terminal 5 16 in Female 14 16 Gauge Two Wire 12 825996 3 Fuse Holder 13 825977 12 Fuse Clip 1 Term 14 16 Gauge 14 825998 6 Fuse Clip 1 Term 10 Gauge 15 825999 2 Fuse Clip 3 Term 14 16 Gauge 16 836892 7 Fuse 10 Amp 16 842983 3 Fuse 15 Amp 16 826000 1 Fuse 20 Amp 16 4113261 1 Fuse 25 Amp 17 843168 2 Connector 15 Amp Relay 842966 8 Terminal Female Relay 18 2700868 1 Connector 70 Amp Relay 842966 2 Terminal 1 4 in Female Relay 2700869 2 Terminal 3 8 in Female Relay 19 826190 AR Tubing 3 8 in I D Black Convoluted 50 Foot Bulk 20 826191 AR Tubing 1 2 in I D Black Convoluted 25 Foot Bulk gt Change from previous revision 135 HAUL STER 50 1 Gas Main Harness Continued Part Number 4115709 Serial No 84058 All Serial No 84059 All Serial No 84060 All Shift Switch 7 gece ig Back Up witc Alarm Starter Solenoid A Fuel Sender Radiator Fan Cab Stop Light Engine Harness Speed Connector Se sof Shift 25 un Back Up Solenoid ST Switch S 2 BAER LP Tail Light Harness Transmi
114. remove the radiator cap while the engine is running Stop the engine and wait several hours until it is cool Even then use extreme care when removing the cap Do not pour cold water into a hot radiator Do not operate engine without a proper coolant mixture Install cap and tighten securely The cooling fan is controlled by a temperature switch and may start at any time coolant temperature is above 150 F 65 C even with the ignition switch in the OFF position Do not attempt to service the cooling system without first disconnecting the negative battery cable or removing the fan fuse NEVER add straight antifreeze to the radiator Mix equal amounts of clean water with ethylene glycol based anti freeze in a separate container before adding it to the cooling system Do not use a mixture of more than 50 antifreeze Always recycle or dispose of used antifreeze in a responsible manner Used antifreeze can be harmful to the environment 1 Check coolant level daily Radiator should be full and recovery bottle should be up to the cold mark a Tilt engine cover forward to gain access to the radiator b With the engine stopped and cool remove radiator cap and check coolant level The coolant level should be at or within 1 4 in 6 mm of the filler port Fill with a 50 50 antifreeze water mixture if required c Visually check the reservoir tank Coolant level should be at or above FULL line but less than 4
115. ren ae 894779 Protecto Seal Gas Cap 894720 Turn Signal with Right Taillight 894764 Back Up Alarm ek 2703183 Exhaust Spark Arrestor 882574 Heater Defroster 894760 Rear Shock Abesorbers seen 2701344 Spare Tire 20 5 x 8 5 10 eese 4139806G02 Support Literature Safety 8 Operation Manual 4175882 Parts 8 Maintenance Manual 4175883 Suzuki Gas Engine Parts Catalog 4140632 Kubota Diesel Engine Parts Catalog 4160162 4 ADJUSTMENTS 4 1 GENERAL To prevent injury depress clutch pedal and shift transmission to Neutral engage parking brake stop engine and remove key from ignition switch before making any adjustments or performing maintenance Make sure the vehicle is parked on a solid and level surface Never work on a vehicle that is supported only by the jack Always use jack stands If only the front or rear of the vehicle is raised place chocks in front of and behind the wheels that are not raised 1 Adjustments and maintenance should always be performed by a qualified technician If proper adjustment cannot be made contact an authorized Cushman Dealer 4 2 ENGINE ACCESS 2 Replace do not components
116. rminal 1 4 in Male 10 Gauge Two Wire 2 829630 2 Connector Four Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 3 826726 1 Connector One Female Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 4 826005 13 Connector Two Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 5 825894 1 Connector Flasher 825899 AR Terminal 5 16 in Female 14 16 Gauge 6 825877 1 Connector Six Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 7 826006 2 Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 8 837296 1 Connector Ignition Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 9 843598 1 Connector Rocker Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 10 843550 1 Connector Eighteen Terminal 843551 AR Terminal 11 837301 2 Connector Headlight 825899 AR Terminal 5 16 in Female 14 16 Gauge One Wire 828629 AR Terminal 5 16 in Female 14 16 Gauge Two Wire 12 825996 1 Fuse Holder 13 825997 4 Fuse Clip 1 Term 14 16 Gauge 14 825998 6 Fuse Clip 1 Term 10 Gauge 15 825999 2 Fuse Clip 3 Term 14 16 Gauge
117. s Haulster liquid cooled gas engine 4 speed manual transmission single speed differential and four Haulster liquid cooled gas engine 3 speed automatic transmission single speed differential and four post ROPS Haulster liquid cooled gas engine 5 speed manual transmission single speed differential and four post ROPS post ROPS 3 2 ENGINE Diesel Engine Make Kubota Governor All Speed Mechanical Model D1105 E3B Low Idle 1300 RPM Horsepnower n se 26 hp 19 4 kW 3000 rpm High Idle 3180 RPM Note Actual sustained horsepower will likely be lower Lubrication than listed in specifications due to operating limitations Capachy 5 4 quarts 5 1 liters and environmental factors Below 32 F 0 C SAE 10W or 10W 30 10W 40 Displacement 68 5 cu in 1123 cc 32 77 F 0 25 C SAE 20W or 10W 30 10W 40 ele UE 52 7 ft lbs 71 5 Nm 2200 rpm Above E E 25 C SAE 30W or 10W 30 10W 40 Fuel AFI Classification CD or CE f TUBE mia No 2 Low or Ultra Low Sulfur Air Filter Dry type with evacuator valve Diesel Alternator 60 amp Rating Cetane Rating 45 Cooling System Om Liquid Cooled Capacity 6 55 U S Gal 24 5 liters Capacity u 5 1 qt 4 81 50 50 water ethylene glycol mix Gas Engine Make uci Suz
118. sconnect electrical connector for easier access to rear of panel Light Bulb Replacement 1 Determine which bulb needs to be replaced 2 Rotate bulb holder 1 4 turn counter clockwise and pull up and away from dash panel 3 Replace old bulb with a new bulb of equal type Location u ee Replacement Bulb A Voltmeter C658 B Temperature Gauge C658 C Fuel Gauge C658 D Hour Meter C658 E Tachometer C161 F Left Turn Signal C161 G Oil Pressure C161 H Glow Plug C161 J Brake Fluid C161 K Right Turn C161 Horn Heater 10 A 10 A Wiper Accessary Dome Light amp Back Up Alarm Figure 5Q L Parking Brake sseeneeeen C161 M High Beam C658 N Alternator Battery C161 4 Place bulb and holder back into panel Turn holder 1 4 turn clockwise to secure into panel Ensure base of holder is properly seated in panel 27 5 MAINTENANCE Tachometer DIP Switch Setting The dash panel uses a DIP Switch sequence code to identify the number of input pulses per engine revolution and engine type to correctly display the engine RPM on the tachometer If you are replacing the dash panel or if the tachometer is not operating correctly check to be sure the sequenc
119. ss 1 825877 2 s Connector Six Female Terminal 825748 AR Terminal 1 4 in Fem 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Fem 10 Gauge Two Wire 2 829630 1 Connector Four Male Terminal 825961 AR Terminal 1 4 in Male 10 Gauge Two Wire 3 884398 3 e Diode Connector Assembly 4 826005 6 Connector Two Female Terminal 825748 AR Terminal 1 4 in Fem 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Fem 10 Gauge Two Wire 5 843168 Ile Connector Relay 842966 AR Terminal Female Relay 6 843167 Ile Relay 12V 15 Amp DPST 7 558019 1 Resistor Plug 8 2700868 1 s Connector 70 Amp Relay 842966 AR e Terminal Female Relay 2700869 AR Terminal 3 8 in Female Relay 9 842959 1 Connector 2 Contact 833257 2 s Terminal 3 32 in Female 838463 2 e Seal Wire 10 NS 2 Block Maxi Fuse 11 1 Fuse 50 Amp Maxi Fuse 12 4113261 1 Fuse 25 Amp 13 2700867 1 Relay 12V 70 Amp SPST 4179801 1 Radiator Fan Harness 14 836536 1 Fuse 40 Amp 15 826006 1 s Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 16 2700868 1 s Connector 70 Amp Relay 842966 AR Terminal Female Relay 2700869 AR Terminal 3 8 in Female Relay 17 2700867 Ile Relay 12V 70 Amp SPST 18 826584 2 Block Single Fuse 825997 AR Fuse Clip 1 Term 14 16 Gauge 4179800 1 Oil Cooler Fan Harness Includes Items 15 18 19 826005 1 s Connector Two Female Term
120. ssion Ground SS Connector Wires 7 l Ignition Switch Option 21 21 20 35 35 1 6 Brake Accessory 20 13 A Option 11 ER 19 Turn Signal 7 Brake Pedal 5 Option Jumper Plug switch E Flasher 12 V Accessory Option 11 Plug e Left Turn 2 Clutch Pedal 7 y Left Headlight Signal 4 N Option C e Right Turn Signal Ex Q Option Right Headlight Tach Speedometer Dash Panel Signal 10 Ground Heater wres Option A Optional 2 Accessories 4 Brake Accessory Positive b Ss SES 33 Standoff Shifter miming 32 Wires i Plug 31 7 Light Diagnostic aj Plug Horn Fan Relay Se Brake Fluid H Ges Fuse Reservoir Fue Block 1 Fuss Relay 2 K Fuse Block 3 2 e Block 2 4 136 HAULSTER Item Part No Qty Description Serial Number Notes 21 7253 AR Tubing 3 4 in 1 D Black Convoluted 22 7251 AR Tubing 7 16 in I D Green Convoluted 23 4116015 1 Connector 12 Contact Male 833257 8 Terminal Female 838463 8 Seal Wire 2700933 4 Plug Cavity 24 845329 1 Connector 26 Contact Male 2700852 1 Lock 26 Contact 2700470 19 Terminal Fermale 2700851 19 Seal Wire 4118039 7 Plug ECU Connector 25 845330 1 Connecto
121. t the preset governor setting Do not change the engine governor settings or overspeed the engine During the break in period Cushman recommends the following 1 During the first 50 hours of operation a new engine should be allowed to reach an operating temperature of at least 140 F 60 C prior to operation at full load 2 Check the engine oil level twice daily during the first 50 hours of operation Higher than normal oil consumption is not uncommon during the break in period 3 Change engine oil and oil filter element after first 35 hours of operation 4 Check and adjust alternator belts 5 Refer to Section 7 3 and Engine Manual for specific maintenance intervals 6 If the injection pump injectors or the fuel system require service contact an authorized Cushman Dealer Keep your engine clean If dirt has accumulated on the engine it should be washed with a nonflammable solvent or strong detergent When washing the vehicle becomes necessary it can be carried out concurrently with servicing the vehicle In order to maintain reliable service from your engine a regular checkup and maintenance schedule should be followed Proper maintenance will prolong the engine s life and avoid premature overhaul 13 5 MAINTENANCE 5 3 ENGINE OIL Check the engine oil at the start of each day before starting the engine To check the engine oil remove the dipstick and wipe it with a clean rag Reinsert the dipstick u
122. te 20 838539 Ile Seal Oil 21 2703309 2 s Washer Hardened 22 844813 4 e Ring Backing 23 800944 8 Screw M10 1 5 x 25 mm 24 2701408 2 e Hub Rear Wheel 25 800908 bis e Bolt Wheel 26 841430 2 Drum Brake 27 306405 10 e Washer 3 8 28 805837 10 e Locknut 3 8 24 Special gt Change from previous revision 117 Serial No All HAULSTER 42 1 Front Cover 11 16 1 Differential 2701165 118 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 836431 1 Cover Front 2 306322 9 Screw 5 16 18 x 7 8 in Hex Head 3 103867 8 Flat Washer 5 16 4 307776 3 Screw 3 8 16 x 2 3 4 in Hex Head 5 810437 2 Clamp 1 2 in P 6 810435 1 Clamp Right Side Brake Tube 7 306981 2 Flat Washer 3 8 8 836852 1 Breather 9 111074 1 Plug Fill 10 836959 1 Bracket Brake Tee Mounting 11 800227 1 Plug 1 2 NPT gt Change from previous revision 119 HAULSTER Serial No All 11 16 1 Differential 2701165 120 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 836423 1 Shaft Input 2 836693 2 Bearing Ball 3 800695 2 Ring External Retaining 4 800737 1 Ring Internal Retaining 5 812335 1 Seal Oil 6 836428 1 Spacer Bearing 7 548952 1 Lockring 8 836420 1 Spacer Pinion 9 836440 1 Pinion 18 Tooth 10 800559 1 Nut 1 2 20 Crown Lock 11 836441 1 Gear 49 Tooth 12 809180 1 Spacer
123. te replacement Cushman Part No 822049 Description bulb type Tail light bulb 1157 1 Remove the two screws securing lens Remove lens and gasket 2 Push bulb in turn 1 4 turn and Dispose of old bulb properly remove bulb 3 Install new bulb in reverse order of removal Ensure lens gasket is properly positioned 4 To remove complete tail light assembly remove two nuts and shake proof washer securing tail light to 28 frame Disconnect harness and remove tail light from frame Remove The Two 2 pim Screws For Bulb 2 Or Lens Replacement S i E e Figure 5T 5 28 EFI DIAGNOSTIC CHECK MAINTENANCE 5 Suzuki Gas Engine units only The electrical system is equipped with a plug in connector which when used with the diagnostic jumper accessory Part No 2700920 will perform diagnostic checks on various engine components Manual transmission Engage parking brake shift transmission to Neutral and turn the ignition switch to the OFF position Automatic Transmission Engage parking brake place gear selector in Park and turn the ignition switch to the OFF position Open the front cowl and locate the plug in connector Black White and Black Wires coming from the wire harness below the brake fluid reservior To run the diagnostic test plug the diagnostic jumper into the plug in connector Turn ignition switch to the ON position The brake fluid
124. ts or lower than 0 15 Volts 44 Shift Solenoid 1 Open or short circuit at pin 27 Blue Black wire of the 34 pin ECU connector Automatic Transmission only Should be 12 Volts if gear selector is in the L position 42 Shift Solenoid 2 Open or short circuit at pin 28 Blue White wire of the 34 pin ECU connector Automatic Transmission only Should be 12 Volts if gear selector is in the L or 2 position Shift Solenoid 3 EE A 43 Automatic Transmission only Open or short circuit at pin 29 Blue Red wire of the 34 pin ECU connector No sigal present at pin 18 Green Pink wire and pin 19 Orange Blue wire Shift Switch ks pin 20 Orange Green wire and pin 24 Ee wire and pin 25 46 ci Green wire and pin 26 Red wire of the 26 pin ECU connector OR signal Automatic Transmission only present at more than one of pins 18 19 20 24 25 and 26 of the 26 pin ECU connector 29 5 MAINTENANCE 5 29 CARE AND CLEANING Wash the vehicle after each use Keep the equipment clean Note Do not wash any portion of the equipment while it is hot Do not use high pressure spray or steam Use cold water and automotive cleaners 1 Use compressed air to clean engine and radiator fins A special blow gun is available through Cushman Dealer 2 Use only fresh water for cleaning your equipment Note Use of salt water or affluent water has been known to encourage rust and corrosion of metal parts resulting in premature deterioration o
125. uki Governor External Mechanical Model tetris K6 Low Idle 950 RPM Horsepower 32 hp 23 8 kW 4450 rpm High ldle 3600 RPM 84058 and 84059 Displacement 40 2 cu in 658 cc High ldle 3600 RPM 84060 Only Torque ien 38 3 ft Ibs 51 9 Nm 3200 rpm Lubrication Fuel Capacity 3 3 quarts 3 0 liters TYPE iius Unleaded Gasoline Below 32 F 0 C SAE 10W30 Rating Min Octane rating 87 32 86 F 0 30 C SAE 10W30 Capacity 6 55 U S Gal 24 5 liters Above 86 F 30 C SAE 10W30W or 10W40 API Classification SJ Air Filter Dry type with evacuator valve Alternator 60 amp Cooling System Liquid Cooled The use of any fuel containing greater than 10 Capacity 3 3 qt 3 01 50 50 water ethanol may harm the engine s emission control ethylene glycol mix system and therefore invalidate the emission related Spark Plugs warranty through the improper action of the operator NGK 3932 DCPR7E Gap Denso XU22EPR U Gap nennen 0 032 0 035 in 0 8 1 27 mm 3 SPECIFICATIONS 3 3 VEHICLE Tires Front and Rear 20 5 x 8 10 USA Trail Tire Pressure Front and Rear 50 psi 3 44 BAR Battery Type 12 Volt Lea
126. ure Sender 3 Ye Bk Bk Wh 4 gt Bk Wh 5 gt 65 Pk Wh 7 Bu Wh LG Wh 8 gt Bu Bk 95 Bk Ye 10 Water Temperature Sensor Bu Ye Bk Wh Ye Bu Wh Bu Bk Rd 11 gt Bk Rd 12 gt Wh Bu gt Wh Gn 142 HAULSTER Injector 1 Br Bk Br Bk Bk Rd Bn Wh Injector 2 Gy Bn Wh A Bk Rd Injector 3 Bk Rd Bn H Bn Rd Bk Bk Rd Bk Rd e de Rd Wire Gy Shield Rd Ye Rd Bu Oxygen Wh Sensor Bn Rd Bk Rd o Wh Rd Wh Wh Bk T Bk Rd Bu Ye Bu Ye Crank Position BaBy Sensor BKW e BkWh Bk Wh Coil Coil Coil 1 2 3 LS TTL 77 Bu Ye Bk Wh Bk Rd 143 HAULSTER 53 1 Diesel Engine Electrical Schematic Serial No 84065 All Automatic gt Gn Transmission Bk Controller fa Heater y w Gn Accessory B
127. urs or 6 Months Every 400 Hours or 9 Months Every 600 Hours or 12 Months See Section Lubricant Type Alternator Battery Belts Brake Fluid Brake Linings Clutch Cooling System Differential Fluid Electrical System Engine Glow Plus r j Engine Idle Speed I Engine Noise Vibration I Engine Oil Suzuki I B R 5 3 Engine Oil Kubota I R R 5 3 I Engine Oil Filter I ps R 5 3 Engine Oil Filter I R R 5 3 Engine Valve Clearance Kos Wee Fluid Leaks I R Fuel System I 5 13 Fuel Filter R 5 13 Fuel Water Separator T Diesel Only Governor Fluid LA VIII Injection Pump Timing Lubricate Chassis L L 7 2 I Muffler and Exhaust I l 5 5 Radiator Screens I C AR 5 7 Power Steering Fluid I 5 4 V Spark Plugs Gas only C A R Starter Motor Brushes I Tires LA 5 14 Transmission Fluid R 5 21 ii Manual Transmission 5 22 Transmission Fluid A Transmission 5 ics is Wheel Bearings Repack A Add or Adjust C Clean I Inspect L Lubricate R Repair or Replace AR As Required 33 7 MAINTENANCE amp LUBRICATION CHARTS Notes Indicates initial service for new machines Depending on operating conditions engine oil oil filter and air filter may require more frequent replacement Inspect visible hoses and tubes for leaks or oil marks Must b
128. us revision 62 HAULSTER Serial No 84059 All 13 1 Automatic Transmission Oil Cooler o o z e a E 3 z S bu E D 2 2 E S 2 a sO EN A ks o De a 582545 ON 5 0 lt o E Se O x lt T FE O T icons gt lt lt o O O O o e lt 000 O CO ON 1 0 ON o amp oO oc Oo 10 z q wea q cO cO CO CO CO D N CO st 10 E o gt Change from previous revision 63 14 1 Frame Attachments HAULSTER HAULSTER Item Part No Qty Description Serial Numbers Notes 1 893404 7 1 Platform 1 Ton Haulster Standard Frame Painted Black 1 893404G 7 1 Platform Galvanized 1 Ton Haulster Optional Galvanized Frame 2 892676 2 Taillight 822049 1 Bulb No 1157 829630 1 s Connector Male 4 Terminal 825886 3 Terminal 1 4 in Male 14 16 AWG 3 4139691 2 Fender Flexible 4 844156 2 Plate Flap Mount 5 450391 4 Flat Washer M10 6 2701210 1 Panel Console See 6 1 7 800026 7 Screw 1 4 20 Truss Head 8 4179842 1 Cover Left Side Engine 9 450398 6 Screw M10 1 5 x 20 mm Flange 10 450454 15 Nut M10 1 5 Hex Flange 11 452399 5 Screw M10 1 5 x 25 mm Flange 12 452402 4 Screw M10 1 5 x 50 mm Flange 13 452414 2 Screw M12 1 75 x 70 mm Flange 14 809156 2 Flat Washer 1 2 15 450455 2 Nut M12 1 75 Hex Flange 16 894314 1 Harness Taillight 829630 1 e Co
129. ushing Diesel Units Only 18 450377 1 Nut M6 1 Nylock Diesel Units Only 19 23266 85002 1 Arm Clutch Release Diesel Units Only 20 01550 08353 1 Screw Diesel Units Only 21 2703002 1 Nut Diesel Units Only 22 4174440 1 Mount Right Side Engine Diesel Units Only See 26 1 23 103867 1 Flat Washer 24 2700757 1 Clamp 25 452695 1 Screw M6 1 x 20 mm Taptite gt Change from previous revision 57 HAULSTER 10 1 Manual Transmission Shifter Linkage Diesel Units Serial No 84065 All p Diesel Unit Cable Attachment Shifter Mounting and Cable Routing View Rotated 90 Degrees for Clarity 58 HAULSTER Item Part No Qty Description Serial Numbers Notes 1 800582 4 Screw 1 4 20 x 3 4 in Truss Head Diesel Units 2 2703956 7 1 Mount Shifter 3 2703953 1 Selector Gear 4 842773 1 Rod End 1 2 20 5 308091 1 Flat Washer 1 2 6 311763 1 Screw 1 2 20 x 2 1 4 in Hex Head 7 843679 1 Plate Wear 8 452692 2 Screw M6 1 x 12 mm Self Tap 9 604174 1 Flat Washer 3 8 in 10 843614 1 Spring Torsion 11 843685 1 Bushing Spring 12 2703951 1 Tab Locating 13 452401 1 Screw M10 1 5 x 40 mm Flange 14 450454 1 Nut M10 1 5 Flange 15 894179 2 Cable Shifter Diesel Units 16 842774 2 Ball Joint 1 4 28 17 816307 1 Flat Washer 1 4 18 306397 1 Nut 1 4 28 Hex 19 843724 2 Clamp Cable 20 452695 4 Screw M6 1 x 20 mm Self Tap 2
130. ves lower implements to the ground 3 engage parking brake stop engine and remove key from ignition switch to prevent injuries 1 7 2 LUBRICATION CHART Always clean the grease fitting before and after 4 lubricating Lubricate with grease that meets or exceeds NLGI Grade 2 LB specifications Apply grease with a manual grease gun and fill slowly until grease begins to seep out Do not use compressed air guns For smooth operation of all levers pivot points and other friction points that are not shown on the lubrication chart apply several drops of SAE 30 oil every 40 hours or as necessary Grease fittings every 100 hours Do not over grease drive shaft fittings A Too much grease will damage the seals Fitting VOOD Description Drive Shaft Upper Ball Joints Lower Ball Joints Tie Rod Ends Qty NN ND D be Brake Fluid Reservoir B Fuse Box N d L U 32 MAINTENANCE amp LUBRICATION CHARTS 7 7 3 MAINTENANCE CHARTS Air Filter Recommended Service and Lubrication Intervals Every 75 Hours or 2 Months Every 100 Hours or 3 Months Every 200 Ho
131. washer M10 15 893632 4 Support Backrest See 2 2 16 800930 8 Screw M8 1 25 x 16 mm Flange gt Change from previous revision 45 HAUL STER 4 1 Upper ROPS Optional Kit Serial No All 46 REF Engine Cover REF Control Console PART NUMBER 893146 Manufactured by JACOBSEN 11524 Wilmar Blvd Char HAULSTER Item Part No Qty Description Serial Numbers Notes 1 4184320 1 Upper ROPS 2 4175340 1 s Decal Warning and ROPS Cert 3 844988 1 Foam 1 2 in Perforated ROPS 4 452411 6 Screw M12 1 75 x 40 mm Flange 5 450455 3 Nut M12 1 75 Hex Flange 6 4140269 2 Seat Belt Assembly 7 N S 2 e Screw 7 16 20 x 1 in Hex Head 8 N S 2 Flat Washer 7 16 9 N S 2 Nut 7 16 20 Hex 10 841799 1 Guard Seat Belt 11 800930 12 Screw M8 1 25 x 16 mm Flange 12 450453 4 Nut M8 1 25 Hex Flange 13 893632 4 Support Backrest See 2 2 gt Change from previous revision 47 HAUL STER 5 1 Throttle Control Serial No All Attach Pivot Link in Bottom Hole SN Z x 9 m X m 29 31 32 31 Hand Throttle Panel 26 27 G 24 be 26 E 6 gt 15 Es sis p el Yo N 22 6 lt i is S Kc Ignition Switch Panel 17 Throttle Pivot 16 All Views Rotated 90 for Clarity 48 HAULSTER Item Part No Qty Description Seria
132. y the quantity desired the part number and description of the part as given in the parts list 5 Send or bring the order to an authorized Cushman Distributor 6 Inspect all shipments on receipt If any parts are dam aged or missing file a claim with the carrier before accepting 7 Do not return material without a letter of explanation listing the parts being returned Transportation charges must be prepaid Use of other than Cushman authorized parts will void the warranty 9 3 TABLE OF CONTENTS PARTS CATALOG 9 1 1 2 Front Body eee 2 4 iss Engine Cover 2 2 ask Engine Cover GD Dero Upper ROPS errem eiectum nie 4 1 Upper ROPS neuere rient 5 15 Throttle Control 6 1 Control Console TA Parking Brake 8 1 Brake Pedal eene 9 1 Clutch Pedal Linkage 10 1 Manual Transmission Shifter Linkage 58 11 1 Manual Transmission Shifter Linkage 60 12 1 Automatic Transmission Shifter 62 13 1 Automatic Transmission Oil Cooler 63 14 1 Frame Attachments 64 15 1 Frame

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